Ethan Clarke
Olefinic thermoplastic elastomers, or TEOs, are composite materials made from polyolefin plastics and rubber. They are used in the automotive industry for their ease of processing, lightweight nature, and recyclability. While the recyclability of TEOs is a positive attribute, the broader plastics industry faces significant challenges in ensuring that plastic waste is effectively recycled. Issues include the high cost of collecting, sorting, and processing plastic, the degradation of plastic quality upon reuse, and the cheap production of new plastic. As a result, the majority of plastic ends up in landfills, contributing to environmental concerns.
| Characteristics | Values |
|---|---|
| What is TEO? | Olefinic thermoplastic elastomers (TEOs) are composed of a polyolefin plastic, such as PP or PE, and a rubber component such as ethylene propylene rubber. |
| TEO Recycling | TEOs can be recycled due to their thermoplastic characteristics. |
| TEO Usage | Up to two-thirds of the world's TEO supply is used in the automotive industry. |
| TEOs and Other Plastics | TEOs are similar to TPEs and include all TPOs, TPVs, and reactor-made TPOs (r-TPOs). |
| Plastic Recycling Challenges | The process of collecting, cleaning, sorting, shredding, melting, and forming plastic waste into pellets for recycled plastic products is complex and expensive. |
| Plastic Production and Waste | More than 90% of global plastic production consists of primary plastics made from non-renewable petroleum products, contributing to waste management issues and greenhouse gas emissions. |
| Plastic Recycling Rates | Only about 10% of plastics ever produced have been recycled once, and only 1% recycled twice. |
| Plastic Recycling Limitations | Different types of plastic don't mix well when melted, and recycled plastic is often lower quality than primary plastic due to unpredictable additive combinations and shortened polymer chains. |
| Plastic Recycling Misconceptions | Oil companies promoted plastic recycling despite knowing it wouldn't work on a large scale to increase plastic sales. |
| Plastic Recycling Solutions | Scaling up established technologies, developing methods for hard-to-recycle plastics, and reducing single-use plastic production are needed to improve recycling rates. |
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What You'll Learn
TEO recycling
Olefinic thermoplastic elastomers, or TEOs, are composed of a polyolefin plastic, such as PP or PE, and a rubber component like ethylene propylene rubber (abbreviated as EPM or EPDM). TEOs are similar to TPEs and include all TPOs, thermoplastic vulcanizates (TPVs), and reactor-made TPOs (r-TPOs). Due to their composite nature, they are widely used in the automotive industry, accounting for up to two-thirds of the world's TEO supply. TEOs are valued for their ease of processing, lightweight nature, and recyclability (due to their thermoplastic characteristics).
Despite the recyclability of TEOs, the plastics industry faces challenges in effectively recycling plastic waste. Currently, more than 90% of global plastic production consists of primary plastics, which are newly manufactured from petroleum products, rather than recycled. This reliance on non-renewable resources leads to significant energy consumption and greenhouse gas emissions. By 2050, emissions from plastic production could reach 15% of the estimated carbon budget needed to maintain global warming below 1.5 °C.
The process of mechanical recycling, the most common type of plastic recycling, involves collecting, cleaning, sorting, shredding, melting, and forming plastic waste into pellets for recycled plastic products. However, the variety of plastic types and the need for careful sorting present significant challenges. Different types of plastic do not mix well when melted, and small amounts of the wrong type can degrade the quality of the entire batch. As a result, recycled plastic is often of lower quality than primary plastic due to unpredictable additive combinations and the shortening of polymer chains during melting.
To enhance the sustainability of plastics, recycling efforts must be significantly scaled up worldwide. This includes improving established recycling technologies, developing methods to handle hard-to-recycle plastics, and reducing the production of single-use plastics. While the plastics industry has been criticized for promoting recycling while knowing its limitations, there is growing pressure, public commitment, and technological advancements that could lead to improved recycling outcomes in the future.
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The automotive industry's use of TEOs
Olefinic thermoplastic elastomers, or TEOs, are composed of a polyolefin plastic, such as PP or PE, and a rubber component like ethylene propylene rubber. They are similar to TPEs but differ in that they can be made to a wide range of specifications. Due to their composite nature, they are highly popular in the automotive industry. TEOs are preferred in this industry due to their ease of processing, lightweight nature, and recyclability (thanks to their thermoplastic characteristics). Indeed, up to two-thirds of the world's TEO supply is used in automotive manufacturing, where they are used in components for car and truck interiors, exteriors, and under-the-hood parts.
Despite the recyclability of TEOs, the plastics industry as a whole faces significant challenges in recycling. More than 90% of global plastic production consists of primary plastics—those that are newly manufactured from petroleum products—rather than recycled plastics. This is because recycling plastic is expensive, energy-intensive, and often results in a lower-quality product. While all used plastic can technically be turned into new products, the process of collecting, sorting, and melting it down is costly, and the resulting plastic degrades in quality each time it is reused.
The automotive industry has taken steps towards recycling TEOs, with companies like Reclaim Plastics focusing on recycling scrap bumper plastics. Additionally, TEOS Powertrain Engineering offers cost-competitive, time-efficient, and high-quality solutions for diesel, hybrid, and electric powertrains, potentially reducing the need for new plastic production.
However, the broader issue of plastic recycling remains a challenge. Studies show that to make plastics more sustainable, recycling must be significantly scaled up worldwide, and new technologies must be developed to handle hard-to-recycle plastics. While mechanical recycling is the most common method, it often results in downcycling, creating products of lesser technical and aesthetic quality. This is due to the difficulty of sorting the vast array of plastic types and the degradation of plastic quality with each reuse.
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Plastic recycling as a lie
Plastic recycling is a lie. Despite the public's best efforts to recycle plastics, the majority of plastic ends up in landfills or the environment. In the U.S., only 5% of plastic waste is properly recycled, while the global plastic recycling rate is a mere 9%. This is because plastic recycling is not an economically or technically feasible solution to plastic waste management. The process of recycling plastic is expensive and requires meticulous sorting, as most of the thousands of chemically distinct varieties of plastic cannot be recycled together.
The plastic industry has known for decades that recycling is not a viable solution to the plastic waste problem but has continued to promote it anyway. In 1974, an industry insider expressed serious doubts that recycling plastic could ever be economically viable, and in 1994, an Eastman Chemical representative acknowledged the lack of proper plastic recycling infrastructure. Despite this knowledge, the industry spent millions promoting recycling to sell more plastic and assuage public concerns about the environmental impact of plastic.
The birth of Resin Identification Codes (RICs), the numbers 1-7 imprinted on plastic products, was a brilliant marketing strategy by the plastic industry. These numbers were perceived as proof of a vast and thriving recycling industry, further duping consumers into believing that plastic is recyclable. However, in reality, only 30% of plastics with RICs 1 and 2 are recycled, while plastics with RICs 6 and 7 are nearly impossible to recycle.
The challenges of plastic recycling are numerous. Firstly, there are thousands of different types of plastic, and they do not mix well when melted down. This means that careful and meticulous sorting is required, which is a costly and time-consuming process. Secondly, plastic degrades each time it is reused, limiting the number of times it can be recycled. Finally, the sheer volume of plastic waste generated is immense, and the global recycling rate has stagnated in recent years.
While mechanical recycling is the most common form of plastic recycling, it is not a perfect solution. Plastic waste is collected, cleaned, sorted, shredded, melted down, and formed into pellets to be sold to producers of recycled plastic products. However, the recycled plastic is often of lower quality than primary plastic due to the unpredictable combinations of additives and the shortening of polymer chains during the melting process. This results in downcycling, where recycled products have inferior technical and aesthetic qualities.
In conclusion, plastic recycling is largely a lie perpetuated by the plastic industry to sell more plastic and divert attention from the environmental impact of plastic pollution. While some countries have achieved higher recycling rates, the global recycling rate remains low, and new technologies are needed to address the challenges of plastic recycling and reduce the environmental footprint of plastic production and waste.
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Plastic recycling methods
Plastic recycling is vital for waste management and creating a sustainable future. However, it is challenging due to the variety of plastic types and the complexity of recycling them. The most common recycling method is mechanical recycling, which involves grinding, washing, sorting, and reprocessing plastic waste into pellets for manufacturers. This method has been used for decades and is responsible for most plastic recycling globally.
The recycling process typically begins with waste collection, where consumers play a crucial role by rinsing plastic items to remove food or other materials. This initial step ensures the rest of the recycling process operates more effectively. After collection, plastic waste undergoes various washing methods, such as friction washers, which use heat, kinetic energy, and pressure to remove contaminants. Rotary washers, on the other hand, employ a heated caustic solution to eliminate oils and food residues.
The next critical stage is shredding or grinding the plastic into smaller flakes or pellets, which can be achieved through different methods, including Hammer Mills and Shear Shredders. Once shredded, the plastic undergoes further sorting to ensure a pure stream of material. Sorting methods include optical sorting machines, sink-float separators, and magnets to separate plastics by thickness, colour, size, and type, removing any remaining contamination.
After sorting, the plastic is ready for reprocessing, where it is melted down and forced through an extruder to form pellets, which are then sold to manufacturers. However, it is important to note that recycled plastic is almost always of lower quality than primary plastic due to the degradation of polymer chains during melting and the varying combinations of additives used in plastics of the same type.
Another type of recycling process is chemical recycling, which is a relatively new technology that can recover plastic material from any step of the cascade and return it to its raw, high-quality state. This process involves breaking down the polymers that make up plastic materials through pyrolysis, gasification, or depolymerization. Pyrolysis heats polymers in the absence of oxygen, causing them to behave like synthetic oil, which can be used as feedstock in the petrochemical industry. Gasification, on the other hand, involves heating polymers in the presence of oxygen and water to produce syngas, a chemical feedstock. Finally, depolymerization cuts down the polymers into monomers, creating a starting material for new plastic production.
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Plastic recycling rates
The recycling of plastics is a complex and challenging issue. While the idea of recycling plastic is appealing, the reality is that the process is not as simple as it seems. Plastic recycling rates vary across the world, and it is difficult to make accurate comparisons due to differences in measurement methods. However, it is clear that the amount of plastic being recycled is relatively small compared to the amount of plastic produced and discarded.
According to the Environmental Protection Agency (EPA) in the United States, the plastic recycling rate was 8.7% in 2018. This rate dropped to around 5% in 2021, possibly due to the global pandemic. Similarly, the UK recycles just 17% of its annual plastic waste. According to the OECD, only about 9% of the world's plastic is recycled, with about 85% ending up in landfills and 10% being incinerated.
The low recycling rates can be attributed to several factors. Firstly, the variety of plastic types poses a challenge during the sorting process. Different types of plastic do not mix well when melted down, and even small amounts of the wrong type can degrade the quality of the recycled product. This sorting process is typically done with the help of high-tech machines in high-income countries, but it still remains a challenge. Secondly, recycled plastic is often of lower quality than primary plastic due to the degradation of polymer chains during the melting process and the use of different additives in plastics of the same type. This results in downcycling, where the recycled products have less stringent technical or aesthetic qualities.
Furthermore, economic factors play a role in the low recycling rates. It is cheaper to produce new plastic products than to collect, recycle, or reuse existing ones. The plastics industry relies on non-renewable resources, with more than 90% of global plastic production consisting of primary plastics made from petroleum products. This reliance on non-renewable resources contributes to the high energy consumption and greenhouse gas emissions associated with plastic production.
Despite these challenges, there is a growing effort by consumers, brands, and governments to curb plastic pollution and improve recycling rates. However, existing recycling practices need to be significantly scaled up and improved to match the increasing production and use of plastic.
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Frequently asked questions
TEO plastics, or Olefinic Thermoplastic Elastomers, are a type of plastic composed of a polyolefin plastic and a rubber component. They are similar to TPEs but differ in that they contain a rubber component such as ethylene propylene rubber.
TEO plastics, like all plastics, create a massive waste management issue. More than 90% of global plastic production consists of primary plastics, which are newly manufactured and made from petroleum products. This reliance requires a huge amount of energy and produces greenhouse gas emissions. By 2050, emissions from plastic production could amount to 15% of the estimated carbon budget needed to keep global warming below 1.5 °C.
TEO plastics can be recycled through a process known as mechanical recycling. Plastic waste is collected, cleaned, sorted, shredded, melted down, and formed into pellets to be sold to producers of recycled plastic products. However, it is important to note that different types of plastic don't mix well when melted down, so TEO plastics must be carefully sorted before being recycled.
