In-House Reuse of Vulcanized Rubber Scraps
Waste Type:
Main Circular Economy Strategy:
Company:
KEYWORDS
Summary
Sirmax Polska, a major producer of polypropylene compounds, has created a circular model by recycling all internal production scrap and integrating post-industrial and post-consumer plastics into new formulations. Through upcycling and closed-loop supply chains, the company delivers high-performance recycled compounds that rival virgin materials.
Description:
Sirmax Polska is the Polish branch of Sirmax Group, a global producer of plastic compounds headquartered in Italy. Operating in Kutno since 2006 and expanded in 2019, Sirmax Polska specializes in polypropylene (PP) compounds and engineering thermoplastics used in automotive, electronics, and appliance manufacturing. With a production capacity of over 55,000 tons annually, the Polish facility is part of Sirmax's global push for sustainable material solutions, integrating both virgin and recycled feedstocks.
Sirmax Polska has implemented a circular solution that combines in-house recycling of production scrap with external plastic waste valorization. The approach includes:
◼ Internal Recycling: All process-generated plastic waste – off-spec material, dust, and changeover residue—is re-ground or melt-filtered and reintroduced into production, forming a closed internal loop with near-zero polymer loss.
◼ External Waste Integration: Sirmax incorporates post-industrial and post-consumer plastics (e.g. automotive bumpers, appliance parts) into their recycled compound formulations. These are collected from local industries and recyclers, sorted and processed, and then blended into high-performance compounds.
◼ Upcycling through Formulation: Recycled materials are enhanced with additives (e.g. glass fibers, talc, compatibilizers) to meet mechanical and aesthetic requirements. This enables recycled content to match or approach virgin quality, as demonstrated by the company’s “Green ISO” product line.
◼ Closed-Loop Supply Chains: Sirmax cooperates with customers by reclaiming their production or end-of-life plastic waste and supplying it back as re-compounded feedstock—completing a material loop between supplier and client.
Environmental Perspective
Sirmax’s dual-loop strategy delivers substantial environmental benefits:
◼ Plastic Waste Reduction: Thousands of tons of post-industrial and post-consumer plastic are diverted from landfill or incineration. Internal scrap is fully reused, significantly lowering waste intensity per unit produced.
◼ CO₂ Emissions Reductions: Life-cycle studies estimate that substituting virgin PP with recycled PP cuts emissions by ~50%. With tens of thousands of tons of output, this equates to tens of thousands of tons of CO₂ saved annually.
◼ Energy Savings: Recycled compounds require less energy than producing new polymers. The avoidance of polymerization steps means lower embodied energy and fewer upstream emissions.
◼ Material Circularity: By combining internal reuse with external recycling and upcycling, Sirmax creates a hybrid circular model, preserving material value in high-performance applications.
Economic Perspective
The program supports both economic efficiency and market leadership:
◼ Raw Material Cost Reduction: Using recycled input—especially post-consumer resin, which is often cheaper than virgin—lowers production costs and reduces price volatility exposure.
◼ Product Differentiation: Sirmax’s ability to offer certified recycled content (e.g., ISCC PLUS) with high technical performance helps meet increasing demand from automakers and electronics brands for sustainable sourcing.
◼ New Revenue Streams: Recycled compound families (e.g. Green ISOFIL, Green ISOGLASS) represent growing product lines sold across Europe and globally, generating revenue while promoting circularity.
◼ Strategic Expansion: The success of circular materials led to new plant investments in Kutno and abroad (e.g., Indiana, USA), supported by favorable tax zones and sustainability-linked financing.
