"This new line of polycarbonate represents a significant step in supporting the automotive industry's transformation towards a circular future," said Lily Wang, Global Head of the Engineering Plastics Business Entity at ����AV. "By offering high-quality PCR materials derived from end-of-life headlamps, we're enabling our customers to meet increasingly stringent regulatory requirements while contributing to closed-loop recycling of automotive plastics."

Under this initiative, ����AV has been collaborating with partners, including Chinese recycler Ausell and leading automakers, to establish closed-loop pathways for high-value plastics from end-of-life vehicles (ELVs). This program focuses on strengthening recycling processes and establishing reliable supply chains for high-quality recycled materials from automotive waste streams. Through this partnership, ����AV and its value chain allies have developed practical solutions for collecting and mechanically processing end-of-life headlamps into high-quality PCR grades suitable for a range of automotive applications.

"This partnership underscores the importance of cross-sector collaboration in driving the circular economy forward," said Martin Hansen, Regional Director of GIZ in East Asia. "By bringing together key industry players, we are not only creating viable solutions for recycling high-value plastics from end-of-life vehicles but also fostering innovation that supports a sustainable, closed-loop material flow in the automotive industry."

The introduction of these new PCR grades comes at a critical time as the automotive industry, one of the most resource-intensive sectors, faces increasing environmental challenges and regulatory pressures. The EU's End-of-Life Vehicle Directive, which sets recycling targets, along with China's Extended Producer Responsibility (EPR) program and growing sustainability requirements in key global markets, are pushing automotive manufacturers worldwide to seek innovative and sustainable material solutions that comply with evolving regulations.

����AV’s new PCR grades meet the high-performance standards required for demanding automotive applications, offering excellent surface quality for superior aesthetics and adhering to strict Vehicle Interior Air Quality (VIAQ) requirements. This combination of sustainable content and premium performance empowers automotive manufacturers to meet both regulatory demands and environmental goals without compromising on product quality.

As part of its broader commitment to sustainability and the circular economy, ����AV continues to expand its portfolio of recycled-content materials. In recent years, the company has introduced PCR polycarbonates with up to 90 percent recycled content, and opened its first dedicated mechanical recycling compounding line for polycarbonates in Shanghai. Last year, it introduced a new range of polycarbonates based on chemically recycled, attributed material from post-consumer waste via mass balance for the first time.

"With our automated laboratory, we can work together with our customers on the future of coatings and adhesives. Because it operates almost completely autonomously and learns from our existing knowledge and data lake as well as newly generated data, it makes the process of optimizing and developing formulations many times more efficient and precise. This allows us to optimize existing formulations faster or even develop completely new formulations for and together with our customers. We can say: We are reaching a new level of modern research," says Thomas Büsgen, head of the laboratory.

Testing Formulations with ����AV Binders and Crosslinkers 

Specifically, the new laboratory will test formulations with ����AV binders and crosslinkers for coatings and adhesives. Their clever selection ensures properties such as hardness, adhesion, opacity, gloss, or durability. Such formulations typically consist of seven to 15 components, whose combination determines the properties of the final product. The resulting high number of possible combinations means that standard formulations are usually used. The new laboratory now enables more extensive test series, also thanks to the computer-aided design of test series and the use of automation.

"Our new automated laboratory gives us more possibilities for testing formulations. It relieves our specialized laboratories of their standard tasks and can analyze samples more systematically. This allows us to focus our expertise and experience even more on customer-specific topics or try approaches we couldn't have implemented otherwise," says Martin Merkens, Head of Sales & Market Development EMLA in ����AV's Coatings and Adhesives business entity. “This will particularly help us in the area of circular economy: Alternative raw materials, for example bio-based or recycled materials, can be tested faster and evaluated for their properties in the final product.”

Facility to Run Tens of Thousands of Tests Annually 

The new facility can operate 24 hours a day, 7 days a week. The goal is to run tens of thousands of tests annually. This sets a new standard in terms of number, variety, precision, and testing speed. Another advantage: The automated laboratory generates a large amount of structured data. The knowledge about formulation possibilities and influencing factors thus will grow rapidly. The collected data, combined with measurement data from existing studies, is evaluated using special machine learning algorithms to further improve formulations. Artificial intelligence is also used to predict new experiments based on property goals and simultaneously verify them in the automated laboratory – creating a self-learning system.

In addition to formulating water- and solvent-based 1K and 2K systems, the automated laboratory also performs numerous material tests on the raw materials themselves, their formulations, and applied films. Application can even take place in different climates in the lab to simulate product use under application conditions. The progressing laboratory digitalization across ����AV also enables easy forwarding of generated samples to more specialized testing laboratories. This makes it possible to supplement the datasets with market-specific test results and identify relevant dependencies more quickly.

����AV at European Coatings Show 2025 in Nuremberg 

At the European Coatings Show from March 25-27 in Nuremberg, experts from application development and segments such as automotive, printing & packaging, or construction & architecture will be present to discuss new, joint approaches made possible by the laboratory with customers. Visit the company's booth in Hall 4A, Stand 438. There you can learn more about the laboratory and other innovative material solutions and technical developments for the coatings and adhesives industry.

Follow further updates on this topic . 

“While the decision to shut down the PO11-unit is difficult, we must ensure all assets within our portfolio are a long-term strategic fit,” said Aaron Ledet, executive vice-president I&D and Supply Chain at LYB. “We are prioritizing our core assets which play a key role in our technology differentiation and circularity strategy or provide attractive returns over the cost of capital. We take our obligations towards our employees, European employee reps, councils, and unions seriously. We have engaged with them in line with these obligations and will continue to do so. We would like to thank them for the constructive dialogue. We are also in communication with customers, suppliers and other parties across the value chain and will continue to do business as usual. There is no change to our working relationship, and we continue to focus on providing an exceptional customer and supplier experience.”

"As part of our Sustainable Future corporate strategy, we’re continuously working to optimally position ����AV to be a reliable partner for our customers and to operate competitively in a challenging market environment," said Hermann-Josef Dörholt, Head of the Performance Materials Business Entity at ����AV. "Due to global overcapacities, persistently weak demand, and high costs in Europe, we have jointly decided with LYB to close the PO11 plant. We will support LYB in implementing this change as socially responsibly as possible. At the same time, we remain committed to the European market and will continue to supply customers with our renowned polyether polyols portfolio.”

The Maasvlakte site, a joint venture between LYB and ����AV, has been operational in the Rotterdam region since 2003. Between now and the end of 2026, LYB will carry out a process to safely shutdown and prepare the demolition of the asset.

In 2024, LYB announced a strategic review of European assets of its Olefins & Polyolefins (O&P) and Intermediates & Derivatives (I&D) business units. LYB has taken the next step in evaluating the option to seek alternative ownership for the O&P sites in the strategic assessment. At this time no decisions have been made and various outcomes remain possible.

Special focus is placed on technologies that increase productivity while promoting circular economy. These include an automated laboratory for formulation development, material screening, and polymer analytics; an innovative Direct Coating process for the automotive industry, and a TÜV-certified, cloud-based solution for product-specific lifecycle analyses (LCA).

"Our customers' and partners' challenges are becoming increasingly complex. Be it accelerated development cycles, ever-higher product requirements, or circularity and recyclability. We offer innovative solutions that not only convince technologically but also make an important contribution to greater sustainability," explains Martin Merkens, Head of Sales & Market Development EMLA in ����AV's Coatings and Adhesives business entity. "At ECS 2025, we demonstrate how we make customers and partners successful and can accompany them every step of the way. We look forward to personal meetings and discussions!"

Automated Laboratory Revolutionizes Application Development

At ECS, the company will announce an automated laboratory for optimizing formulations with ����AV's binders and crosslinkers for coatings and adhesives. With this, ����AV sets new standards in the productivity of its application development. The new facility can operate 24 hours a day, 7 days a week. The goal is to conduct tens of thousands of tests annually. This sets a new benchmark in terms of quantity, variety, precision, and testing speed. Another advantage: The automated laboratory generates a large amount of structured data. The knowledge about formulation possibilities and influencing factors thus will grow rapidly. The collected data, combined with measurement data from existing trials, is evaluated using special machine learning algorithms to further improve formulations. Application development experts and specialists from segments such as automotive, printing & packaging, or construction & architecture will be present at ECS to discuss new collaborative approaches now made possible by the laboratory.

Digitalized Lifecycle Analyses for Greater Transparency

As a pioneer in the digital transformation of the chemical industry, ����AV announced in January the use of a new cloud-based solution for product-specific lifecycle analyses (LCA). The TÜV Rheinland-certified software solution not only enables significantly faster and more precise calculation of a products' environmental footprint but also identifies concrete approaches to reducing the CO₂ footprint, thus supporting ����AV's customers in their sustainable transformation.

Direct Coating: Solutions for the Automotive Industry

With the innovative Direct Coating technology, ����AV presents a pioneering solution for the automotive industry that fundamentally simplifies the coating process while making it more sustainable. This technology enables direct coating of plastic components in the injection molding machine without pretreatment or separate painting and drying. At ECS, ����AV will display products that were manufactured using this process.

Focus on Sustainability

����AV aims to fully align itself with the circular economy. This includes using alternative raw materials, transitioning to green energy, and developing recycling technologies and recyclable products. To make sustainable products more easily identifiable, the company has introduced the "CQ" label, which stands for "Circular Intelligence." Products labeled this way contain at least 25% alternative raw materials. Several examples used in coatings and adhesives will be exhibited at ECS. For example, food packaging coated with fully recyclable, partially bio-based resins, or water-based polyurethane dispersions for textile printing.

Additional information on ����AV’s presence at the ECS can be found at: or on the .

In response to the growing demand for sustainable solutions in currency printing, ����AV is introducing Autentium^®, an innovative polymeric printing substrate. Designed exclusively for currency printing applications like banknotes, Autentium^® combines cutting-edge anti-counterfeiting technology with a recyclable mono-material design.

"The launch of Autentium^® represents a significant breakthrough in currency printing, offering an innovative, recyclable polymeric substrate that excels in printability, durability and is more sustainable," says Daniel Hentschel, Global Segment Manager for ID & Security Printing at ����AV.

Key Features of Autentium^® include:

• Exceptional printability: It supports secure printing techniques such as intaglio and offset, enabling embossed structures and therefore tactile security features that differ from traditional paper and existing polymer substrates.
• No coatings or primers needed: Its secondary properties as a hot-melt adhesive contribute to superior ink adhesion without requiring additional primers or coatings, streamlining the printing process and improving durability.
• Water & Stain Resistance: The polymer absorbs only minimal moisture, which contributes to a low static charge, while at the same time being resistant to contamination.
• Advanced laser engraveability: It allows precise micro-engravings, providing advanced anti-counterfeiting measures and enhancing currency security.
   

As a single-polymer solution, Autentium^® is recyclable, addressing the demand for sustainable materials in banknote production. Its high tear propagation resistance and excellent ink adhesion contribute to extend the lifespan of printed currency and can help reducing the environmental impact and conserving resources.

Furthermore, its durable composition can translate into long-term costs savings by minimizing replacements, making it an ideal choice for governments and the public sector that prioritize security and environmental responsibility.

Meet ����AV at Intergraf Currency + Identity 2025 

����AV will showcase Autentium^® and other advanced polymeric solutions at the Intergraf Currency + Identity 2025 trade show. Join us from March 5-7, 2025, at the Allianz MiCo, Milano, Italy. Visit us at booth 16 to discover how Autentium^® can redefine your security printing requirements and drive innovation in currency production.

The competition, which will be contested by university undergraduates from the UK and Ireland, is asking students to design a product, made primarily from plastics, which will promote or monitor either physical or mental health.

Chairman of DIP, Martin Sixsmith, said that with increased focus on the self-care agenda, the 2025 theme offers an exciting opportunity for creating a product which can seamlessly integrate into daily life and which can help all age groups.

“This is a subject which resonates with many people and it therefore offers a huge amount of scope for students to showcase their creative talents for the benefit of others,“ he said. “We are very much looking forward to seeing their end product!“

Students will need to submit their entries by March 14, when DIP’s panel of industry judges will whittle the submissions down to a final six. Final judging will take place in London on May 9, with the award ceremony on June 20.

Design Innovation in Plastics is the longest running plastics competition of its kind in Europe, having been established in 1985. It is supported by the Institute of Materials, Minerals and Mining, the Worshipful ����AV of Horners and sponsored by leading design and plastics organisations, including ����AV.

Notes to editors 

1. Established in 1985, Design Innovation in Plastics is the longest running student plastics design award in Europe. For more information visit .

2. The Institute of Materials, Minerals and Mining (IOM3) is a major UK engineering institution and is the professional body for the advancement of materials, minerals and mining to governments, industry, academia, the public and the professions. For more information visit .

3. The Worshipful ����AV of Horners is one of the oldest livery companies in the City of London, formed to regulate the horn-working trade. In 1943 it adopted its modern equivalent, the plastics industry. For more information visit .

4. Headline industry sponsor – ����AV

Hanno Bruemmer, Head of Supply Chain and Logistics EMLA at ����AV, stated: “The entire value chain must be involved to achieve our joint goal of climate neutrality by 2050. Reliable, efficient and sustainable logistics for our ever more sustainable products are integral to this effort. We collaborate with our customers and transport companies to optimize the supply chain. This includes improving load capacity, selecting the best transport modes and routes, and introducing using sustainable and future-oriented energy sources like green electricity or HVO to replace fossil fuels.”

As part of the collaboration, DB Cargo BTT provides ����AV with an end-to-end transport solution that combines several sustainable approaches: First, the chemicals are transported in tank containers from the production sites of ����AV in Germany to a nearby railway terminal using bio-fuel (HVO 100)-driven trucks. The tank containers are then transported to a distribution center in Poland via rail, keeping trucks off the road and saving respective emissions. From there, bio-fuel (HVO 100)-driven trucks are again deployed to distribute the chemicals to end customers in Poland to ensure on-time delivery. This particular bio-fuel is one of the most sustainable alternatives to fossil diesel. Altogether, the combination of these modes of transport saves at least 70% of CO₂ emissions compared to conventional road transport methods.

Torsten Lüders, Managing Director of DB Cargo BTT GmbH, points out: “At DB Cargo BTT, we also rely on working with external partners across all modes of transport in order to arrange traction or first and last mile services as efficiently as possible for our customers. For ����AV, we have recently transported essential chemical products to Poland and we’re now happy to combine our rail expertise with bio-fuel-driven trucks for the first and last mile. This collaboration exemplifies our commitment to enabling more sustainable supply chains and supporting the transformation of the chemical industry. Projects like these demonstrate how we, as part of the DB Cargo group, offer our customers a significant degree of added value and are an essential part of European supply chains.”

The collaboration is designed to be flexibly scaled in the future to accommodate growing business needs. It also sends an important signal to customers of ����AV, such as the Polish Selena Group, a global manufacturer of construction chemicals and materials, who benefit from the delivery of MDI with a lower carbon footprint, as it helps to reduce their Scope 3 emissions.

Bernd Hennig, Head of Trading Cluster MDI at ����AV remarked: “Together with Selena Group, we are committed to advancing sustainable solutions across the entire value chain, offering our valued customers not only more sustainable materials but also sustainable transportation solutions.” Michal Specjalski, Member of the Management Board of Product and Innovation at Selena Group added: “Today, sustainable business no longer means having to compromise between efficiency and quality. In Selena Group we are constantly increasing our commitment to the development of sustainable construction. We carefully follow trends and changes in the world around us. We are constantly working on minimizing our environmental impact and rational resource management. That’s why we are delighted to have ����AV and DB Cargo BTT at our side as strong partners who share our commitment to reducing emissions and achieving climate neutrality targets in Europe and worldwide.”

Selena Group and ����AV are already collaborating in multiple ways to advance the circular economy. For instance, they are developing polyurethane (PU) foams for improved thermal insulation in buildings which are based on MDI of the Desmodur^® CQ product range. It is ISCC Plus-certified, using plant-based raw materials through mass balancing. As a result, these products have a lower carbon footprint compared to those derived from fossil raw materials—and now, thanks to the transport solution, they will also be delivered to Selena in a more sustainable way.

¹ _{The reduction in CO₂ emissions is based on a comparison between the use of HVO100 renewable diesel and conventional fossil diesel}

����AV is one of eight companies, including partners from the fields of AI, information technology for low-altitude aviation and carbon fiber composite materials, to sign a Memorandum of Understanding (MOU) with GOVY, a newly established subsidiary of GAC dedicated to the development of eVTOL aircraft. As a key partner in this ambitious project, ����AV brings its unique expertise in high-performance materials and sustainable solutions for the advancement of next-generation flying cars.

“Our collaboration with GAC represents a significant step forward in transforming urban air mobility. By leveraging ����AV’s expertise in sustainable and innovative materials, and GAC’s visionary leadership in flying car development, we are poised to create solutions that redefine the possibilities of urban transport,” said Lily Wang, President of the Engineering Plastics Business Entity at ����AV.

“We are committed to pushing the boundaries of innovation and bringing the future of mobility closer to reality,” said Su Qingpeng, General Manager of GOVY. “Partnering with ����AV and other industry leaders allows us to accelerate the development of our flying cars, creating safe, more sustainable, and groundbreaking transportation solutions for urban environments.”

China is making significant strides in the development of eVTOL aircraft, leveraging its advancements in battery technology to integrate these innovations into urban transportation systems. This strategic focus is driven by the potential of eVTOL vehicles to alleviate urban congestion, reduce pollution, and enhance connectivity, aligning with consumer desires for efficient transportation and the government’s goals for technological innovation and sustainable urban development. These vehicles are designed for short-distance urban travel, with current models offering ranges suitable for inter-city commutes.

Under the agreement, ����AV and GOVY will collaborate on several priority areas. Key initiatives will include developing innovative polycarbonate glazing solutions to reduce vehicle weight while maintaining high performance and safety standards, and exploring materials for smart and efficient lighting systems tailored to the unique requirements of eVTOL aircraft. The collaboration will also address high-performance materials that enable seamless integration of smart systems and components. A strong emphasis will be placed on low-carbon solutions, utilizing materials with attributed bio-circular content and recycled feedstocks to reduce emissions across the vehicles’ lifecycle.

At the signing ceremony, a demo flying car was unveiled, featuring an impressive range of 200 kilometers in just 40 minutes. This prototype showcases a hybrid design that integrates both fixed-wing and rotary-wing capabilities, combining the efficiency of conventional airplane-like forward flight with the vertical takeoff and landing versatility of helicopters. Pre-order of such models will begin in 2025, heralding a new era in personal and urban transportation.

These new displays overcome the performance, size and geometric limitations of traditional HUD systems, enabling the practical and scalable implementation of multiple displays in one windshield and elsewhere in side-light glazing. Proof of concepts (PoCs) developed with OEMs will be showcased at CES 2025 in Las Vegas from January 7–10.

The MOU builds on years of collaboration, leveraging each company’s technologies to manufacture holographic-enabled transparent HUDs for the automotive market. It enables to look into the steps needed to setup and establish the required facilities and manufacturing capacity, ensuring an efficient, market-ready supply chain to meet the planned production timelines of OEMs wishing to adopt the technology for new driver and passenger experiences. The partnership aims to accelerate the commercialization of the HUD solution, with Eastman leveraging its relationships with automotive OEMs and Tier One suppliers.

A proven solution

In 2024, Ceres and Eastman demonstrated the latest holographic transparent display HUDs to OEMs in Europe, the USA, and China. These HUDs featured multiple transparent displays within a single, fully laminated windshield, each measuring up to 400mm by 300mm. Custom-designed holographic optical elements (HOEs) were incorporated into a single sheet of Bayfol HX^® film, laminated with Eastman’s new developed interlayer stack, achieving the industry's largest field of view.

This achievement was enabled by combining ����AV’s expertise in photopolymer films, Ceres’ digital mastering and HoloFlekt^® roll-to-roll replication system, which produces finished films up to 1400mm wide, and Eastman’s solutions to encapsulate functional films into automotive approved laminates.

“This agreement solidifies our collaboration and moves us closer to delivering a full-stack solution for innovative display implementations,” said Hemant Dandekar, Eastman's global commercial director of automotive for advanced materials, interlayers. “With the building blocks and relationships in place, we’re excited to define a path to viable holographic transparent displays globally.”

“Our Bayfol^® HX enables next-generation truly transparent projection displays for windshields while meeting the high automotive safety requirements.” said Günther Walze, Head of Holographic Lightguiding at ����AV. “With the necessary establishment of hologram mastering and scalable mass-production replication equipment by Ceres, combined with Eastman’s windshield lamination technology, this innovation is ready for deployment to end customers.”

“We have been working closely with global OEMs for years and are now at a tipping point for adoption and scaling of this display technology,” said Andy Travers, CEO of Ceres Holographics. “This is being driven by a combination of a desire for more safety-oriented and intuitive information display features, pressure from safety regulators to reduce driver distractions, and the accelerated pace of innovation and associated need for differentiation among a new generation of car makers.”

This agreement joins the material expertise of ����AV, Eastman’s interlayer solutions and encapsulation know-how, as well as Ceres capabilities in mastering and high-volume manufacturing technology for the successful commercialization and industrialization of holography in transparent displays for windshields.

A fully functional transparent display windshield demonstrator laminate will be showcased at CES 2025 in both the Eastman/Ceres Holographics demonstration suite at The Venetian Hotel - Murano suite, #3201A, and ����AV’s booth in the North Hall, location #8311.

For the highly competitive construction sector, the product sold by Selena offers clear advantages: It can be used with various types of blocks (ceramic, silicate, ACC) with high accuracy and allows for a higher yield compared to traditional cement mortars. The product also improves construction efficiency by curing twice as fast as traditional cement mortars. Additionally, it can be used in a wide range of operating temperatures from -5 degrees Celsius to +30 degrees Celsius, which helps reduce temperature-induced work stoppages.

“Materials play a decisive role for an ever more climate neutral and circular economy”, said Bernd Hennig, Head of Trading Cluster MDI EMEA at ����AV. “If materials providers early in the value chain join forces for climate neutrality, the impact on end products will be significant. In this spirit, we are therefore very happy to deepen our collaboration with our like-minded partner Selena to help the construction sector bring down emissions and meet its climate neutrality targets in Europe and worldwide.”

Buildings are responsible for over one third of greenhouse gas emissions in the EU alone. As about 75% of the buildings in Europe do not meet energy efficiency requirements, the building sector faces a wave of renovations over the coming years. In fact, the EU has just recently updated the Energy Performance of Buildings Directive (EPBD). It states that by 2050, all buildings in the EU should be net-zero emission buildings².

More sustainable adhesive instead of cement

“With existing and upcoming climate neutrality regulations for the construction sector, we expect a steeply rising demand for sustainable building materials”, said Miroslaw Truchan, Senior Category Development Manager, Selena Group. “With a great partner like ����AV, we jointly drive innovation in the construction materials industry. We both believe that innovative products can play a vital role in achieving climate neutrality targets and put us ahead of the curve.”

The Tytan Professional^® Adhesive for Bricklaying uses Desmodur^® CQ MB of ����AV, a bio-based MDI (methylene diphenyl diisocyanate), of which the plant-based feedstock is mathematically attributed to the final product via the mass balance approach certified by the ISCC Plus standard.

Tytan Professional^® Adhesive for Bricklaying is the third product launched from the collaboration between Selena and ����AV. The partnership was deepened in 2023, aimed at collaborating to craft a more sustainable range of polyurethane (PU) foams for enhancing thermal insulation of buildings. Bio-attributed methylene diphenyl diisocyanate (MDI) of the Desmodur^® CQ MB-series of ����AV is already being used in an enhanced version of Selena’s Ultra Fast 70 one-component foam, primarily applied in the . Also, this product is ISSC Plus certified to include plant-based feedstocks through mass balancing and allows for an up to 45% reduced carbon footprint compared to fossil-based products.

_{¹Comparison of 1 can of Tytan Adhesive for Bricklaying (750ml) with the data for generic cement mortar for 1,5 x 25 kg bags.
²}

����AV’s CERTEVO^® revolutionizes security printing with several key features: It supports excellent printability via intaglio and offset processes, enabling embossing structures—surpassing traditional paper and enhancing security elements. Its hotmelt nature eliminates the need for coatings and primers, ensuring superior ink adhesion that simplifies printing and boosts durability. Additionally, advanced laser engravability allows precise micro-engravings, making counterfeiting efforts more challenging.

As a single-polymer composition, CERTEVO^® is recyclable, meeting the demand for sustainable security printing materials. Its high tear resistance and ink adhesion extend the lifecycle of printed items while conserving resources. CERTEVO® thereby addresses environmental concerns and meets evolving sustainability requirements in document production.

Furthermore, its durable composition lowers long-term costs by minimizing replacements, making it an ideal choice for governments and the public sector that prioritize security and environmental responsibility. 

Meet ����AV at TRUSTECH 2024

����AV’s team will be present at the trade show, held at the Paris Expo Porte de Versailles - Pavilion 5.2, from December 3-5, 2024. We invite industry professionals and stakeholders to discuss with us at meeting room 8 and discover how CERTEVO^® and other advanced polymer materials can transform their security printing needs.

Since 2020, ����AV has been partnering with Ausell to recycle 1 million 19-liter polycarbonate water barrels annually, converting them into high-performance post-consumer recycled (PCR) polycarbonates for various industries such as electronics, home appliances and automotive. With this strengthened collaboration, Ausell will supply recycled polycarbonates derived from discarded automotive headlamps, which ����AV will then process into high-quality PCR materials for automotive engineering applications. This partnership marks a further step to effectively closing the plastics recycling loop within the automotive sector, reducing waste and carbon emissions while enhancing resource efficiency.

Lily Wang, Global Head of the Engineering Plastics Business Entity at ����AV, said: “We are excited to deepen our partnership with Ausell as we work closely with our value chain partners to accelerate the circular transformation of the automotive industry. Together, we are committed to pioneering sustainable solutions that will lead the way toward a circular and climate-neutral future.”

Xia Wenjun, CEO of Ausell, added: “Our enhanced collaboration with ����AV represents a significant step toward achieving our shared vision of a circular economy. By turning end-of-life automotive components into valuable resources, we are not only reducing waste but also contributing to the development of sustainable materials for future vehicle production.”

The automotive industry, facing increasing regulatory pressures for sustainability, as well as following their own roadmap to “close the loop” of materials, is looking for robust and adapted solutions to their challenges.

This collaboration positions ����AV and Ausell at the forefront of efforts to develop compliant, high-performance materials while addressing the challenges of plastic waste management and resource utilization in the automotive industry. The recycled polycarbonates will not only enhance the sustainability of automotive components but also demonstrate the potential for high-value recycling solutions.

“Healthcare manufacturers are increasingly adopting sustainable materials to reduce their carbon footprint, and it is our goal to help customers reach their sustainability ambitions,” said Sam Shodi, Head of Specialty Films North America, ����AV.

According to Shodi, the Makrofol^® polycarbonate film provides the transparency, toughness and sterilization suitability needed for many medical applications an example of which is medical implant packaging. “This advancement meets the demands of our healthcare customers, where sustainable materials are crucial for reducing environmental impact while maintaining high quality and safety standards,” he concluded.

With the mass balance approach, bio-based or recycled raw materials are fed in at an early stage of raw material extraction and mathematically allocated to the finished products. This saves fossil raw materials and reduces CO₂ emissions, while the quality of the mass-balanced products remains identical to that of purely fossil-based products. With this drop-in solution, manufacturers can continue to use their proven formulations, equipment and processes.

ISCC is an internationally recognized sustainability certification for biomass and bioenergy. The standard covers all stages of the value chain and is used worldwide. ����AV has major sites across all regions that are ISCC PLUS certified. Among them are world-scale sites like Baytown, Texas; Leverkusen, Dormagen and Krefeld-Uerdingen, Germany; Shanghai, China; Map Ta Phut, Thailand; and Antwerp, Belgium.

Customers can discover more about ����AV’s mass balance films and other premium material solutions, including how they support sustainability goals and drive advancements in medical devices, at the upcoming and trade fairs, November 11-14 in Düsseldorf, Germany.

“Our products touch everyday life in thousands of applications, from cars to electronics to footwear. To accelerate circularity and sustainability we need to work closely with our customers and partners along the value chain on adopting alternative raw materials, renewable energy sources and recycling technologies”, says Dr. Guido Naberfeld, Senior Vice President, Head of Sales and Market Development Mobility at ����AV. “We are excited to show some of our latest developments and projects and are eager to engage in discussions about them at this year’s Fakuma.”

The Fakuma in Friedrichshafen, Germany, is a leading annual international trade fair for plastics processing. Visitors of the ����AV booth will discover a set of exhibits ranging from Polycarbonates to Specialty Films to Thermoplastic Polyurethanes, demonstrating how sustainability and performance can go hand in hand across industries.

Key exhibits include an innovative automotive frontend design that combines looks and functionality while also incorporating electronics. The materials used in the concept are Makrolon® and Makrofol®. The same materials can be used to create nearly monomaterial electronic displays, ideal for integration into smart surfaces in kitchens, vehicles and consumer electronics. One demonstrator, featuring in-mold printed elecontric circuits, will be exhibited.

����AV's recently announced partnership with Neste and Borealis will also have a spot at the booth. It showcases the closed-loop recycling of old tires into highly transparent polycarbonates that can be used in automotive components, such as car headlamps. This innovation exemplifies circularity in the automotive industry through the Makrolon® RP product range, which uses chemically recycled raw materials, attributed via the mass balance approach.

����AV in general aims to become increasingly circular and climate-neutral, with the goal of operational climate neutrality (Scopes 1 and 2) by 2035, and full climate neutrality by 2050. To make products that are advancing toward these goals easily identifiable, ����AV, besides RE or RP, also uses the “CQ” label. CQ stands for “Circular Intelligence”. CQ ecompasses, for example, products that contain at least 25% alternative, non-fossil raw materials, either as components or through the mass balance methodology. This helps to reduce their carbon footprint while contributing to circularity. Some of the abovementioned and more products can be seen at Fakuma.

Beyond Leather’s approach captures the value of apple waste – of which around 4 million tons is produced every year – by upcycling it into a high-performance and more sustainable alternative to conventional leather made with animal skin. With a high content of short fibers and polymers, apple waste (including cores, seeds, and stems) can be activated to give a strength and suppleness to the final material, recreating the functional and aesthetic properties that make leather so desirable. To produce LEAP^®, the apple-waste blend is applied to a TENCEL^TM textile backing and finished with the protective coating containing INSQIN^® PU.

Inspirational leather-look products; aspirational performance

For brand customers and end consumers looking for leather alternatives, the launch of LEAP^® stands as a testament to the power of innovation and collaboration.

“With around 25% of an apple discarded after pressing, we wanted to capture this waste’s value in premium applications. We believe that looking into waste streams and using upcycling is crucial to reduce emissions. It is our mission to show how much value there is in waste and, ultimately, make waste beautiful,” says Mikael Eydt, Co-Founder & CEO, Beyond Leather Materials.

“����AV is delighted to have contributed to the development of this leather alternative made with apple waste, which has significant potential to improve textile sustainability in a wide range of industries,” says Dr. Torsten Pohl, Head of Global Textile Coatings ����AV. “Our low-VOC, low-emission, waterborne, and partly-bio-based INSQIN^® coating technology is the perfect fit for LEAP^®, enabling the premium durability, flexibility and perceptual quality needed in today’s market while offering a more sustainable solution for partners like Beyond Leather. We look forward to continuing our collaboration in applications spanning everything from small goods typically made of leather such as wallets, purses, and key cases, to automotive interiors.”

“We are excited to partner with Li Auto and support their pursuit of intelligence and electrification in automobiles,” said Guido Naberfeld, Senior Vice President, Head of Sales and Market Development Mobility at ����AV, during the MOU signing event at ����AV’s integrated production site in Shanghai. “By leveraging our expertise in engineering plastics and circular solutions, we aim to enable innovative future-oriented mobility solutions and reshape automotive material cycles, driving the industry towards a smarter and more circular economy.”

Under the MOU, ����AV and Li Auto will establish a “Joint Innovation Platform” to drive the development and application of more sustainable engineering plastics with alternative feedstocks, such as bio-waste and recycled sources, across various automotive components. Key initiatives will involve integrating materials attributed with bio-circular content through mass balancing into automotive lighting, functional interior and exterior parts, and smart system components. The two sides also agreed to explore innovative processes and business models for using recycled lighting materials in new automotive parts together with value chain partners.

Under the joint platform, the two sides also seek to deepen their collaboration in developing lighting, smart systems, and thermal management solutions. This will include high-performance optical-grade materials, smart surface technologies and thermally conductive solutions.

“Li Auto is dedicated to implementing the ‘Smart + Electric’ strategy with innovative materials and designs, aiming to offer users a safer, more comfortable, convenient and refined travel experience,” said Liao Mengjun, Vice President of R&D Operations at Li Auto. “Our partnership with ����AV will expedite our exploration in advanced materials, supporting the ongoing enhancement of user product demands.”

During the event, the two parties also unveiled two jointly-developed, industry-leading materials: innovative light-diffusing and infrared-transparent Makrolon® polycarbonates. The light-diffusing polycarbonate allows for a more refined and evenly-distributed illumination effect for smart headlights. Meanwhile, the new infrared-transparent polycarbonate achieves a high transmittance of over 85 percent in the near-infrared spectrum. Compared to conventional black polycarbonate, which absorbs solar energy across the entire spectrum, this new material significantly enhances the light aging resistance of components, contributing to greater durability for the smart headlights of Li Auto.

The film documents the development of the innovative solar racing car “����AV Adelie” and the participation of the team of around 50 students in the Bridgestone Solar World Challenge 2023 in the Australian outback. Using state-of-the-art technology and innovative high-performance materials from ����AV, the students have designed an energy-efficient and environmentally friendly racing car. The solar racer paves the way for the development of environmentally friendly vehicle technologies.

From design to the race track

The documentary follows Team Sonnenwagen from the design of the “����AV Adelie” through to qualifying and then the race across Australia. In addition to the technical aspects of the racing car, the documentary also focuses on the emotions, challenges and tireless team spirit behind this ambitious project. In addition to the interviews with the dedicated students, numerous experts also have their say, including the renowned science journalist Ranga Yogeshwar, the Minister for the Environment, Nature Conservation and Transport in NRW, Oliver Krischer, the former Opel boss and CEO of Continental, Dr. Karl-Thomas Neumann, and Sucheta Govil from ����AV.

Available online on YouTube

“We are extremely proud that there is a documentary about our team and the great work of the past two years. This project is so important because it can play a small part in solving an important sustainability problem - greenhouse gas-neutral mobility,” says Sonnenwagen team leader Leonie Brandt.

The documentary “SONNENWAGEN - Future Mobility” will be available online on from August 27, 2024 at 6:15 p.m. The trailer is already available .

Although less associated with the chemical industry or the circular economy, design plays a key role in enabling circularity through various means. It offers a huge opportunity for providers of sustainable and high-performance materials like ����AV to bring in their expertise.

“The design phase determines a large part of a product’s environmental impact: From the choice of materials to repairability, from a long and useful product life to recyclability. We therefore can’t understate the topic of design when we want to become fully circular,” explains Dr. Christopher Stillings, Head of Color & Design at the Business Entity Engineering Plastics within ����AV. “As materials experts early in the value chain, we at ����AV sit in the sweet spot to consult our customers and partners on how to use circular design principles when conceiving a product. We want to systematically collaborate with designers to make use of that.“

Gaining momentum

And while product design is not new, a shift is indeed happening - also due to regulators placing increasing emphasis on the topic. For example, the EU is tightening its requirements for , and to make products sold in the EU more reusable, repairable, upgradeable and recyclable. There is also a proposal for a DIN “Method to achieve circular design of products” on its way. In the USA, the Department of Energy is pursuing its “”, which also includes the factor of “Recyclability by design”. Other regulatory bodies are discussing similar initiatives.

To use that momentum, ����AV offers solutions in several main areas:

• Dematerialization, e.g. by digitalizing sampling processes. ����AV recently announced its new digital sampling tool for that purpose.
• Design for longevity. This is bread and butter for a high-performance materials manufacturer that provides materials e.g. for products for cars, buildings or the cold chain that have a lifetime of several decades.
• Modular design makes it easier to disassemble products and recycle the parts.
• The use of circular raw materials with a low emission footprint make products made of such material more circular to begin with.

The push for circular design is getting stronger and ����AV is addressing the topic on various fronts. In fact, it has been addressing the topic for decades already and can build on that expertise. The K67, a car entirely made of plastics made for the K-fair back in 1967, is just one example.

Under this partnership, one of ����AV’s key roles is to provide more sustainable plastic solutions along with their carbon footprint data. Alibaba Cloud’s Energy Expert, an AI-driven sustainability platform, plays a crucial role in realizing the whole life cycle emission accounting from recycled materials to final consumer products leveraging digital technology such as blockchain. It also provides an end-to-end solution for industrial companies to measure and optimize their carbon footprint across their production lifecycle.

“As a materials manufacturer with a high focus on sustainable material innovation, ����AV is committed to driving circularity and climate neutrality. Our collaboration with Alibaba Cloud marks a significant milestone in our journey towards a circular and climate-neutral future,” says Lily Wang, Global Head of the Engineering Plastics Business Entity, at ����AV. “With our joint solutions, we are supporting our customers to improve their supply chain transparency while building trust among environmentally conscious consumers, thereby driving industries towards a greener future.”

“We are proud to partner with ����AV in pioneering sustainable solutions that drive positive environmental impact,” says William Xiong, Vice President of Alibaba Cloud Intelligence. “By leveraging our advanced cloud infrastructure and expertise in sustainability technology, we are enabling value chain partners to trace materials with enhanced transparency and efficiency as well as to optimize their carbon footprint to achieve their sustainability target. This partnership exemplifies the transformative power of technology in creating a more sustainable future.”

The joint solutions offered by the two parties have already been implemented in the consumer goods sector. For example, ����AV collaborated with China’s leading beverage maker Nongfu Spring to recycle its 19-litre water barrels into post-consumer recycled polycarbonate. The material was then used by KACO, a niche stationary brand in China, to produce gel pens. Through Alibaba Cloud Energy Expert’s carbon emission accounting and digital tools, consumers can scan a QR code on the packaging of the pens to trace the origin of the material, see a detailed breakdown of the carbon footprint at each stage in the production chain and the number of carbon emission slashed compared to the virgin materials.

The automotive supplier Webasto has developed the prototype of a Roof Sensor Module (RSM) in an elegant design. It is equipped with a polycarbonate panel for aesthetic and seamless integration of sensors for automated and autonomous driving. For the module’s bezel, ����AV supported with its injection molding expertise at the technical center at its Headquarters in Leverkusen.

The bezel is produced on ����AV's 2300-ton injection molding machine. The first shot is made of the transparent polycarbonate Makrolon^® AG, which is highly permeable to various sensor signals. For the second shot, the black, mineral-reinforced PC-ABS Bayblend^® T95 MF is used. Thanks to the combination of both materials, the roof module meets high mechanical requirements while offering an attractive design with glass-like surfaces and transparent sensor windows.

Integration of components and coating

In addition, the combination of these materials provides the necessary design freedom for the integration of all relevant electronic and mechanical components. Many of such parts are furthermore attached by elements that are formed in the second shot. Suitable potential coating systems for the RSM are polysiloxane coatings, which are sprayed via a high-speed rotary bell to ensure homogeneous layer thicknesses over the entire component surface.

In use, radar and lidar sensors, as well as cameras, measure the distance and speed of objects in front of and next to the vehicle and also reliably detect traffic lights, traffic signs and road markings. In order to function optimally, the temperature of the electronics must be regulated. This is ensured by an integrated thermal management system. The high heat deflection resistance of polycarbonate ensures that the roof module remains in shape even at high outside temperatures and strong sunlight and that the functionality of the sensors is not impaired.

The Makrofol^® ST polycarbonate film, which is introduced in specific sections and is characterized by a defined transmission spectrum in the visible and infrared range, enables a seamless design with high transparency for LiDAR signals. In addition, the film serves as a carrier for Canatu's transparent heating system. This de-icing function as well as the specially developed cleaning system ensure flawless operation even under adverse weather conditions.

All in all, this development offers not only a portfolio of engineering solutions, but also concepts for developers of advanced driver assistance systems (ADAS) who need reliable and cost-effective bezels for their 3D imaging systems.

At the international VDI Congress PIAE on June 19 and 20, 2024 in Mannheim, Germany, ����AV expert Christoph Klinkenberg and Head of Research and Development Magnus Sviberg from Webasto Roof & Components SE will give a presentation on this development on June 19 from 12:15 p.m. The co-author is Rainer Hagen from ����AV. The company will also be exhibiting at the accompanying exhibition.

“Circularity requires cooperation, and this cooperation with our partners Neste and Borealis is testament to the possibilities at our disposal,” says Guido Naberfeld, Senior Vice President, Head of Sales and Market Development Mobility at ����AV. “We are creating options to turn old tires into new car parts again. With that, we are supporting our automotive customers and addressing an increasingly prominent question discussed across the value chain: How to match high-performance materials with recycled content? Projects like this can be the answer.”

As part of the collaboration, Neste turns liquefied discarded tires into a high-quality raw material for polymers and chemicals manufacturing and supplies it to Borealis. Borealis will then process the Neste-produced raw material into base chemicals phenol and acetone, which are supplied to ����AV. ����AV can use these materials to make polycarbonates. The share of recycled content is attributed via the mass balancing approach all the way to the final products using ISCC Plus certification.

The first products based on the collaboration are already available as each party has manufactured the first batch of their respective contribution to the project. Aside from polycarbonates, the project partners may also consider polyurethanes as a possible end product, which could also find its way into parts of the interior of a car. The companies emphasize that the potential to scale-up these types of developments should be considered when setting ambitious targets for future EU regulations, such as the End of Life Vehicles Regulation.

“We are demonstrating the importance of value chain cooperation to give new value to waste,” says Thomas Van De Velde, Senior Vice President Base Chemicals at Borealis. “We are proud that Borealis, in collaboration with Neste, is able to play a role in this project, providing more sustainable solutions for polymer applications for ����AV and its customers.”

“This project can serve as a blueprint when it comes to establishing circularity in the field of plastics in cars,” says Jeroen Verhoeven, Vice President Value Chain Development for polymers and chemicals at Neste. “It shows how low-quality waste materials can be turned into very high-quality plastics. This is good news for the polymers and automotive industries as well as for the environment.”

The collaboration will be presented during the PIAE in Mannheim on June 19-20, 2024.

The aim of the partners is to recycle the sorted polyurethane foams as efficiently as possible by combining mechanical and chemical technologies after careful sorting by foam type in the mattress cutting plants.

Collaborations leveraging own expertises with like-minded partners are key: In addition to Ecomaison and ����AV, the French dismantling company Secondly and Federal Eco Foam, a Belgian specialist in the mechanical recycling of flexible foams, are involved as partners in the project, which is planned to run for a maximum of 24 months. The project is called Foam Recycling Ecosystem Evolution (FREE) and coordinated by ����AV and half-funded by Ecomaison.

For the FREE consortium, the motivation lies in the added value of the material that can be recovered from the used foams and the opportunity to enter a more sustainable circular economy. The partners want to explore all possibilities in a future-oriented foam recycling ecosystem and are convinced that chemical and mechanical recycling will complement each other in a meaningful way. As dismantler and sorting actor, Secondly is interested in empowering its sorting processes to be able to supply to recyclers a specified quality of foam.

At the same time, the project will provide a good picture of how the foam recycling market in the coming years may look like. The partners truly believe that chemical and mechanical recycling can be complementary given different specifications of inlet materials being sorted already at dismantlers. To provide added value to the PU foam material, the consortium will investigate all possibilities in a future oriented eco-system of foam recycling.

The research and development project includes the foam sorting at the dismantling step, as well as a comparative feasibility study for two recycling processes for the sorted foams covering economic and ecologic value co-creation.

A few years ago, ����AV and its partners developed a chemical recycling process that is the only one of its kind capable of ultimately recovering both main raw materials of flexible PU foams in high purity. The company also operates a pilot plant at the Leverkusen site for this purpose. Together with the waste management industry, the company wants to drive the process forward to industrial use.

To make its vision of a fully circular economy a reality, ����AV is making the development of innovative recycling technologies a priority and calls the evolution of recycling . The chemolysis of PU mattress foam is the first initiative of ����AV of its kind and is called Evocycle^® CQ Mattress.

The award is presented by the "German Design Council." Candidates submit projects that have been launched on the market no longer than five years ago, but they can also be nominated by the council. The evaluation is carried out by an independent, interdisciplinary expert jury. The award ceremony took place on May 14 in front of around 300 invited guests at the Futurium in Berlin.

"We are very pleased that the German Design Council has honored us with this award," said Joan Miquel García Martínez, Senior Project Manager Arfinio^® at ����AV. "Arfinio^® is a real breakthrough for design, surfaces, and sustainability. This award shows the relevance of combining design, manufacturing technology, and materials for the development of new products and confirms that we are on the right track."

The Arfinio^® technology, which ����AV has developed together with its partner Arcesso, a manufacturer of custom polyurethane parts, combines liquid high-performance polymers and unique minerals with the RIM process (reaction injection molding). This combination enables seamless shapes and surfaces – and was long considered impossible. The resulting products are durable, repairable, and lightweight, can be produced quickly, and allow for free designs. The material also contributes to sustainability as it can be produced with partially bio-based raw materials, can be mechanically recycled at the end of its life cycle, and reused for the production of new products.

During the joint developments with ����AV, it turned out that a plastic from the Makrolon^® RE series meets the aforementioned requirements very well. This is an ISCC PLUS-certified polycarbonate with raw materials from biological waste and residues allocated via the mass balance approach.

Compared to a fossil-based standard type, the selected polycarbonate during its production (cradle to gate¹ ) has a CO₂ footprint that is reduced by around 80 percent with a share of more than 85 percent allocated renewable raw materials. Makrolon^® RE polycarbonate is part of ����AV's CQ family, a label used by the company to identify products with a physical or attributed content of at least 25 percent alternative raw materials.

In addition to the selection of more sustainable materials, the development of the new device focused on energy efficiency during use. Deutsche Telekom specifies the carbon dioxide equivalents saved for 1,000 MagentaTV One-devices in energy-saving mode at around 15,500 kilograms per year. Accordingly, the telecommunications company has marked the device with the #GreenMagenta label to underline its positive contribution to climate protection and the responsible use of resources.

"Reducing the CO₂ emissions of plastic parts is an important issue for us in order to achieve our ambitious climate targets," says Dr. Steffen Wasmus, Group Partnering & Devices at Deutsche Telekom. "Makrolon^® RE makes a valuable contribution to this. The collaboration with the global ����AV team was extremely helpful, as they significantly supported us in the selection and application of suitable materials." Deutsche Telekom aims to achieve net-zero emissions in scope categories 1 to 3 by 2040 across the entire value chain, from production to the use phase of their products.

"Deutsche Telekom is an important partner for us. We jointly want to achieve climate goals and drive the transition to renewable raw materials. Makrolon^® RE makes it possible to use biowaste as a renewable carbon source for the telecommunications value chain without compromising on performance and design," adds Dr. Niklas Meine, Industrial Marketing Electrical & Electronics in the Europe, Middle East, Africa (EMEA) region at ����AV.

Deutsche Telekom's design team was particularly interested in high-quality processing of the devices, as well as intuitive handling of the device and user-friendly plug-and-play installation.

The mass-balanced polycarbonates from the ����AV RE portfolio offer the important advantage of achieving virgin product quality and covering a wide range of applications, as they have the same good product and processing properties as their purely fossil-based counterparts. In the case of MagentaTV One, Deutsche Telekom is for the first time using a Makrolon^® RE which displays high transmittance in the near-infrared (NIR) radiation for the TV box and remote.

¹ _{This takes into account a partial product life cycle from raw material extraction (cradle) to the factory gate (of ����AV), also known as cradle-to-gate assessment. The methodology is based on the ISO 14040 and 14044 standards and has been critically tested by the TÜV Rheinland on plausibility. The calculation takes into account biogenic carbon uptake.}

"A paradigm shift and intensive cooperation along the value chain are needed for the transition to a circular economy to succeed. The chemical and waste management industries in particular must continue to grow together in the future in order to create synergies and develop solutions together," says CEO Dr. Markus Steilemann. "With innovative recycling technologies and now also as an authorized waste dealer, ����AV is well equipped for this. We can now actively shape partnerships for waste management and a recyclate portfolio in the EU ourselves."

"IFAT brings together many established players in waste management. In addition to making new contacts, we also want to position chemical recycling, which is often still viewed skeptically, as an integral part of a modern circular economy. By participating in IFAT, ����AV is demonstrating to many stakeholders the contributions our company wants to make to circular integration," says Tara Nitz, Manager Global Circular Economy and responsible for IFAT cooperation at ����AV.

Broad portfolio of recycling technologies

In addition to various exhibits showing current examples of recycling solutions and partnerships, ����AV uses the world's leading trade fair for the waste management industry to explain mechanical and chemical recycling technologies in order to create transparency and strengthen confidence in the efficiency of such developments. The company has many years of experience in the mechanical recycling of polycarbonates and thermoplastic polyurethanes (TPU) and only last year significantly expanded its capacities for the processing of mechanically recycled products in China and Thailand.

For ����AV, chemical processes include chemolysis as a method for recovering raw materials under the influence of chemicals, smart pyrolysis at elevated temperatures and enzymatic recycling, in which microorganisms break down the chemical bonds. What they have in common is that the polymer molecules are converted back into the original raw materials, from which new products of the same quality as new goods can be created. The processes will be clearly explained at the ����AV stand on the "Recycling Wheel".

At IFAT, ����AV will also show how circular solutions in its product portfolio are becoming even more recognizable for customers. With the “CQ” concept, ����AV emphasizes the alternative raw material base for its products if it is at least 25 percent. “CQ” stands for Circular Intelligence. With the new recycling technologies, the CQ portfolio is now growing even further. This includes the reuse of polyurethane mattress foam components – the first chemical recycling initiative marketed by ����AV under the name Evocycle^® CQ.

For the 2024 brief, undergraduate students from all around the UK and Ireland were invited to design independently powered products made primarily of plastics, capable of being used off-grid and targeted at either the domestic or sports and leisure markets.

Chairman of the DIP judging panel, Richard Brown, praised the sheer range and creativity of ideas as well as the quality of the products, which he said made the task of selecting six finalists from a vast number of entries particularly challenging.

"The final six have interpreted the brief in innovative ways, made good use of materials and demonstrated that they have researched their subject thoroughly in order to create their solution. We are very much looking forward to seeing them at the final judging session in London on May 24."

As part of their prize, all finalists have been invited to attend a two-day plastics processing training course at the UK headquarters of Sumitomo (SHI) Demag, a world-leading manufacturer of injection moulding machines. The DIP judges have also provided each finalist with feedback and areas for improvement, so they can refine their products before May 24.

During the final judging, the products will be carefully evaluated and the results will be announced at the prize-giving ceremony on July 5, in London.

Design Innovation in Plastics is the longest running plastics competition of its kind in Europe, having been established in 1985. It is headline sponsored by ����AV, the Institute of Materials, Minerals and Mining, The Worshipful ����AV of Horners and also supported by leading design and plastics organisations.

This year’s finalists:

Gargi Agrawalla, Loughborough University: Ear Boost, a product for simutaneously dehumidifying and charging cochlear implants.

Brandon Hopkins, London South Bank University: Saltbuoy, a salt-water powered data buoy.

Jake Lee, Glasgow School of Art: SkinTemp, a core temperature sensor to keep people safe in cold water.

Jem Mitchell, Glasgow School of Art: Sentree, a sonic deterrent for trees to protect them from overgrazing.

Isabel Payne, Glasgow School of Art: SafiCase, a self-powered case for sterilising a menstrual cup with minimal water.

Joe Shade, De Montfort University: Beehive, a smart beehive for monitoring and providing information about the wellbeing of the bees.

About the Design Innovation in Plastics Award:
Established in 1985, Design Innovation in Plastics is the longest running student plastics design award in Europe. For more information visit:

The Institute of Materials, Minerals and Mining (IOM3) is a major UK engineering institution and is the professional body for the advancement of materials, minerals and mining to governments, industry, academia, the public and the professions. For more information visit

The Worshipful ����AV of Horners is one of the oldest livery companies in the City of London, formed to regulate the horn-working trade. In 1943 it adopted its modern equivalent, the plastics industry.
For more information visit

Under a joint pilot program initiated by German federal enterprise GIZ (Deutsche Gesellschaft für Internationale Zusammenarbeit), ����AV and partners will collaborate to establish closed-loop pathways for high-value plastics from end-of-life vehicles (ELVs). The goal is to create an efficient and sustainable automotive plastic recycling system, advancing the more sustainable “transformation of the industry”. The pilot program was announced at ����AV’s booth during the CHINAPLAS 2024 international trade fair in Shanghai. Notable partners include leading automotive brand owners such as NIO of China and Volkswagen, Chinese recycling company GEM, and third-party certification bodies like TÜV Rheinland.

"We are proud to partner with like-minded value chain allies to pioneer closed-loop plastic recycling in the automotive sector," said Lily Wang, Global Head of the Engineering Plastics Business Entity at ����AV. "By leveraging our collective strengths and resources, we are confident in our ability to build a closed-loop for automotive plastics recycling, thereby reducing waste and carbon emissions at the source while improving resource use efficiency. Through this joint program, we aim to expedite the automotive industry’s transition toward a more climate-neutral and sustainable future."

"The automotive industry stands as one of the most resource-intensive sectors globally, yet the potential of high-value plastics from ELVs remain largely untapped," said Martin Hofmann, Cluster Head in charge of Climate, Energy, Environment and Biodiversity at GIZ. "GIZ is steering an innovative endeavor to explore closed-loop pathways for high-value plastics from ELVs. I firmly believe that GIZ and our partners can forge a path towards the transition to a sustainable, circular economy."

As part of the pilot program, a team of professionals will explore methods to recycle and process waste polycarbonate components, such as end-of-life car headlights, into post-consumer recycled (PCR) polycarbonates. The recycled materials will then be reused for various interior and exterior vehicle applications, saving resources and reducing carbon emissions.

This could offer urgently needed long-term solutions for the automotive manufacturing industry, which seeks high-quality PCR materials that are compliant and high-performance amid increasingly stringent regulations. For example, in 2023, the European Commission proposed a new regulation to enhance the circularity of the automotive sector, mandating that 25 percent of the plastics used in a new vehicle must come from recycling, of which 25 percent must be recycled from end-of-life vehicles.

����AV will also be showcasing more solutions for the automotive industry at its booth at the CHINAPLAS 2024, such as an intelligent front grill and mono-material polycarbonate headlamp that are designed for a connected and circular future.

For a closer look at ����AV’s solutions at the CHINAPLAS 2024, visit the company at booth 7.2-C38, at the National Exhibition and Convention Center (Shanghai) from April 23 to 26, 2024.

Initial market engagement with automotive brand owners for a serial application of a high-purity polycarbonate is promising, it would represent having a transparent polycarbonate attributed with chemically recycled raw materials.

"We are very excited to expand our existing portfolio of more sustainable polycarbonates with this new product range, which marks another milestone in building the circular economy," explains Lily Wang, Global Head of the Engineering Plastics Business Entity at ����AV. "Together with our partners, we are already helping to conserve fossil resources and to give a second life to existing waste streams. We also support our customers in achieving their sustainability goals by providing materials that meet the highest purity standards."

Recycled raw materials in trend

More and more industries are asking for products with a specific proportion of recycled raw materials, also in the expectation of upcoming regulatory requirements or voluntary programs, such as the European End-of-Life Vehicle Directive under review (ELV) and the U.S. Electronic Product Environmental Assessment Tool (EPEAT) for electronics products. The RP series offers identical quality as incumbent fossil grades and belong to ����AV's CQ family. The company uses this suffix to identify products that contain at least 25 percent alternative raw materials. At certain sites, such as Krefeld-Uerdingen in Germany, the plastics in the new range are also produced exclusively using renewable electricity.

The input for Makrolon^® RP is provided by Neste and Borealis: Neste provides high-quality recycled feedstock for new polymers, which is then turned into phenol and acetone by Borealis before it finds its way to ����AV’s site to produce Makrolon^® RP.

"Through chemical recycling, we can enable recycled content even for the most demanding applications," says Jeroen Verhoeven, Vice President Value Chain Development for Neste’s polymers and chemicals business. "Therewith, we can help companies across various sectors to achieve their recycling-related targets – and we are excited to see ����AV put it into motion."

"Borealis is very happy to support ����AV in this important initiative – helping to provide credible sustainable solutions and demonstrating the importance of value chain cooperation to give new value to waste," says Thomas Van De Velde, Borealis Senior Vice President Base Chemicals.

In addition to applications in the automotive industry, ����AV also wants to address other key industries such as the electrical & electronics and the healthcare industry. The aim is to manufacture high-quality and durable products with chemically recycled attributed feedstocks. At the end of a long usage phase, the plastics can still achieve a "third product life" through mechanical recycling and the further development of chemical recycling technologies.

The new series complements ����AV's existing portfolio of more sustainable polycarbonates – the mechanically recycled Makrolon^® R products and certified mass-balanced grades of the Makrolon^® RE series, which are produced using biowaste and bio-residues. The RE series are now also available with 25 percent renewable attributed sustainable share.

The first applications for the new grades could be in the electrical and electronics industry, as well as in healthcare. Both sectors are particularly well represented in Asia. For their use in housing parts, plastics of the new Apec^® XT line must above all offer freedom of design, dimensional stability, impact as well as chemical resistance and, in some cases, good flame retardancy.

There are also promising prospects for the copolymers in telecommunications and photovoltaics, for example in antenna housings, where weather-resistant, electrically insulating, ductile and flame-retardant materials are needed.

Further product innovations based on the new copolymer technology platform could focus on the automotive industry and infrastructure, where plastics from the new series have good prospects for use in housings for residential energy storage systems, charging stations and wall boxes, for example, thanks to their good electrical insulation properties, weather resistance and flame retardancy.

Apec^® XT grades will be designed to remain resilient even in the harshest conditions. The new copolymer technology enables the production of products that exhibit high impact strength even at temperatures as low as minus 40 degrees Celsius. In addition, these copolymers have improved chemical and ageing resistance, making them ideal for applications that require contact with aggressive cleaning agents and long durability in outdoor applications.

More sustainable products also available

APEC^® XT will also be part of the ����AV CQ portfolio of more sustainable product solutions. In that regard, ����AV will offer copolymer-based products in a version with up to 80 percent of ISCC PLUS-certified mass-balanced raw materials attributed from biowaste and bio-residues.

In addition, the company will offer products that incorporate recycled materials in order to also further reduce its environmental footprint. Moreover, due to its superior weatherability performance, the extended service life of APEC^® XT based products will improve product carbon footprint over its entire life cycle.

The advantages are obvious: customers do not need to invest in expensive prototype tools and replacement materials or in complex color matching processes. ����AV expects that initial sampling loops can be carried out completely virtually to a certain extent – this saves time and material resources. In future, the company will offer all services related to sampling under the Imagio^® CQ brand. The suffix "CQ" stands for Circular Intelligence and emphasizes that the technology makes its contribution to a circular economy in the form of significant material savings.

ʺOur strategy is to get in touch with our customers at an early stage of product design, when the first material specifications are being defined,ʺ explains Dr. Tobias Rausch, Business Development Digital Sampling in the Engineering Plastics business unit at ����AV and head of the project. ʺWe also want to facilitate collaboration between cross-site teams with new digital tools such as catalogs and material twins.ʺ

Faster and more efficient

Customers' product development requirements are constantly growing: they want to be flexible in their choice of materials and increasingly value a more sustainable origin. At the same time, they want to bring their products to market faster while increasing efficiency and saving costs. In addition, they often work in several teams across regions, which need to communicate effectively with each other and also exchange sample parts.

The optimal solution for these requirements is to involve ����AV and its Imagio^® CQ program at an early stage. This enables customers to make a material decision more quickly and generate and visually evaluate sample parts in the early stages of development. This saves time and costs during specification, and the suitability of more sustainable plastics can also be tested at an early stage. In the three-dimensional space of color, material and finish (CMF), the possibilities are almost unlimited.

The backbone of the digital solution is X-Rite/Pantone's Total Appearance Capture (TAC) technology, which captures optical properties such as color, gloss, transparency, translucency or texture of a specific material sample using an optical appearance measurement device. The data is stored in a special data format. This is supported by leading rendering software tools that ����AV customers use for their design and marketing visualization. ����AV's Color & Design Centers (CDCs) in Filago, Italy, Newark, USA, and the Caojing and Guangzhou facilities in China are already equipped with the technology to create digital twins of materials.

A new tool for sales and marketing to search for color combinations – the Imagio^® Color Finder (ICF) – also serves to achieve this goal. Overall, ����AV expects a shift from costly color matching requests in the CDCs to existing color codes with a better search experience.

The Imagio^® CQ family has now been expanded to include a module called Imagio^® Optical Material Data. The target group here are experts from the field of development and simulation of optical components, i.e. vehicle headlights and interior lighting, as well as general lighting. The module is already being tested with customers and will be the first Imagio^® module to be available after the required registration. On the one hand, it will be possible to search specifically for optical material properties in our EP portfolio, and on the other, ����AV will provide the necessary data for optical simulation programs such as Ansys Speos, Optis LightTools or customers' own simulation solutions.

At its booth (C20), ����AV will present materials and solutions that support the corporate vision of achieving a circular economy. Climate neutrality¹ is a core element of that, for which the company just recently announced its “Scope 3 emission” targets, encompassing anything from the raw material base of products to their transport, the performance during their lifetime and the end of their life. By 2035, ����AV intends to reduce 30% of those emissions, while being entirely climate neutral across all scopes by 2050. Working towards that goal, the company’s product portfolio will become ever more sustainable.

“As provider of polyurethane raw materials and solutions, including for example systems for Elastomers, we are at the forefront of circularity and climate neutrality. We take that responsibility seriously and develop recycling technologies, switch to renewable energy and already started the switch to an alternative raw material base,” says Thomas Braig, Head of Elastomers at ����AV. "All the while we ensure maximum quality and performance of our products and to enable our customers to be successful to meet the needs and demands of the market. At our booth at UTECH Europe, customers and interested parties can get a glimpse of how we combine circularity and climate neutrality with product and innovation quality.”

To achieve full circularity, collaborations across value chains in and beyond core industries such as Automotive, Building and Construction or Furniture and Appliances will be key. The motto of ����AV’s booth therefore is “Crafting Solutions For You”, inviting for in-depth exchanges and discussions. It is divided into three core areas:

Crafting Sustainability

In the area dubbed “Crafting Sustainability”, ����AV will be showcasing innovative products and solutions from the fields of alternative raw materials, innovative recycling and renewable energies that tile the way to circularity. One example among the exhibits is Desmodur^® CQ MS. This climate-neutral MDI (cradle-to-gate assessment) is a key component in the production of low-carbon PU insulation boards, specifically designed for thermal insulation purposes.

Crafting Innovations

In the area “Crafting Innovations”, ����AV shows that innovative materials and solutions will be key to answer an ever more demanding market in terms of properties and reliability while striving to cope with the commanding challenge of a more circular and climate neutral world. At the booth, the company will for example showcase a Baulé^® alpha low pressure dispensing machine for cast PU processing. This machine is notably equipped with catalyst and pigment direct injection and allowing an output up to 10 kg/min. To demonstrate automated production capabilities, the company will also showcase a 3-axis robot equipped with sensors and camera allowing automatic mould detection and casting frame selection as well as safety alarms to improve and secure the casting process.

����AV will furthermore give a glimpse on the latest in terms of recycling with its Evocycle^® CQ program. The goal of the Evocycle^® CQ Mattress initiative is to bring end-of-life polyurethane (PU) mattress foam back to its building blocks polyether polyol and toluene diamine (TDA), a key precursor of toluene diisocyanate (TDI), via chemical recycling. These shall then again be used just like virgin materials.

Crafting Performance

Circularity won’t happen unless sustainable products provide at least equal value and quality for customers and industries. ����AV aims to provide its customers with exactly that – and will showcase some examples how it “crafts performance” during UTECH Europe. For example several products made with Desmodur^® 15 prepolymer based systems. On top of improving safety and comfort in the railway sector, these cost-effective and safe solutions can also boost the sewing process in the loom shuttle or reduce maintenance costs in the offshore wind industry.

¹ _{Climate neutrality is the result of an internal assessment of a partial product life cycle from raw material extraction (cradle) to the factory gate (of ����AV), also known as cradle-to-gate assessment. The methodology of our LCA, for which an external audit and certification will soon be available, is based on the ISO 14040 and 14044 standards. The calculation takes into account biogenic carbon sequestration based on preliminary data from the supply chain. No compensation measures were applied.}

The wire and cable industry plays a central role in the global networking of society, especially in the transmission of energy and data. Reliability and efficiency are of paramount importance for these products. That is why ����AV supports its customers with durable, high-performance and more sustainable material solutions.

The materials presented include:

• Coatings, inks and matrix: ����AV's innovative coatings, inks and matrix materials are designed to provide exceptional protection and performance in various applications in the energy and telecommunications industries. With more than 40 years of industry experience in fiber and cable materials, ����AV offers improved design capability, field deployability, reliable performance, ultra-fast curing and excellent protection against attenuation and micro-bending.
• Polycarbonates: ����AV's polycarbonate materials are characterized by excellent strength, transparency and versatility, making them well-suited for a wide range of energy and telecommunications applications. From optical fibers to electrical housings, ����AV's polycarbonates ensure dimensional stability and impact resistance over a wide temperature range.
• Thermoplastic polyurethanes: ����AV's thermoplastic polyurethane (TPU) solutions combine flexibility, toughness and chemical resistance, making them ideal for the protection of flame-retardant cables in various energy and telecommunications applications.
• Elastomers: ����AV's elastomer materials are tailored for exceptional durability and strong resistance against wave and tidal action for energy subsea applications. They offer thermal stability, impact resistance and reliable protection against flex fatigue and hydrolysis. They are durable and reduce maintenance in the offshore wind industry.

Visit ����AV at booth H51 in hall 10 of wire fair to learn more about its innovative materials for the energy and telecom value chain. Further information:

In addition to the reduced complexity of the new production process, the connection to the existing infrastructure in Antwerp with four production lines for polycarbonate also has an advantageous effect, as it combines global scale in production with the flexibility of a stand-alone unit.

"The new production process is the first and only one of its kind in the world and enables us to offer a broad portfolio of material innovations," says Sucheta Govil, Chief Commercial Officer at ����AV. "With the new plant, we can now produce and launch new polymer materials on an industrial scale much faster than before. This is the result of several years of development work by our research and process technology teams, as well as our long-term experience with polycarbonates. In our Solutions & Specialties segment, we focus on sophisticated products with a high pace of innovation, which is a key success factor since customer requirements change quickly. The new production line is a prime example of how we implement this strategy and support our customers to the best extent."

"Compared to pure polycarbonates, the copolymers open up new possibilites for us to integrate further functionalities and properties into our materials," explains Lily Wang, Global Head of the Engineering Plastics business unit. "These can range from improved mechanical properties, a higher resistance against chemical attack to an enhanced flame retardancy. By that, we can offer innovative materials that meet the high requirements of our customers in a wider range of applications. We will focus first on materials for the electrical, electronics and healthcare industries, while future innovations might focus on mobility and other trends." To understand its customers' needs, ����AV will showcase some of the products that could be produced with the new plant at the Chinaplas exhibition in Shanghai in April and looks forward to talking to customers about these innovative material solutions.

The company's stand A39 in Hall 8.0 will showcase commercial luminaires from well-known manufacturers using these more sustainable types of plastic, as well as switches and sockets from the SAGA^TM series from ABB, a leading technology company in the fields of electrification and automation, in which Makrolon^® RE is used.

However, ����AV not only offers the right plastics for increasing technical and sustainability requirements, but also supports customers from conception through product and design development to commercialization. The company's application and material experts strive to meet customer requirements in terms of colors, materials and surface finishes (Color, Material, Finish; CMF). This also includes a close cooperation with industrial designers.

Realistic virtual prototypes

The use of digital technologies in particular contributes to accelerated product development. Complex optical measurement processes can be used to create digital twins and thus photorealistic renderings that allow the appearance of the finished product to be recognized at an early stage without the need to produce complex prototypes. New color trends will be presented at the trade fair stand and digital materials can be tried out on a wallbox rendering on site.

Tailor-made polycarbonates from ����AV are available for lighting and illumination technology, covering a whole range of requirements and properties:

• High light transmission: The Makrolon^® LED range offers exceptional light transmission of over 90 percent, which improves the light output of transparent luminaire covers, lenses, light guides and other optical products. It enables more efficient lighting solutions while maintaining transparency and aesthetics.
• Different levels of translucency: ����AV offers three levels of translucency with maximum light transmission to realize customization of opacity for luminaires. The Makrolon^® DQ range ensures optimum lighting conditions without compromising on design and visual appeal.
• Diffuse reflection: Ideal for reflectors, Makrolon^® RW offers aesthetic white surfaces combined with up to 97 percent diffuse reflection in all directions. This property results in glare-free, eye-friendly light and makes it an excellent choice for various lighting applications. An opaque version is also available to avoid light emissions.
• Good thermal conductivity: The Makrolon^® TC range offers plastic solutions with maximum thermal conductivity. As an alternative to metal heat sinks, these materials not only enable weight reduction, but also design flexibility and more energy-efficient production than with the conventional material aluminum.
• Flame retardant plastics: Under the name Makrolon^® FR, ����AV offers flame retardant variants of Makrolon^® LED, DQ, RW and TC products for applications with high lighting and safety requirements. These include materials that are suitable for use in trains or other means of mass transportation.

If you would like to find out more about the functional and more sustainable material solutions for the lighting industry, visit us at the ����AV stand in Hall 8B, Stand A39.

On March 5, ����AV expert Dr. Niklas Meine will give a presentation entitled "Smart Plastics Solutions for a Circular Economy – Combining Performance, Aesthetics and Sustainability" at stand B60 in hall 5.0 from 2:30 pm.

"Collaborations along the value chain with like-minded partners are key to enable a circular and climate neutral world. Materials play an important role for example in reducing the carbon footprint of buildings. With Henkel’s new wood adhesive based on ����AV’s ever more sustainable raw materials, we jointly contribute to the circular transformation of the construction industry", says Dr. Thomas Roemer, Head of the Coatings and Adhesives Business Entity at ����AV. 

Materials are key for sustainability of various sectors 

By enabling timber construction, load-bearing adhesives already contribute to sustainability of building structures. Since timber is a natural material, its properties inherently underly bigger variations than most synthetically produced materials. It is for example prone to deformation, inhibiting aesthetics as well as functionality, usually limiting its use in load-bearing or other demanding applications. The solution: Utilizing technologies and processes to bond different layers of wood, like cross-lamination or glue-lamination with polyurethane adhesives. Thereby it is possible to create wood panels that maintain strength, form and functionality over time. By increasing the use of alternative raw materials, the carbon footprint of such material can further be improved. 

"This is another step towards an ever more sustainable and circular future. Thanks to our work with ����AV, we are able to supply two of our best-selling polyurethane adhesives now being manufactured using alternative raw materials. In addition and by using the mass balance approach, there is no change in product performance and all load bearing certificates of the adhesives remain. With this, we provide our direct customers as well as architects and construction companies with a solution that contributes to their aim of reducing the impact of materials on the overall carbon footprint of buildings", says Dr. Claudia Meckel, Head of Product Development Engineered Wood at Henkel. 

Henkel and ����AV both treat sustainability and fostering a circular economy with high priority. For ����AV, broadening its raw material base with bio-based or recycled solutions is key part of that endeavor. Since such alternatives are blended with conventional raw materials in the manufacturing process, segregation and allocation are challenging. To attribute the used alternative feedstock to a final product, the mass balance approach is therefore used. That is a chain of custody method allowing to mix traditional and alternative raw materials during production, but separating and allocating them to products in bookkeeping. The soundness and compliance of this approach is certified externally by the internationally recognized ISCC PLUS scheme. For the wood adhesive, all involved sites and partners of Henkel and ����AV are certified according to this scheme. 

^{1 share of the organic mass excluding inorganic materials}

The Makrolon^® RE used by ABB has a very low carbon footprint; at best, it is climate-neutral**. In addition, the raw materials used in the synthesis of its starting materials are largely derived from mass-balanced organic waste and residues such as used cooking oils and fats.

Climate neutral** across the entire value chain as a common goal

"We are delighted to be able to effectively support ABB in its ambitious sustainability goals. Basically, we are doing everything we can to help our customers and their clients with more sustainable product solutions in the development of climate-neutral and resource-saving material cycles," emphasizes Lily Wang, Global Head of the Engineering Plastics Business Entity at ����AV.

ABB manufactures the majority of the SAGA^TM range in its climate-neutral factory*** in Porvoo, Finland. With the help of a highly efficient energy management system, the plant uses only renewable energy and processes low-emission materials such as Makrolon^® RE. "Porvoo is one of the first milestones in our Mission to Zero™ program, which aims to achieve climate neutrality for both our own sites and those of our customers. Materials such as Makrolon^® RE are an important building block in our sustainability strategy," says Mikaela Ahlnäs-Mäkeläinen, Local Product Group Manager at ABB.

Highest quality standards met

The Makrolon^® RE variant used by ABB is colored in signal white (RAL 9003) and is characterized by excellent UV stability. For example, it easily passed a test that simulates two years of horizontal, two-dimensional UV exposure under northern European light conditions. In addition, its electrical properties – such as high dielectric strength and tracking resistance – meet all electrical safety requirements. "The Makrolon^® RE compound is a successful example of how aesthetics, performance and sustainability can be harmonized with just one material," explains Dr. Niklas Meine, Senior Marketing Manager and responsible for Marketing Electrical Engineering and Electronics EMEA at ����AV.

Drop-in solution without compromising on performance

The proportion of attributed alternative raw materials in the compound is over 80 percent. It is mass-balanced and certified in accordance with the established ISCC PLUS standard (International Sustainability and Carbon Certification). In principle, the material variants of Makrolon^® RE are completely identical to their purely fossil-based counterparts in terms of chemistry, physics and processing behavior. "Our customers can therefore replace these counterparts as a drop-in solution in ongoing production processes without having to change processing parameters on the injection molding machines," explains Niklas Meine.

SAGA^TM is designed for the electrification of commercial and public buildings, private residential buildings and the hospitality sector. It can be integrated into the ABB i-bus^® KNX and ABB-free@home^® building automation systems and will initially be marketed in Northern Europe.

^{* Based on an ABB estimation.
** Climate neutral according to verified life cycle assessment based on ISO standards 14040/14044. Climate neutrality is verified by assessing a partial product life cycle from resource extraction (cradle) to factory gate, also known as cradle-to-gate assessment. The calculation takes into account the biogenic carbon sequestration and not the impact from the first "life". It is based on preliminary data from the supply chain and replaces the electricity grid mix with renewable electricity used for the manufacturing process at ����AV. No compensation measures were applied. The LCA methodology developed by ����AV is scientifically sound and state of the art. ID no. 0000083440: ����AV – Certipedia.
*** According to ABB. More information about the Porvoo site is given in the ABB press release:}

"We work closely with our healthcare customers and recognized that we could offer a polycarbonate made for highest curing temperatures in silicone over-molding, helping them more than double production volumes in the same amount of time due to shorter cycle times," said Pierre Moulinie, Global Healthcare Technology Lead, ����AV LLC.

"Our experts provide support every step of the way," he continued, “helping our customers calculate possible savings when switching to this new high-heat Apec^® copolycarbonate grade – for example, simulating material performance in specific applications and calculating cost benefits with our LSR calculator tool.”

In addition to offering high heat resistance and high productivity, Apec^® 2045 copolycarbonate offers other important benefits for this market. These include:

• Durability: Tough engineering plastic with the highest heat resistance in the medical polycarbonate portfolio
• Transparency: Produces transparent parts with high optical clarity
• Biocompatible: Biocompatibility testing according to ISO 10993-1 and USP Class VI for contact of 30 days or less
• Sterilizable: Supports sterilization methods most prevalent in the healthcare industry, including irradiation, autoclave and hot air
• Processability: Consistent and efficient processing

Furthermore, using this new material may contribute to customer sustainability goals, as it can enable circular business models by supporting close- and open-loop recycling, as well as the possibility of attributed bio-circular content.

Attendees at , February 6-8 in Anaheim, California, can visit the ����AV booth (#2221) to learn how the company’s materials push boundaries in healthcare applications.

Polycarbonates from ����AV are found in some of modern technology’s most essential medical devices and play a major role in developing next-generation, life-saving technology. Used in applications where strength, clarity and toughness are necessary, polycarbonates from ����AV exemplify the innovation, safety and biocompatibility that healthcare and life sciences designers and manufacturers across the world have come to know and trust. To learn more about how your company can use ����AV’s material expertise to enhance your medical and healthcare manufacturing, visit our .

Building upon previous sustainable sourcing efforts, this marks the first major procurement agreement involving chemically recycled, circular-based raw materials for ����AV, a major step in the company’s journey towards full circularity. It also helps reduce scope 3 emissions for ����AV and its customers.

"The ability to source raw materials from used plastics for the manufacture of our products makes a decisive contribution to realizing our vision of a circular economy," said Thorsten Dreier, Chief Technology Officer at ����AV. "This is because such raw materials not only enable the reuse of used plastics, but also have a lower carbon footprint, which leads to more sustainable end products."

Benzene and toluene are important raw materials in ����AV’s manufacturing processes used for the production of methylene diphenyl diisocyanate (MDI) and toluene diisocyanate (TDI), respectively. MDI and TDI are critical raw materials used to produce rigid and flexible polyurethane foams, which are used in applications such as household appliance and building insulation as well as furniture and car seats.

Benzene can also be used for the synthesis of phenol and acetone – raw materials for making polycarbonate plastics such as Makrolon^®, which are used in high-quality applications for the automotive, electronics, IT and other industries.

Encina’s proven proprietary catalytic technology produces circular feedstock with a lower carbon footprint when compared to those based on fossil fuels and an exceptionally high yield.

"Encina is proud to be working with ����AV, a company with a long track record of innovation and commitment to sustainability. This agreement represents the beginning of what we hope to be a long-standing partnership between our companies as we work to create a truly circular economy and realize a future in which nothing is wasted," said David Roesser, Chief Executive Officer of Encina.

����AV’s vision to become fully circular is predicated on four key drivers: the use of alternative raw materials, innovative recycling and renewable energy, as well as engaging in joint solutions. The agreement with Encina represents a pioneering milestone for incorporating innovative recycling technologies, in this case chemical recycling of end-of-life plastic, into ����AV’s production.

Joining forces for global automotive advancement

����AV excels in offering a diverse array of solutions for the automotive industry. Polyurethane, invented by Otto Bayer at ����AV’s predecessor company Bayer, is the vital material for automotive interiors. Polyurethane-based automotive interior applications, such as instrument panels, door panels, and center armrests, offer a soft, tactile feel, enhancing the comfort of both drivers and passengers. Polyurethane materials are known for their lightweight properties, minimal odor, and low levels of volatile organic compounds. These attributes create a comfortable and environmentally compatible interior environment, answering key demands of the automotive industry.

Having cultivated a successful cooperation with Xinquan for ten years, ����AV possesses a deep understanding of the evolving requirements of Chinese enterprises striving to expand their global presence. Xinquan’s global expansion strategy involves localizing research, production, and sales, in the respective regions. Its plant in Mexico has already started production last year, and there are plans for a North American technical center along with new facilities in Europe and ASEAN.

����AV is well-equipped to effectively support Xinquan’s global aspirations. With its focus on innovation and research, ����AV has established ten innovation hubs across America, Asia and Europe. Furthermore, ����AV operates production facilities in Mexico and the U.S., where they have delivered polyurethanes to Xinquan’s new plant in Mexico. The partnership exemplifies the effectiveness of globalization in driving innovation and highlights ����AV’s commitment to globalization and expanding its presence in key markets.

"����AV thrives on dynamic global partnerships, fueling innovation and tailoring solutions for the automotive industry. Together, we power our customers’ global expansion and zero-carbon journey. At ����AV, customer centricity isn’t just a phrase – it’s our energizing force, creating unmatched value through vibrant collaborations," said Christine Bryant, Head of the Tailored Urethanes Business Entity at ����AV.

Low-carbon polyurethane solutions for auto interiors and new energy vehicles

Expanding their technical collaboration, ����AV and Xinquan will harness ����AV’s global R&D capabilities to develop low-carbon polyurethane solutions for vehicle interiors by using partially bio-based raw materials. Besides, the cooperation extends to the development of polyurethane applications for electric vehicle battery packs. This partnership is intended to assist the automotive industry in attaining its carbon reduction objectives and embracing circular economic practices.

"During Xinquan’s global expansion, we have worked with ����AV closely to share resources and complementary advantages. By improving production efficiency and quality, reducing costs and risks, Xinquan has strengthened its core competitiveness," said Zhihua Tang, Chairman of Xinquan. "With this new global partnership, we will jointly promote technological innovation and low-carbon applications of polyurethane materials to advance the sustainable development in the automobile industry."

For a closer look at ����AV’s solutions for a fully circular future at the CIIE, visit us at booth 3B6-05, at the National Exhibition and Convention Center (Shanghai) from November 5 to 10, 2023.

Thanks to its long history in polyurethanes chemistry, ����AV boasts a portfolio of insulation material solutions renowned for exceptional thermal and weather resistance. Initially used in refrigeration, they have great potential to enhance energy efficiency in construction.

“����AV is devoted to becoming fully circular. At the same time, we help our customers and major industries to achieve climate neutrality through our material innovations.¹ The construction industry, particularly in China, is central to this mission. With our new partnerships we will expedite the adoption of more sustainable construction practices in China and jointly play a vital role in mitigating climate change,” said Dr. Markus Steilemann, CEO of ����AV, during the signing of agreements with named companies at the China International Import Expo (CIIE), an event dedicated to promoting imports and international trade.

One key collaboration involves PDG Group and insulation integration specialist Collodin, working on an innovative polyurethane exterior wall insulation system designed to be thinner and lighter than conventional alternatives. This system, named the ‘carbon-optimized composite wall insulation structural integration system’, combines polyurethane insulation with low thermal conductivity and a lightweight non-combustible layer, further reinforced by composite tie bars, ensuring superior insulation. A comprehensive study will evaluate its energy efficiency, safety, and economic viability before implementation on the developer’s future projects, provided it meets all compliance conditions.

“We look forward to partnering with sustainable material expert ����AV in promoting this innovative solution, which could also set new standards in the industry. We believe this collaboration will facilitate the transformation and upgrade of the construction sector, promoting low-carbon, high-quality development in line with China’s dual carbon goals,” emphasized Li Junlan, Chairman of PDG Group.

Another groundbreaking partnership involves Lujiazui Group and Chinese composite profile maker Deyilong. Together, they are developing a low-carbon, energy-efficient window and door system tailored to meet Shanghai’s requirements on ultra-low energy buildings. This system will leverage ����AV’s Baydur^® Pultrusion, a composite material with exceptional thermal insulation, mechanical strength, and durability. The whole window system thereby can be made thinner for better aesthetics.

“We look forward to working with partners including ����AV, which has a proven track record in the field of efficient insulation in windows and doors. We aim to leverage Lujiazui Group’s property development strengths in Pudong, Shanghai to promote these excellent window and door systems and help elevate the industry’s energy efficiency level,” said Xu Erjin, Chairman of Lujiazui Group.

“We are excited to be connected by the CIIE with Chinese property developers, which provides us with new opportunities that will last long. We intend to promote more sustainable and low-carbon solutions for the construction industry, enhance market penetration of energy-saving building solutions, and make efforts towards China’s infrastructure development and dual carbon goals,” said Holly Lei, President of ����AV China.

For a closer look at ����AV’s solutions for a fully circular future at the CIIE, visit us at booth 3B6-05, at the National Exhibition and Convention Center (Shanghai) from November 5 to 10, 2023.

^{1 Carbon neutrality of ����AV products is the result of an internal assessment of a partial product life cycle from raw material extraction (cradle) to the factory gate (of ����AV), also known as cradle-to-gate assessment. The methodology of our LCA, for which an external audit and certification will soon be available, is based on the ISO 14040 and 14044 standards. The calculation takes into account biogenic carbon sequestration based on preliminary data from the supply chain. No compensation measures were applied.}

The joint lab will mainly focus on the commercialization of low-carbon material solutions in future EV models and the establishment of relevant standards, as well as the development of next-generation smart surface technologies and battery solutions. This initiative builds upon a cooperation agreement signed between the two companies at the CIIE last year.

"We’re delighted to deepen our collaboration with HiPhi," said Dr. Markus Steilemann, CEO of ����AV, during the unveiling ceremony at ����AV’s booth at the CIIE. "We set out to address the key challenges of future mobility with the launch of the joint lab. With our common commitment to pioneering low-carbon smart mobility and by combining our strengths and resources, we believe the lab will accelerate the automotive industry’s transformation towards a smarter and climate-neutral future."

"HiPhi aims to redefine the luxury brand in the new era. We are accelerating the adoption of intelligent and low-carbon technology in smart EVs to provide global users with a safe, efficient and sustainable travel experience, thereby changing the future of mobility and contributing to society," said David Ding, Founder and CEO of HiPhi. “����AV’s advanced material expertise is key to helping us achieve this vision. The establishment of our joint laboratory stems from ����AV’s recognition of the innovative strength represented by HiPhi and other Chinese companies. We also aspire to empower our global partners and foster mutually beneficial relations through the CIIE.”

On display at ����AV’s booth at the CIIE is the HiPhi Y, the latest luxury SUV that incorporates advanced polycarbonate solutions from ����AV, most notably in the headlamp and LiDAR lenses. As EV becomes increasingly smarter, the headlamp presents new opportunities in digital communication beyond lighting. On the HiPhi Y, the headlamp lenses are turned into a projector to display signs and patterns in front of the vehicle, creating an interactive interface with pedestrians and other vehicles. ����AV’s high optical performance Makrolon^® AL solutions offer the needed dimensional stability, UV resistance and high transparency required for this application. In the LiDAR lenses, the Makrolon^® AX portfolio demonstrates superior performance compared to glass, including excellent infrared transmittance, shaping curved surfaces and impact resistance against stone chips. They can also endure the working environment of LiDAR at temperatures from 110 to 115 degrees Celsius for extended periods.

"As the mobility industry embarks on a journey towards carbon neutrality, the demand for circular, low-carbon footprint materials is growing rapidly and will only accelerate in the near future," said Lily Wang, President of the Engineering Plastics segment at ����AV. "We hope to collaborate with more like-minded companies, like HiPhi, to accelerate the decarbonization trend and pioneer smart technology development at the same time."

HiPhi has been a long-term partner of ����AV since 2018. ����AV’s material solutions have been applied to HiPhi’s flagship models, such as the polycarbonate solutions that enable a "smart" B-pillar equipped with complex functions in the all-electric SUV HiPhi X. HiPhi Z, a smart sports sedan, employs polycarbonate grades for the touchpad switch on its steering wheel – enabling a futuristic interactive design – as well as high performance waterborne polyurethane adhesives for auto interiors.

For a closer look at ����AV’s solutions for a fully circular future at the CIIE, visit us at booth 3B6-05, at the National Exhibition and Convention Center (Shanghai) from November 5 to 10, 2023.

“In the face of global challenges such as climate change, innovative materials like plastics are needed more than ever to drive progress towards a truly sustainable future ,” says Dr. Markus Steilemann, CEO of ����AV. “China, with its ambitious climate targets, is a leader in dynamic markets like electric vehicles and renewable energy. We are eager to contribute our material expertise to aid the nation’s transition, while driving fresh business momentum.”

Under the banner of “Becoming Fully Circular and Climate Neutral,” ����AV’s CIIE booth features dedicated areas, including “Beyond Mobility”, “Green Home”, “Renewable Energy” and “Fully Circular”. Several showcases will highlight the pivotal role of sustainable materials in these sectors. Additionally, a dedicated “����AV Story” area shall engage visitors, particularly those outside the chemical industry.

Chemical recycling of polyurethane foams

The “Fully Circular” zone will for example demonstrate advancements in recycling technologies and in the use of alternative raw materials. Notably, it will showcase a recycled foam created through ����AV’s proprietary chemical recycling process. This groundbreaking process is capable of transforming end-of-life mattress foam directly into its core building blocks, breathing new life into old foam.

At the center of “Beyond Mobility” stands Chinese EV maker HiPhi’s latest luxury SUV – the HiPhi Y. It extensively incorporates ����AV’s advanced and sustainable material solutions in interior and exterior components. This includes the use of high optical performance polycarbonate in LiDAR lenses, taking advantage of the material’s temperature resistance up to 115 degrees Celsius along with its excellent infrared transmittance, ensuring the reliable and stable operation of the entire system. The strengthened partnership builds upon a cooperation agreement signed between the two sides at last year’s CIIE.

����AV also aims to foster collaborations for ultra-low energy buildings (ULEB). The company’s materials can support making buildings more energy efficient and causing less emissions – key to the sector, which is one of the major contributors of global emissions. ����AV will for example show polyurethane pultrusion composites for window frames, and highly efficient building insulation solutions at the “Green Home” zone. At this year’s CIIE, the German materials manufacturer will sign agreements with Chinese real estate developers and value chain partners, forming multi-party business collaborations in this vital domain to expedite the adoption of sustainable solutions.

“The CIIE has consistently proven to be a highly rewarding endeavor for ����AV. It offers a unique platform to strengthen partnerships and promote our approach to becoming circular and how we can support downstream industries to do the same,” says Holly Lei, president of ����AV China. “We are committed to delivering versatile solutions and exploring innovative business models in collaboration with value chain partners both within and beyond the CIIE venue, in support of China’s sustainable development.”

The CIIE stands as the world’s first national-level import-themed exhibition, an annual event since 2018. This year, it draws over 3,400 international exhibitors and is expected to host hundreds of thousands of visitors. The CIIE serves as a platform that fosters international procurement, investment promotion, cultural exchange, and open cooperation. China’s ambitious climate goals, including reaching peak carbon emissions by 2030 and attaining carbon neutrality by 2060, carry global significance to meet the Paris’ agreement and remain a consistent focal point in the exhibits and activities at the CIIE.

For a closer look at ����AV’s solutions for a fully circular future at the CIIE, visit us at booth 3B6-05, at the National Exhibition and Convention Center (Shanghai) from November 5 to 10, 2023.

"For me, Team Sonnenwagen had already won even before the race! Team Sonnenwagen had captured the hearts and minds and the collective enthusiasm of all ����AV employees around the globe," says Sucheta Govil, Chief Commercial Officer of ����AV. "The team grabbed its rightful first place in qualifying and set its sights on victory from the start from pole position. The ����AV team was integral in its support. Yes, support to the students via innovative material developments but also fully involved throughout the race. And the Aachen-based team did its part: With their efficient car design and sophisticated driving performance, they led from the very front in performance, in design and in resilience, guts and stamina. I'm very proud of the team!"

"Of course, risk always rides along, especially if you want to achieve a top position," says Simon Zaers from Team Sonnenwagen. “Nevertheless, our intensive development work of around two years really paid off, especially because we also attached importance to a safe design. It played its part in ensuring that no one was injured in the accident. We were also able to gain a lot of valuable experience for the construction of our next solar runabout, with which we would like to participate in the World Solar Challenge 2025. Together with the other teams, we continue to pursue our goal of enabling more sustainable mobility with innovative designs – powered only by the power of the sun.”

����AV shares the enthusiasm of the Aachen team and has been supporting it as a main sponsor for around five years. The company is convinced that high-performance plastics are the key to climate-neutral and circular mobility in the future, and is working with customers and partners to develop material innovations and new recycling technologies to achieve this.

����AV also believes that the 50-strong Sonnenwagen team is on the right track in terms of cooperation: from development and design to the race itself, nine departments worked closely together to optimize aerodynamics and electrical engineering, the chassis, the powertrain and, not least, the driving strategy. The result after more than 200,000 hours of calculations for the outer shape and around 10,000 workshop hours for the body is impressive – and weighs a lot: the structure of the Adelie weighs in at 16 percent less than its predecessor, and the chassis even weighs a fifth less. These improvements are also due to materials from ����AV.

"After the race is before the race," sums up Lina Schwering, 1st Chairwoman of Team Sonnenwagen. "We will also learn from this competition and continue to optimize our design with a partially new team, just as the other teams are doing. There are very many parameters on whose interaction the race will be decided, and consistency and the will to consistently learn from experience will ultimately lead to the goal. However, this race has also shown us that in the end it also depends on a certain quantum of luck."

"The launch of our MCR production line marks another significant stride in our journey towards achieving a circular economy and operational climate neutrality by 2035," said Sucheta Govil, Chief Commercial Officer of ����AV. "Plastic waste recycling is pivotal in realizing this vision, and through the expansion of our recycled plastics production capacity, we aim to lead the way in driving sustainability across diverse industries."

����AV is committed to supplying over 60,000 tons of recycled-content polycarbonates annually in the Asia Pacific region by 2026, in response to robust market demand. Recently, the company also transformed an existing compounding line at its Map Ta Phut site in Thailand for mechanically recycled polycarbonate.

"These investments enable us to meet the rising demand for PCR polycarbonates, enhancing our capacity and efficiency. With new or repurposed capacity now operational, we are better positioned to assist our downstream customers in their journey towards more sustainable products, expediting the transformation of industries towards a circular and climate-neutral future," said Lily Wang, Head of ����AV’s Business Entity Engineering Plastics.

A broad range of PCR portfolio

The demand for such materials is surging on a global scale, driven by regulatory initiatives like the European Union’s proposed Directive on end-of-life vehicles (ELV Directive), which sets strict benchmarks for the utilization of recycled plastics. Furthermore, industries like consumer electronics are poised for increased demand for recycled materials, especially those with a substantial recycled content.

These market dynamics underscore the significance of ����AV’s recent developments in providing PCR polycarbonates. Earlier this year, the company unveiled a polycarbonate boasting 90 percent recycled content. This grade not only attains outstanding whiteness and highly saturated colors but also touts a sustainable feature – a 70 percent reduction in carbon footprint compared to its fossil-based virgin plastic counterpart. Achieving this remarkable accomplishment requires a meticulous selection of high-quality recycled materials and precise optimization of material composition during the compounding process.

Furthermore, ����AV is actively engaged in pioneering the chemical recycling of polycarbonates. Having successfully developed an innovative process within the laboratory, the company is now embarking on the technical implementation of this breakthrough at a pilot scale.

Expansion of polycarbonate production capacity in Asia Pacific

After debottlenecking multiple production lines at the Map Ta Phut site in Thailand, ����AV is nearing the final stages of a program to enhance polycarbonate production capacity and capabilities across the Asia-Pacific region. This program also includes the addition of new production lines at sites in Shanghai and Guangzhou, China, as well as Greater Noida, India, in recent times. The combined additional capacity now exceeds 100,000 metric tons annually. These strategic projects, aimed at optimizing the regional production network, have been supported by using digital tools, which also reduced investment costs.

"In this way, we aim not only to meet the growing demand for polycarbonate in Asia, but also to offer our customers there an improved product quality," says Dr. Nicolas Stoeckel, Head of Operations in the Business Entity Engineering Plastics. "Depending on demand, the upgrades can be used for compounding recycled or conventionally produced polycarbonate." Therefore, both projects are also about improving ����AV´s ability to produce more plastics with higher recycled content.
 

This site of Epurex Films, a wholly owned subsidiary of ����AV, houses research & development, application development and production for the semi-finished products. The company has invested a low double-digit million Euro amount in the expansion of the center of excellence for TPU-Films.

The new capacity is intended to meet the growing global demand for multilayer TPU films. They are used in automotive interiors and construction, among other applications. Breathable, water-impermeable specialty films have also proven their worth in wound care and outdoor clothing.

"With this capacity expansion, we are strengthening our Bomlitz site and our position as a leading supplier of technical specialty films," said Dr. Thorsten Dreier, ����AV's Chief Technology Officer, at the inauguration. "At the same time, we are investing in promising technologies and applications and creating new jobs."

For Aleta Richards, global head of the Specialty Films business entity, the expansion offers opportunities to respond even better to individual customer needs and offer more sustainable products. "For some time now, we have also been developing customer-specific solutions with films made from alternative raw materials, as we are also seeing increasing demand in this area. The development and production of partially biobased products is therefore to become a new focus at the Bomlitz site."

����AV is fully geared toward the circular economy and aims to become climate-neutral by 2035. In 2022 the Bomlitz site has switched its power supply completely to green electricity. Epurex Films is one of ����AV's three competence centers for specialty films in Germany, along with Leverkusen and Dormagen.

TPU is a versatile plastic material used in a variety of applications such as sports shoes, IT devices such as sweepers, smart speakers, phone cases, automotive applications like paint protection film or for the protection of wind turbine blades.

"We are excited to announce that the construction on our new TPU site commences. It shows our commitment to strengthen our production network for our Solutions & Specialties business entities overall and for the TPU business in particular,” said Dr. Andrea Maier-Richter, Head of TPU at ����AV. “It reinforces our position as one of the leading global suppliers of TPU and puts us right where important value chains are."

Once completed, the site will span across 45,000 square meters. With its potential maximum capacity of up to 120,000 tons it will then also be ����AV’s largest TPU site worldwide.

"We are committed to working closely with our customers and partners," said Lisa Ketelsen, Head of TPU in APAC at ����AV. “As Guangdong province is a major hub for the IT, consumer electronics, footwear and other industries, we believe that locating our production in close proximity enables us to collaborate optimally. To underline that, an innovation center will be part of the next phase of our investment, enabling our researchers to design customized material formulas and do formula adjustments to meet customer demands within very short cycles.”

The new TPU site will enable ����AV to provide high-performance yet sustainable solutions to its customers faster and more flexibly. At the new site in Zhuhai, ����AV shall to that end eventually offer products with the label “CQ”. Products labelled as such consist of at least 25 percent alternative, non-fossil raw materials. The site will also utilize the most advanced production technologies and be run on 100 percent renewable power.

“Together with recent investments in new plants for Elastomers, Polyurethane Dispersions and a production line for the mechanical recycling of polycarbonates in our site on the outskirts of Shanghai, this new site for TPU in southern China shall capture the robust growth of the core industries served by our Solutions & Specialties business entities in China, the region and worldwide,” said Holly Lei, President of ����AV in China.

Offering sustainable and ever more circular solutions are among the long-term core targets for ����AV overall and for the new TPU site. The company for that purpose in general works on broadening the raw material base for its products, using ever less crude oil and its derivatives. It works on using recycled materials and can also already offer core materials with attributed alternative raw materials (such as biomass) via the . Besides using less fossil-based raw materials, the company also want to use clean energy sources to run its plants and manufacturing processes and aims at becoming operationally climate neutral by 2035. By the end of 2023, it expects to already cover 16 to 18 percent of its energy demand from renewable sources.

Dr. Christopher Stillings, Vice President and Global Head of Color & Design in the Engineering Plastics segment, offers support to designers: "����AV is not only a pioneer in the research and development of material technologies, but also has strong color and design teams worldwide. Our collaboration with RAL highlights the precision that our polycarbonate materials offer for color matching and the leading expertise of our color and CMF experts. Together, we are setting standards." The project is another example of the company's commitment to developing solutions and services in the CMF (Color, Material, Finish) design field.

"RAL offers professional color charts for the industrial design sector, which requires the highest level of color accuracy," says Markus Frentrop, Global Head of RAL Colours. "With the color matrix and RAL Trendbox, we offer designers a comprehensive color and material approach as part of our continued collaboration." The 15 trend colors in the RAL Trendbox are each available as D6 single sheets, plastic color samples, powder-coated metal sheets and designed textile surfaces. They can also be combined with each other. "The color effects between the different material types are precisely coordinated by RAL and the cooperation partners," says Markus Frentrop.

To ensure accurate and fast color matching, ����AV's Color and Design Centers in Italy, Thailand, India and China worked together with RAL on solutions and were able to complete the precise matching of the 15 trend colors in a short time. ����AV also uses the RAL color codes in its CMF trend reports for the automotive, electronics and appliance industries.

Live presentation on September 28, 2023

On September 28, 2023, at 11 a.m. RAL plans to inform the public about the RAL COLOUR FEELING 2025+ Trend Report and the RAL Trendbox. The presentation will be broadcast live from the ����AV Campus building in Leverkusen via its channels at the following link: https://go.covestro.net/ralstreamenglish

It is not without reason that the 14 sensors and cameras are located in the roof module: At the highest point of the car, they are ideally positioned to provide a complete overview of the surroundings. The lightweight plastics also ensure a low center of gravity for the vehicle and thus better road holding. However, while technology developments for autonomous driving are making progress, previous solutions for positioning the sensors are often not yet visually satisfactory. Webasto has now presented a new concept that also meets demands for aesthetic vehicle architecture.

"We are proud to work with Webasto and other partners to develop innovative solutions for autonomous driving," says Dr. Fabian Grote, Head of Global Technical Marketing Mobility in ����AV's Engineering Plastics segment. "The complete sensor technology is hidden under a seamless roof module made of Makrolon^® AG. Our plastic is lightweight, durable, robust and transparent, and offers an ideal solution for integrating sensors into vehicles. We are pleased to be contributing to more sustainable mobility."

The sensors and cameras measure the distance and speed of objects in front of and alongside the vehicle and also reliably detect traffic lights, traffic signs and road markings. To function optimally, they must not get too warm. This is ensured by a thermal management system from Webasto. Here, the high heat resistance of polycarbonate ensures that the roof module retains its shape even at high outside temperatures and in strong sunlight and does not impair the function of the sensors. Cleaning and de-icing systems, on the other hand, ensure flawless operation in winter.

Cooperations with leading automakers

����AV is also a leading supplier of material solutions for autonomous driving and is working with various partners on the use of special polycarbonate grades for the cover panels of LiDAR sensors. At the International Symposium for Automotive Lighting (ISAL) in Darmstadt, Germany, Sept. 25-27, 2023, the company will showcase a roof module equipped with LiDAR sensors from Chinese automaker Human Horizons.

Human Horizons is equipping its new HiPhi Z model with LiDAR sensors protected by a housing made of PC-PET Makroblend^® UT235 M. The optical signals from these sensors pass through a cover glass made of the special polycarbonate Makrolon^® AX ST, which ensures maximum efficiency.

A total of a dozen cameras and several LiDAR and RADAR sensors are installed in the Chinese luxury model. As a result, it achieves driving assistance level 3 of autonomous driving.

"With our multi-layered campaign, we are pursuing the goal of establishing contacts with many partners to advance the industry on its path to climate neutrality and the circular economy," explains Dr. Christian Haessler, one of the two project managers for K 2022 at ����AV. "This communicative 360° approach was also expressed in the motto of our appearance at K 2022, 'Crafting Connections With You'." The Red Dot label has established itself internationally as one of the most coveted seals of quality for good design.

Rüdiger Maeßen, CEO Europe at Uniplan, is equally positive: "The good co-creative collaboration and the innovative concept were fundamental to the success of this holistic campaign. Together with ����AV, we have driven the circular economy agenda in the industry by creating an authentic exchange on multiple channels. Therefore, we are even more pleased that the sustainable campaign approach not only convinced the global target audience, but also the jury of the Red Dot Award."

Creating connections with digital platform

In order to connect with target groups around the world at an early stage and offer them a holistic, long-term experience as a "home base," ����AV and Uniplan designed a digital event platform called "SPACE." It went live several months before the start of the trade show and provided information about planned activities at the booth and the company's major highlight topics:

• Crafting Circular Economy
• Crafting Electrification
• Crafting Sustainable Living
• Crafting Smart Designs

A stage for current trends

These Topic Clusters also formed the basis for the second pillar – the integrated STAGE booth concept. As the other ����AV project manager Dr. Christopher Stillings explains, "Not only the exhibits and topic clusters, but also the wide-ranging lecture program in the central Talks Arena were tailored to these topics. Inspiring guests from well-known companies and universities – all actors in their respective fields – captivated the audience with keynotes on current trends and technologies and during panel discussions. Not only booth visitors participated, but also viewers around the world who followed the live broadcasts via social media."

Another highlight is the Color Material Finish (CMF) Sample Library, a collection of plastic samples that makes materials visible and tangible. Part of Uniplan´s and ����AV's STAGE concept is that the booth – or parts of it – can be used repeatedly for further exhibitions. Sustainability aspects and the reduction of CO₂ emissions were also at the forefront in the selection of materials for the trade show appearance itself. The success proves both partners right: Thus, the quality of contacts was significantly improved compared to K 2019, and a positive response developed both externally and internally over a longer period of time.

Innovators in the spotlight

While innovative developments are showcased and (hopefully) get the attention they deserve, the researchers behind them are often not visible. In the video series "Meet The Innovators" ����AV gives a voice to some of them and their inventions – see the blog post. They were introduced to a larger audience at K 2022, but prominent guests continue to discuss important innovations and technologies in the "Meet The Innovators" livestream series.

Many inspiring encounters at K 2022 have already led to a large number of new partnerships, technologies and material solutions. They form a valuable basis for developments that ����AV plans to showcase at the next major trade show appearance at K 2025. The company's motto may be different then – but the message remains that partnerships are the key to achieving a climate-neutral and circular economy: "Crafting Connections With You".

A Red Dot Award rarely comes alone

Back in May 2023, ����AV and its partner Accesso Dynamics were honored with an award offered by Red Dot and Koelnmesse. At the furniture supplier trade show interzum 2023, they received the "Best of the Best" interzum Award for their technology. This technology, first presented at K 2022, enables products with complex but seamless shapes. The development also contributes to sustainability, as the products are partly made from bio-based raw materials, are repairable and can be mechanically recycled at the end of their useful life.

����AV and Uniplan were also nominated for the Heavent Award in the "Forum, Summit, Congress, Fair Award" category for their communication concept for K 2022. A total of 132 projects from event, experimental and live marketing agencies as well as companies and trade fair and congress organizers were submitted for this year's event competition.

"I am amazed by the increased efficiency and energy savings you achieve with each new car model," said Chief Technology Officer Dr. Thorsten Dreier in welcoming the guests. “The ����AV Adelie shows on a small scale what high-performance plastics can do for a sustainable future on a large scale. We are convinced that they are the key to sustainable mobility. That's why we are consistently driving forward material innovations and recycling solutions together with our partners in industry and science.”

Optimization through teamwork

Even during the two-year development period of the ����AV Adelie, the teamwork of around 50 students led to success: aerodynamics, electrical engineering, driving strategy, chassis, powertrain and structure interlock perfectly. More than 200,000 hours of calculations were required to optimize the exterior shape, plus 10,000 workshop hours for the body, and many more days for electrical and mechanical components and the development of the driving strategy.

"A lot of work, heart and soul and the concentrated experience from our three predecessor models have gone into the ����AV Adelie," confesses Clemens Odendahl, head of marketing at Team Sonnenwagen. "Now we hope to win the Challenger class, in which we are the only German team competing. There, it's all about performance and maximum energy efficiency."

Thanks to the optimizations, the structure of the new model weighs 16 percent less than that of its predecessor, the Photon, and the chassis even has 20 percent less weight. This improvement is also due to some ����AV materials, such as a battery cover made of the high-performance plastic polycarbonate and the construction of the seat shell with thermoplastic polyurethane. The Photon is also currently on campus and will remain there for some time.

More sustainable outfit

But the Aachen-based tinkerers are not only committed to more sustainability on the road – their official outfit was also produced using alternative raw materials with fewer petrochemical components. Both the shoes and the shorts were provided by ����AV's Chinese partner Huafeng. The two companies jointly developed a design for them using Huafeng's HAPTIC^® textile coating system, which is made with ����AV's partially bio-based Impranil^® CQ DLS/1 polyurethane dispersion.

����AV wishes Team Sonnenwagen every success and victory in the Bridgestone World Solar Challenge. This time, 42 teams from 23 countries are taking part in what is probably the toughest solar car race in the world. Under harsh climatic conditions, they have to master the more than 3,000-kilometer route from Darwin to Adelaide as quickly as possible, right across the Australian outback.