Circular Economy: using digital tools to produce high-quality recyclates

Only a small percentage of materials currently used in plastic processing are recyclates. Yet these secondary plastics are in no way of inferior quality to virgin material. The culprit is often a lack of data – the right data on the quality and availability of the recycled materials, for example – and poor communication between recyclers and plastic manufacturers. Digital solutions can help close material cycles in the plastics industry.

In this K-MAG interview, Dr. Holger Berg from Wuppertal Institute for Climate, Environment and Energy talks about the "DiLinK" project (Digital Solutions for Industrial Plastic Cycles), explains how digitalization can contribute to more sustainability in the plastics industry and reveals why he believes there are too many types of plastic.

Dr. Berg, what is the objective of the DiLinK project?

Dr. Holger Berg: The DiLinK project aims to enable producers to create high-quality products from recycled plastics with digital technologies. The idea is to demonstrate the quality of recyclates during the recycling process, thus giving plastics companies better options to use recyclates and enable better, simpler, and more cost-effective processing.

How do you plan to achieve this goal?

Berg: In our research, we first started to analyze the whole system, identify the present problems and challenges, and use this as a foundation to subsequently develop or improve technologies along with our project partners to facilitate the respective quality assessments. This especially pertains to sensor technologies in the recycling process. We are also developing software that can process and transfer the collected data in the system. Finally, we are developing an ecosystem concept for all applications to ensure the seamless data transmission between recyclers and plastic manufacturers and create a distinct framework for this exchange.

Who are the project participants and what does this team collaboration look like?

Berg: Besides the Wuppertal Institute, this includes the SKZ – German Plastics Center, Infosim (an international IT company with headquarters in Würzburg), FIR e.V. (the Research Institute for Rationalization at RWTH Aachen University), and the two plastic recycling companies MKV and HOFFMANN + VOSS. We focus on applied research, which means all efforts are aimed at the practical application. This is why these companies are invaluable as research partners. We team up to test actual items in production to create practical solutions.

How can digitalization help close material cycles in the plastics industry in the future?

Berg: One important aspect for us is to create, transfer, and share valuable data. The lingering issue is that the markets - if one ignores the current distortions – lack a lot of information and data pertaining to questions such as "Which plastic recyclates are available?", "What is the quality of the recycled materials and can I trust that they have the right quality?", "Which quantities are reliable and available long-term?", or "Where can I obtain recyclates?". Digital technologies are ideal to answer all these questions. The other issue is to create the right data. This means the process must be measured, quality assured, and the transferred data must promote an increased understanding of recycling and circular processes. This is the main role of digitalization in the plastics industry.

When it comes to closing material cycles in the plastics industry, what areas still need improvement in your opinion?

Berg: I ​​think we can look at the overall cycle. One area is the information deficit I already mentioned. We must also work on educating plastics processing companies and make them understand that recyclates are not necessarily a second choice. Many recyclates can be used just as safely as virgin material – they sometimes just need to meet different requirements. If we look at the end user, the goal is likewise to generate a more positive image of recyclates. Of course, another objective here is to encourage proper waste separation, thus creating an awareness of the importance and the positive impact of waste separation on the part of the end user. The plastics industry might also want to contemplate whether we truly need so many types of plastic. After all, we are talking about literally millions of different kinds of plastic that are currently being used. Limiting the variety would obviously greatly benefit a circular economy. Fewer types of plastic would also mean an increased use of recyclates, which saves money and reduces costs.