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Recycled textile fibres by Circular Materials incorporated into plastic mouldings

Circular Materials Fibre Pellets are produced from waste textiles, such as old clothes and production offcuts. The recycled fibres can be used as fibre reinforcement for plastics, such as polypropylene (PP), polyethylene (PE) and thermoplastic elastomer (TPE). The fibre-based composite is compatible with conventional plastic manufacturing processes, such as injection and compression moulding. It is suitable for a range of applications including products, packaging, point-of-sale (POS) and fashion accessories. For example, this tray in injection moulded using 25% fibre pellet and 75% recycled PP (rPP). Image Circular Materials.

 

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Swanline Cygnus Eco Board alternative to PVC for print and graphics

Swanline Cygnus Eco Board is a fibre-based board suitable for print, graphics, packaging (including food contact) and point-of-sale (POS). It is resistant to water and moisture, and so suitable for temporary outdoor signage and short term moisture sensitive signage and packaging. It provides an alternative to plastic for graphics applications, such as polyethylene (PE) coated paper, high impact polystyrene (HIPS) and even aluminium composite panels. Available in a range of thicknesses, it is recyclable, compostable and available with up to 70% recycled content. Image Swanline.

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Recycled and bio-based Surlyn ionomer plastic for cosmetics packaging

Two new Surlyn ionomer resins developed by Dow offer carbon savings compared to virgin material. Surlyn REN ionomers are produced using bio-waste such as cooking oil. This process utilises waste residues or by-products from alternative product processes from other industries meaning the raw feedstock materials will not consume extra land resources or compete with the food chain. Surlyn CIR ionomers are created through chemical recycling technologies, breaking down mixed waste plastics into their basic chemical elements, giving plastic waste a second life. This produces a raw material that is equivalent to those made from virgin fossil feedstock. Image Dow.

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Jackoboard Ligno recycled and partially bio-based insulation foam

Jackon Insulation have developed a recycled and partially bio-based insulation panel, Jackoboard Ligno, with a core made of lignin and recycled polystyrene foam (rPS). The lignin biopolymer is made from renewable raw materials, a by-product of the paper industry. Using recycled general purpose polystyrene (rGPPS) in the extruded polystyrene foam (XPS) and bio-based lignin in the core reduces the carbon footprint of the panel by more than 60%, according to the company.

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Syklo biocomposite made with recycled waste

Syklo produce an innovative biocomposite consisting of post consumer recycled (PCR) polypropylene (rPP) combined with recycled paper. The paper is shredded and micro fibrillated (MFC) to create a highly functional additive that provides significant mechanical benefits. It can be injection moulded and provides a bio-based recycled alternative to conventional PP materials in packaging and product applications. Image Syklo.

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Hexpol Dryflex Circular recycled elastomers

Hexpol produce a range of thermoplastic elastomers with recycled content (rTPE). This includes post industrial recycled (PIR) available in natural colours and suitable for consumer goods, sports equipment, footwear and automotive interior and exterior parts; post consumer recycled (PCR) material available in dark colours, from end of life vehicles and household waste, suitable for automotive exterior and technical parts, safety products and outdoor equipment; and maritime waste from old rope and fishnets available in available in black, blue, green and mint colours.

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Concrete4Change sequestration technology that turns CO2 into concrete

Concrete4Change (C4C) is developing additive materials for concrete that act as carbon carriers. Recycled wood and plastic waste are prepared to become an ‘adsorbent’ that may capture and release CO2. Then, using a process unit, the carrier is loaded with carbon dioxide – mainly utilising CO2 captured from the carbon heavy flue gas from cement production as feedstock. This loaded carrier is mixed into either wet or dry concrete wherein it slowly releases the CO2, allowing for permanent mineralisation. Not only does this mineralisation make the concrete stronger, less cement is required to do the same job. With this technology, C4C also promises 10 times more carbon sequestration than existing approaches for ready-mix concrete. Image Concrete4Change.

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Morssinkhof – Rymoplast MOPET post consumer recycled polyethylene terephthalate (rPET) packaging for food contact

Morssinkhof – Rymoplast recycle polyethylene terephthalate (PET) packaging and convert it into MOPET rPET suitable for converting back into food contact packaging. MOPET-A, MOPET-Clear and MOPET-Green can be used at 100% for the production of clear, transparent food contact packaging: preforms, bottles and sheet. MOPET rPET is suitable for converting into other polyester products like fibre and injection mouldings. Image Morssinkhof – Rymoplast.

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Ravapura post-consumer recycled (PCR) plastic compounds

Ravago Ravapura compounds include 50-70% recycled content low density polyethylene (rLDPE), 50-75% recycled content high density polyethylene (rHDPE), 33-50% recycled content polypropylene (rPP), 50-70% recycled content high impact polystyrene (rHIPS), 50-70% recycled content acrylonitrile butadiene styrene (rABS). They are suitable for packaging (non-food contact), electrical, products, furniture and appliances.

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Made of Air carbon-negative additive for plastics

Made of Air convert biomass waste streams (such as forestry offcuts and secondary agricultural materials), which have photosynthesised CO2, into a form of biochar through controlled pyrolysis. Burning materials without oxygen means the carbon cannot form CO2 and instead forms biochar. Using their technology the biochar is converted into a functional carbon-rich filler for plastic biocomposites. Biochar has been produced for centuries and is increasingly being used as a fertiliser as well as a way of sequestering carbon in the soil, because the carbon is locked in and it remains stable for hundreds of years. Image Made of Air.

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UBQ thermoplastic additive made from household waste

The feedstock for UBQ is household waste, which is largely comprised of organic materials – everything from food residues and mixed plastics to cardboard, paper, and even dirty diapers, that would have otherwise been sent to landfill or incineration. Metals and minerals, which have high recyclability, are removed and sent over to traditional recycling streams. UBQ’s waste conversion technology breaks down the organic matter into its basic particulate constructs—lignin, cellulose, fibres, and sugars—and then reassembles them into a matrix. Residual plastics present in the waste stream melt and get mixed into the matrix to create a homogeneous and consistent composite thermoplastic material. Image UBQ.

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Ecor bio-based and recycled panels

Ecor convert agricultural and post-consumer waste (paper and card) into building materials, providing an alternative to engineered wood panels. Raw materials are processed into usable feedstock via a mechanical pulping process to achieve the desired properties for the pulp. The pulp is then dispersed in water and through controlled processing the lignin acts as a natural glue, like hardboard, binding the fibres together. Image Ecor.

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Recover Fiber recycled cotton

RCotton (RPure, RMix, RDenim) is made with >90% recycled cotton from industrial and post-consumer textile waste. Old clothes and scraps are shredded and opened up into fibre, which can be spun into yarn for new garments. RColorBlend is an alternative they make, a ready to spin fibre without the need for blending or dyeing, containing around 50% recycled cotton mixed with recycled polyester (PET) from bottles (RBlue), or organic cotton (REarth). Image Recover.

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Green Cast recycled acrylic sheet

Green Cast by Madreperla is 100% recycled and recyclable cast polymethyl methacrylate (PMMA), acrylic, sheet. The company’s environmental product declaration (EPD) gives a carbon footprint of 2.13 kgCO2/kg for this material. It is produced with 100% R-MMA, recycled methylmethacrylate monomer produced by Madreperla in Italy. It is available in transparent, as well as a wide range of colours and finishes. Image Madreperla.

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Syre chemically recycled polyester

Backed by H&M Group, Syre have developed a chemical recycling process to convert waste polyester (PET) textiles into new fibres. The polyester, derived from post-consumer waste and direct industry waste from factories, is depolymerised to make BHET, which forms the building block for new polyester fibre. Syre claim that the fibre gives the same performance as virgin polyester but with 85% lower carbon footprint. Image Syre.

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HeiQ AeoniQ regenerated cellulose fibre

HeiQ AeoniQ is made from cellulose feedstock, which ranges from natural materials to waste textiles. HeiQ AeoniQ have developed a gentle, PH-neutral chemistry and >99% of the water is recycled in the process. This is different from conventional regenerated cellulose production, which relies on some hazardous chemicals and solvents to extract and spin the cellulose, and it is not a closed loop process. HeiQ AeoniQ fibre has similar elongation and tenacity to polyester (PET). Image HeiQ AeoniQ.

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Eos Eco enzymatically recycled nylon 66 fibre by Samsara Eco and Lululemon

Samsara Eco have developed an almost closed loop process that uses enzymes to attack plastic waste and revert it to its original chemical building blocks. These monomers can be used to make new plastics without any loss of quality. So far they have developed this depolymerisation technique for polyamide (PA), nylon, and polyethylene terephthalate (PET), polyester. Image Samsara Eco.

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Circ Polyester fibre

Circ have developed a unique hydrothermal process for recycling mixed textiles made up of cotton and polyester, like polycotton. With their technology, it is possible to extract both materials separately and convert them into the raw materials for new fibres. Usually with mixed material recycling, certain ingredients are sacrificed to save one. In this case, both are useable in new textiles and products. The polyester is recovered from the mixed waste and converted into TPA and MEG, the building blocks required for new polyester. Image Circ.

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Circ Lyocell fibre

Circ have developed a unique hydrothermal process for recycling mixed textiles made up of cotton and polyester, like polycotton. With their technology, it is possible to extract both materials separately and convert them into the raw materials for new fibres. Usually with mixed material recycling, certain ingredients are sacrificed to save one. In this case, both are useable in new textiles and products – the cotton is converted into lyocell. Image Zara.

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Ioncell regenerated cellulose fibre

Ioncell regenerated cellulose fibre is the result of a collaboration between Aalto University and the University of Helsinki. The process utilises an ionic liquid solvent to dissolve cellulose. Once dissolved, the cellulose is converted using dry-jet wet spinning technology. The only chemicals applied are the non-toxic ionic liquid and water. They are both re-circulated in the process in a closed loop. Image Ioncell.

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Treekind plant-based leather by Biophilica

Biophilica Treekind is a flexible, leather-like material, made from urban plant waste, agricultural waste and forestry waste. It is made up of lignocellulosic feedstock (leaves, agricultural waste and forestry waste) with a natural binder. It is coated with a bio-based material to make it waterproof. Available in a range of natural colours, it may also be modified with plant pigments as well as non-toxic natural pigments. It is home compostable, recyclable and estimated to have a very low resource footprint. Image Biophilica.

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K-Briq recycled construction brick by Kenoteq

The Kenoteq K-Briq is produced from recycled materials – such as plasterboard, brick, stone, rubble and mortar – mixed with a non-toxic binder. The mix is compressed at high pressure and cured, as opposed to being fired like conventional clay products. The use of recycled material and eliminating firing helps to ensure minimal energy and CO2 emissions. The building brick a carbon footprint of only 0.02 kgCO2, which equals around 1 kg CO2/m2. This is 95% less than a conventional clay brick or slip. Image Kenoteq.

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Magna Glaskeramik panels from recycled glass

Magna Glaskeramik panels are made with recycled glass – specifically industrial waste from the production of packaging and solar panels. The sheet materials, which are suitable for furniture and facades, for example, have a maximum dimension of 2800 x 1250 mm (up to 3500 x 1500 mm on request) and a standard thickness of 20 mm (15-40 mm available on request). Image Magna.

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Seawool insulation by Seastex

Seastex convert waste byssus (known as the ‘beard’, is an inedible part of edible mussels that is usually removed during cleaning) into a soft, cloud-like raw material called Seawool. This by-product of food production is typically disposed in landfill of uses as biomass. Suitable for construction, furniture and textile industries, it is 100% bio-based, biodegradable, fire retardant and odourless. Image Seastex.

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Pangaia Frutfiber

Pangaia Frutfiber is a blend of bamboo lyocell regenerated cellulose combined with pineapple leaf and banana leaf fibres – two natural materials that are usually considered agricultural waste as byproducts of the food industry. After the fruits are harvested, these fibrous leaves are typically thrown in landfill or burned. Developed in collaboration between RDD Textiles and Pangaia. Image Pangaia.

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Kirei Wheatboard

Wheatboard by Kirei provides an alternative to medium density fibreboard (MDF), plywood and particleboard. It is produced from agricultural waste (wheat stalks) pressed into panels with polyurethane resin (PUR) binder – so no added formaldehyde (NAF). It is used in manufacture of cabinets, millwork, furniture, and subflooring, for example. Image Kirei.

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Recycled carbon fibre (rCF)

Recycled carbon fibre (rCF) by Gen 2 Carbon is produced from waste generated in production – around 30% of produced carbon fibre ends up as waste at some point in the process. Companies such as Gen 2 Carbon (formerly ELG Carbon Fibre) convert this waste into rCF. The cost is around 40% less than industrial grade virgin carbon fibre and Gen 2 Carbon, who reclaim carbon fibre by pyrolysis, say their fibre retains 90% of its tensile strength and 100% stiffness. Image Gen 2 Carbon.

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Malai coconut leather

Malai coconut leather is produced through bacterial fermentation of waste coconut water, a byproduct of coconut production. The bacterial cellulose that develops is enriched with natural fibres (banana, sisal, hemp), gums and resins to create a durable and flexible material which is converted into flat sheet or 3D parts. It is coloured with plant-based mordant-free dyes. Plant extracts like indigo, madder, cutch or marigold petals are used in order to achieve the colour. It is plastic-free, vegan and home compostable. Image Malai.

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Kvadrat Really recycled textiles

Kvadrat Really materials are produced from recycled textiles collected from production waste, industrial laundries, the fashion industry and Kvadrat’s production and supply chain. The textiles are sorted by colour and re-milled in Denmark. Subsequently, the fibres are either blended into standard products or used to create a nonwoven base for Kvadrat Really materials, such as acoustic solutions and panels for furniture and interiors. The compressed panels are made with 9% bio-based polypropylene (bio-PP) and 17% bio-based polyethylene (bio-PE) binder. Image Kvadrat.

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Hydro CIRCAL 100R and 75R aluminium alloys

Hydro CIRCAL 100R and 75R are recycled aluminium alloys made up of a minimum of 75% post-consumer scrap, such as window frames, doors and facades that have reached the end of their life. The balance being a combination of manufacturing waste and alloying elements to bring it in line with 6060 specification. Hydro CIRCAL 100R has a carbon footprint below 0.5 kgCO2e (according to Hydro internal estimates) and Hydro CIRCAL 75R has a carbon footprint of 1.9 kgCO2e on average according to the company’s EPD. Image Hydro.

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GrapeSkin synthetic leather by Vegea

GrapeSkin synthetic leather by Vegea is made using by-products from wine making in Italy. The solid remains of grapes after pressing (known as pomace this include the skins, pulp, seeds and stems) are combined with vegetable oil and water-based polyurethane resin (PUR). It is coated onto cotton fabric or recycled polyester (rPET). The finished material comprises around 55% grape waste. Image MoEa.

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Circulose regenerated cellulose fibre by Renewcell

Circulose by Renewcell is a regenerated cellulose textile produced from old cotton garments. The waste material is shredded, de-buttoned, de-zipped, de-coloured and turned into a slurry. Contaminants and other non-cellulosic content are separated and removed. The slurry is dried to produce Circulose dissolving pulp, which is used to make new cellulose fibres, such as viscose, lyocell, modal and acetate. The company launched their first factory in 2023 and was declared bankrupt in February 2024. Image Renewcell.

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Boliden recycled copper

Copper mining and smelting have a significant carbon footprint. The global average, according to the International Copper Association (ICA), is 2.3 kgCOe/kg. Boliden low-carbon copper, produced with renewable energy and recycled contents (up to 100%), has a reduced carbon footprint of 1.5 kgCO2e/kg. The primary raw material for Boliden’s recycled copper is used electronics. Image Boliden.

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Biopure bio-recycled polyester by Protein Evolution

Biopure bio-recycled polyester by Protein Evolution is made from rigid packaging waste and industrial textile strappings. Protein Evolution uses AI-designed enzymes to break down polyester (PET) waste into the raw materials of new polyester that are indistinguishable to the petroleum-derived raw materials used in polyester manufacturing. The process is capable of handling a variety of waste streams, from plastic bottles and clam-shells, to industrial textiles and garments. Image Stella McCartney.

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AppleSkin by Vegatex

AppleSkin by Vegatex is a synthetic leather produced with a mix of plant-based materials (by-product of apple processing for the beverage industry) mixed with water-based polyurethane resin (PUR) on a Tencel Lyocell, or recycled polyester (rPET), textile backing. Similar materials from Vegatex include LemonSkin made with by-products of apples and lemons from the beverage industry, and BarleySkin made from brewer’s spent grains. Image Vegatex.