Di-Plast—Digital Circular Economy for the Plastics Industry


Project Summary

The digital solutions developed within this project, enable companies to ...

... find suitable recyclate grades for specific products

... improve the quality control during production phase and establish a stable process with high recyclate ratio

... optimize value streams, to forward the plastic material to the costumer

All Di-Plast tools are developed as stand-alone tools that can be used independently from the other tools but also in any combination you like or need. The following example shows one possible way of using the tools.

Do you want to know more about Di-Plast?

Meet us at the following event

Circular Hotspot @Bottrop

_ 14. September 2022 https://www.circularhotspot.nrw/

Multiplicator workshops (all online)

_ 20. September 2022 09:00 – 10:30 (in German)

_ 28. September 2022 09:00 – 10:30 (in dutch)

_ 5. October 22022 09:00 – 10:30 (in English)

Multiplicator workshops (all online)

_ 20. September 2022 14:00 – 15:30 (in German)

_ 28. September 2022 14:00 – 15:30 (in dutch)

_ 5. October 22022 14:00 – 15:30 (in English)

Register here LINK

Events

Di-Plast Workshop "Prozessdaten - Transparenz und Relevanz für den Rezyklateinsatz" (Online)

11-05-2022 - 11-05-2022, Online

Workshop in the importance of process data for the transparency of the plastic industry, conduct by SKZ - Das Kunststoff-Zentrum Read more

View more

News

Publication on Holistic System Change towards Circular Economy within Supply-Chains by Uni Luxembourg

Posted on 30-07-2021

Jeff Manger and Peter Plappert form the University Luxembourg, one of our project partner responsible for the VSM tool, published a paper on "An Innovative Strategy Allowing a Holi... Read more

Di-Plast Workshop "Work more sustainably with recyclate" @Zwolle

Posted on 04-04-2022

On the 29th of March 2022 the Di-Plast workshop "Work more sustainably with recyclate" took place at Zwolle. The workshop was organized by our project partner Polymer Science Park ... Read more

View more

Project Partners

  • SKZ-KFE gGmbH

    22 Friedrich-Bergius-Ring
    Würzburg
    97076
    Germany

    View partner details

  • Stichting Polymer Science Park

    15 Ceintuurbaan
    Zwolle
    8022 AW
    Netherlands

    View partner details

  • University of Luxembourg

    6 Rue Richard Coudenhove-Kalergi
    Luxembourg
    1359
    Luxembourg

    View partner details

  • East Netherlands Development Agency

    40 Laan van Malkenschoten
    Apeldoorn
    7333NP
    Netherlands

    View partner details

  • Umwelttechnik BW GmbH State Agency for environmental Technology and Resource Efficiency

    45 Friedrichstr.
    Stuttgart
    70174
    Germany

    View partner details

  • Tilburg University (JADS)

    2 Warandelaan
    Tilburg
    5037 AB
    Netherlands

    View partner details

  • Osnabrück University

    29 Neuer Graben
    Osnabrück
    49074
    Germany

    View partner details

  • Wuppertal Institute for Climate Environment Energy gGmbH

    19 Doeppersberg
    Wuppertal
    42103
    Germany

    View partner details

Lead partner

Organisation Address Email Website
Wuppertal Institute for Climate Environment Energy gGmbH 19 Doeppersberg
Wuppertal
42103
Germany
holger.berg@wupperinst.org www.wupperinst.org
Name Contact Name Email Country
SKZ-KFE gGmbH Hermann Achenbach h.achenbach@skz.de Germany
Stichting Polymer Science Park Femke de Loos f.deloos@polymersciencepark.nl Netherlands
University of Luxembourg Peter Plapper peter.plapper@uni.lu Luxembourg
East Netherlands Development Agency Martijn Kerssen Martijn.Kerssen@oostnl.nl Netherlands
Umwelttechnik BW GmbH State Agency for environmental Technology and Resource Efficiency Jonas Umgelter jonas.umgelter@umwelttechnik-bw.de Germany
Tilburg University (JADS) Corine Goossens c.l.a.goossens@jads.nl Netherlands
Osnabrück University Martin Atzmüller martin.atzmueller@uni-osnabrueck.de Germany

News



Blog-post 7;

The preliminary OECD report “Policy Scenarios to 2060” predicts that, if no far-reaching measures are taken, worldwide plastic consumption is set to increase from 460 million tonnes (Mt) in 2019 to 1,231 Mt in 2060. This would represent a significantly higher increase in comparison to most other raw materials.

This leaves us with a problem, despite the fact that plastics are a wonderfully versatile material.

If we successfully manage to recycle this material in a consistent way, we can reap the benefits of having a flexible material available to use and, at the same time, minimise negative environmental impact.

The EU-funded Di-Plast research initiative tackles every stage of the value chain of recycled material. A digital toolkit, made up of eight tools, has been developed to provide effective support for research, science, politics and industry. These digital tools support data analysis and process optimisation. This ultimately leads to more recycled material being used in production.

Using the Value Stream Management (VSM) Tool, you can find out the best way to present material and information flow data which is both analysed and optimised with the circular economy in mind.

The VSM Tool is clearly explained in an easy-to-follow video, which focuses on the optimisation of individual processes. A fictitious business is used as an example:

Pipe is a company that manufactures plastic tubes which are necessary components in the shells of buildings. The plastic they use offers high standards in terms of quality and durability. To make their production more sustainable in future, recycled materials should now start to be used. This adjustment forces changes in the manufacturing process, as the new material has to be prepared for use first. Their production times still appear to take too long.

By preparing a Value Stream Management of all the individual stages of production, they were able to identify a bottleneck in the extrusion stage which was caused by the changes in the production process. The tool also recognised that potential savings could be made when materials are premixed. By optimising these two factors, Pipe not only improved their production times compared to their previous process, but they also saved money.

Get to know the VSM Tool, as well as the entire Di-Plast digital toolkit, and learn how to use more plastic recyclates in your production process. And, at the same time, you can become a driving force behind the implementation of a circular economy in the plastic industry.

And if you have any questions, send us an email or give us a call. We’re always happy to help!

Blog-post &

The Di-Plast research initiative funded by the EU aims to improve every link in the recycling value chain. One output of the project is the development and implementation of a digital toolkit made up of eight different tools.

The Matrix Tool helps you to match process and product requirements to the properties of recycled material, making it one of the most important tools. This will enable you to work in a more targeted way when producing, marketing or finding recyclates with a specific use in mind. The Data Extractor is another practical tool, which makes it easier to digitalise material data from data sheets to ensure compatibility with the Matrix Tool.

These tools work together to simplify the consistent recycling of plastics. The possible uses of this wonderfully versatile material are maximised, while the negative impact on the environment is minimised at the same.

Reports predict that future plastic discharge into the environment is set to double to reach 44 million tonnes per year worldwide, while the build-up of plastic in our lakes, rivers and oceans is expected to at least triple. These figures stem from a predicted rise in plastic waste, from 353 million tonnes in 2019 to 1,014 million tonnes in 2060.

The digital tools launched as part of the Di-Plast initiative analyse data and optimise processes. At long last, thanks to the Matrix Tool, more recycled materials can be used in production because the tool makes it possible to align process and product requirements with material properties.

The capabilities of the Matrix Tool are clearly explained in an easy-to-follow video, using a fictitious business as an example:

Plastics are regarded as a basic raw material in the packaging industry. Tetrabox is no exception – this company relies on plastic to manufacture food packaging.

To make their production process more sustainable, the business plans to replace some of their plastics with recycled materials. Their team faced the challenge of finding suitable material that could also meet the high food industry standards. The material also had to be flexible in terms of procurement methods and conforming to new production standards, as the food industry in particular is liable to constant changes.

This is where the Matrix Tool comes into play. The tool identified several materials that could both replace the current material and be obtained via several different suppliers. As a result, their production became more sustainability-oriented and their dependence on single suppliers was reduced.

Take advantage of the digital Di-Plast toolkit to discover how you can use more plastic recyclates in your production process. And, at the same time, you can become a driving force behind the implementation of a circular economy in the plastic industry.

And if you have any questions, send us an email or give us a call. We’re always happy to help!

Blog-post 5

The European Union still has a long way to go before it can reach its goals for recycling plastic. The Di-Plast research initiative funded by the EU aims to improve every link in the recycling value chain. One output of the project is the development and implementation of a digital toolkit made up of six different tools.

A new project video now provides a general introduction to the initiative and these tools. All the information is presented clearly to make it easy enough for everyone to understand. As the first of seven videos, this initial overview is aimed at anyone interested in finding out more about the tools. The idea is to explain their benefits and help promote recycling within the plastic processing industry.

There’s no denying that plastics are wonderfully versatile in so many ways. But they leave us with a serious waste problem. A problem that we can minimise by recycling more plastic.

A small percentage of plastic is recycled already, but we’re far from seeing plastic recyclate being used consistently.

  • Recycled material is often lacking in quality
  • and not reliably available.
  • Not to mention that demand among end customers is still too low.

If we’re going to have any chance of raising consumer awareness, we have to start focusing on the quality and availability of recycled material. That’s why the Di-Plast initiative is centred around the development and introduction of a digital toolkit designed to support the use of recycled plastic.

The digital tools in the kit build on one another, raising the level of information available. And yet each of the tools also works as a standalone solution.

  • The Value Stream Management (VSM) tool helps you present and analyse data on your material and information flows with a view to optimising it in relation to the circular economy.
  • The Sensoring Tool can be used to select suitable sensors for process optimisation. When it comes to searching for the ideal software for data processing and storage, turn to the Data Infrastructure Wiki.
  • The functions in the Data Analytics application (Data Validation, Data Analytics and Exploratory Pattern Analytics) can be used to validate process data for analysis and detect patterns and anomalies as a way of optimising processes.
  • The Matrix Tool helps you to match process and product requirements to the properties of recycled material. This will enable you to work in a more targeted way when producing, marketing or finding recyclates with a specific use in mind. The Data Extractor is another practical tool, which makes it easier to digitalise material data from data sheets to ensure compatibility with the Matrix Tool.

It may all sound a little complicated, but the video guides for each of the tools will change all that in no time.

So why not give them a watch now? (click ont he link below)

And if you have any questions at all, send us an email or give us a call. We’re always happy to help!

For all the videos, descriptions, detailed guidelines and more, head over to the Di-Plast Knowledge Hub (link will be added shortly).

Blog-post 4

Sustainability and recycling have become more and more relevant within society. The public opinion is shifting more towards a world where recycled plastics becomes the norm to reduce the amount of plastic waste in our oceans and its impact on the environment. However, recycling plastic is not as easy as it sounds, and therefore much of our plastic waste is not usable for recycling. One of the main issues with recycled plastic material is the quality of the material. There are many different characteristics that influence this quality, for instance, the colour of the plastic waste or the amount of dirt within the plastic waste. If we want to increase the amount of recycled plastic, we should focus more on improving the overall quality of the material.

With this improvement, organisations are able to use the recycled material in more delicate applications such as packaging of food (this is currently really difficult to achieve due to many quality regulations). One possible solution for quality improvement can be achieved using advanced data analytics, which is something that the Di-Plast projects aims to do. This works in the following way:

  • Think of a machine that processes plastic waste and creates new granules (small grains of plastic material to be used in creating new products). This machine has several settings and parameters on which it can create these granules. On the inside of the machine, you will find many sensors that measure characteristics of the process. think of temperature of the material, humidity, rotation speed of some specific parts from the machine. These characteristics (also called parameters) indicate the performance of the machine. When something becomes for instance too hot, the operator of the machine will receive a message to check what is going on inside the machine. However, smaller deviations are not always noticed, while they could influence the end product of the machine.

  • With data analytics methods, we are able to spot these small deviations and analyse why and how they could have happened. With this information, processes and machine settings can be adjusted to prevent these small deviations and therefore improve the overall quality of the end product. How this complete analysis process works is a bit too detailed for this summarised explanation. If you are interested in the background of our analysis techniques, please contact us!

If you are interested in learning more on data analytics to improve your processes or want to be part of the Di-Plast project to co-develop or use oiur tools, just contact our experts below.

Anomaly detection

Anomalies in process data (red line) made visible via data analytics (blue line)

Blog-post 2

The concept of circular economy (CE) is currently receiving encouraging attention among scholars and industrials, as a convenient solution to move away from the linear economy concept, without neglecting the goals of sustainable development. As main goals, the closing of resource loops and the keeping of resources in the system for as long as possible at the highest utility level, are mentioned as main goals of CE. Nevertheless, most companies still adopt a linear approach or just focus on providing information to the end-user to maximize their satisfaction during the use phase, while only a small amount have approached CE in a holistic way.

This gap between aiming to implement CE principles and apply them in a holistic manner is a widespread inconsistency. The VSM-tool, which is provided within the Di-Plast project, intervenes at this exact point, and can help YOU to get a clearer and more holistic view about your internal processes (micro-level) and if possible, about your supply-chain interdependencies (macro-level).

VSM is an effective, easy to use tool to collect, evaluate, and continuously improve product and information flows within companies or interrelated supply-chains in a common and standardized manner (ISO 22468:2020). While being one of the more common lean methods, its aim is to deliver value from your customer’s perspective and continuously improve your processes. This is done according to the statement: ‘Learning to see’.

Within the Di-Plast project, the VSM method was adapted with new indicators (e.g., energy- & water consumption, scrap rate, different material flows, etc.) and visualizations, enabling a circular perspective on resource flows within companies and throughout supply-chains.

  1. The macro-level VSM is suited to get a better understanding about the resource flow throughout a supply-chain, regarding CE aspects. With this in mind, we visualize the overall resource flow as well as the information flow to get a better overview about the respective interdependencies. This is important with regard to misalignments between the resource recovery infrastructures (end-of-life, EOL) and the product design phase (beginning-of-life, BOL). The aim is to improve the circularity throughout a supply-chain in a holistic way, by improving the information exchange between the EOL and the BOL.
  2. The micro-level VSM is an analysis at a deeper, more precise level. This means that data which is important at the macro-level is being collected. Here, the aim is to get a precise overview about internal resource and information flows, regarding CE aspects. The application of the micro-level analysis is also independently possible and helps to gain valuable insights about the interrelations of internal processes. This could be for example beneficial if you are aiming to integrate internal recycling possibilities or to detect and fix inconsistencies between different processes. This is important, since the main share of non-value adding activities occurs in-between processes and not within individual processes.

VSM figure

Figure 1 Example of a CE adapted value stream map
            at micro-level

Currently, the method is tested and further developed within several companies in the Di-Plast pilot phase. If you are interested in joining the pilot-phase and apply the tool together with our experts within your company or within your supply-chain to increase the overreaching cooperability, feel free to contact us. Otherwise, you still have the chance to apply the finished tool during the Di-Plast uptake acceleration program.

CONTACT: Open Call

 

Di-Plast Pilots

Selected companies are given the opportunity to participate in the development of the Di-Plast Toolkit. The aim is to increase the proportion of recycled material in their products and to improve the quality of the process and product using digital tools. By joining these pilots, companies can directly influence the development of the tools in the co-creation process. This ensures that the functions are tailored to their needs. In addition, the pilots offer many other advantages for the companies:

  • Support for selection of sensor-based quality control mechanisms and support for selection of suitable software for data acquisition depending on budget and internal knowledge (Process Quality Pilot)
  • High quality data allows the company to better understand the data that was gathered and to draw better informed conclusions in follow-up data analysis tasks (Process Analytics Pilot)
  • Better understanding of processes through data-driven insights and visualisations (Process Analytics Pilot)
  • Smart material selection, which means converters can easily select material that match their criteria and the criteria for their markets and recyclate suppliers can check the needs per market segment and have their products ready for the converters (Matrix Pilot)
  • The VSM tool helps to visualise and better understand internal resource flow (time, material, energy or water) and localise bottlenecks (Value Stream Management Pilot)
  • Free consultancy from data, plastics and value stream experts for the implementation of data driven solutions

If you would like to learn more about the pilots, please follow the links below.

If you are interested in beeing part of the pilots, please contact Heicke Gaedeke via e-mail.

Di-Plast Pilots

LINKS: Open Call

Di-Plast Pilots

There is still a huge gap between the goals of the European Union for plastic recycling in 2030 and the status quo today. One key chance for closing this gap is the application of digital technologies like data science to improve processes and information flows throughout the entire recyclate supply chain.

Di-Plast develops and applies digital tools to enable high value plastics recycling, i.e. bring recycled plastics to its highest application possible. Supported by Interreg North-West Europe, we aim to close the knowledge and information gaps which inhibits plastics recycling. We enable companies to achieve access to highly relevant yet mostly hidden data, parameters and analytics from and for their own production processes. To realise this, our toolkit combines a distinct set of tools:

  1. VSM Tool: Value stream mapping to visualise and improve process-flows.
  2. Sensoring Tool: a process problem / solution case library to support with the selection of suitable sensor-based quality control mechanisms.
  3. Data Science Tools: This is a sub-toolkit of data science applications that creates, validates and extrapolates data:
    1. Data Validation Tool: Assesses data, gives insights in the variables and their data quality to increase the overall quality. Allows to prove stable processes and thus high quality recyclates to your customers.
    2. Exploratory Pattern Analytics Tool: Works on prepared/preprocessed tabular data. It provides explanatory patterns, i.e., simple rules between parameters (e.g., temperature, pressure) that are predictive for a certain target parameter (e.g., scrap rate). This helps to identify optimisation possibilities in your process through unveiling unrecognised correlations.
    3. Process Analytics Tool: Provides insights consisting of reports, visualisations and other analytical methods that describe the state of your processes and/or machinery. .Using this information, production processes with recyclates can be streamlined and output quality and quantity can potentially be increased.
    4. Machine Data Acquisition Tool: A wiki for selection of a data acquisition infrastructure based on your budget and technical expertise.
    5. Forecasting Tool: A system where information is combined to predict future quantities. This tool helps to create information of future supply of plastic recyclates and therefore enhance procurement and production planning.
  4. Matrix Tool: The Matrix tool helps to find matches for recycled plastic suppliers and converters based on multiple given constraints

Currently, we are testing our toolkit with several companies and to validate their fit to industry’s needs. However, we are still looking for partners to test and apply these tools and for companies interested to learn about them in our uptake acceleration management.

Events


Di-Plast at the PIUS conference (03th and 04th of March 2021)

, Digital

The project team will conduct a workshop on ressourc efficiency within the value chain, presenting the aim and approach of Di-Plast at the PIUS (Production-Integrated Environmental Protection) conference in Frankfurt. This time, due to the pandemic, the event will be held online. Holger Berg of Wuppertal Institut will speak on the 4th of March 2021 within the workshop "Use of plastic recyclates".
Read More

Webinar on the Di-Plast digital toolkits

, Webinar

If you are working in the plastics industry and want to know more about our digital toolkit, please join our Webinar on the 12th of December. The Webinar starts at 15:00 PM (CET) with the duration of about one hour. The Webinar provides an exstensive overview of the Di-Plast project and the designed tools are provided and gives you the opportunities to ask questions to our experts.
Read More

KONGRESSBW

, Filderstadt, Germany

Ressourceneffizienz- und Kreislaufwirtschaftskongress - Congress in German language (mainly) - Largest congress of this kind in Europe. Two days full of information and discussion about resource efficiency and circular economy. Di-Plast will be introduced in a forum at the 23th of October. This specific presentation will be held in English. More Information will follow - for regularly updated information go to the link below.
Read More


Digital Toolkit

London

London

London

 

London

London

All Di-Plast tools are developed as stand-alone tools that can be used independently from the other tools but also in combination. The following example shows one possible way of using the tools.

Start by getting an overview on your internal processes and information flows so that you can optimize them and make more out of your processes which include rPM or prepare your processes for rPM integration (VSM). The VSM tool helps to analyse, display and later optimize your cross-company product and information flows. It supports you in getting better knowledge about resource flows and localise bottlenecks either internally or withing your overall supply-chain.

Learn which sensors could help to get more information from your production (Sensoring) and learn how to get access to machine data that most likely is already there but not yet used (Machine Data Acquisition).

Now more in-depth work with your process data can start. Ideally you first use the Data Validation tool to assess data quality, gain insights in the variables and receive tricks how to increase your over all data quality. This might mean, that you go back to the Data Acquisition and the Sensoring tool but can also imply other steps.

Once your data quality is sufficient, we recommend using the Process Analytics Tool. It provides insights consisting of reports, visualizations and other analyses methods that describe the state of your processes and/or machinery. Errors in data found during the processing of specific materials can be automatically detected and made visible through reports and visualizations. This allows you to improve processes and their results. One module of this tool provides the opportunity to forecast future rPM quantities.

Our Matrix Tool can help you to find matching process and product requirements with material properties. Plastics users can find suitable recyclates for their applications here. The recycler, in turn, can offer its products (recyclates with specific material specification) or identify material specifications required by the market - and modify its recycling process to produce these materials. You will, therefore, gain a better understanding of the plastics recyclate market and opportunities, both as a user or supplier of rPM.

Interested in applying our tools?

Share your interest in the Di-Plast solution and support with us and we contact you according to your preferences!

Get in touch with us

Voucher header

Do you see opportunities to increase the usage of plastic recyclates and do you want

financial support for this project?

1

I

I

 Select a voucher see voucher description  below  
2

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Check your eligibility

- Economically active in the North-West European Region?

- Are you a Compounder, Converter, Recycler, Re-compounder, and Companies creating commercial polymer waste or a Trader?

- You don’t exceed the De-minimis state aid limit (excluding corona support). The De-minimis regulation limits the support to EUR 200,000 in a three-year period

For more information on De-minimis, please downlaod the info sheet on the right.

DOWNLOAD
De-Minimis Info-Sheet 

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Prepare the application

Prepare your application with the help of the application template (download link on the right)

 

This includes solely:

  1. General information on the applicant (company, person) and the field of work
  2. The estimated costs for the recyclates uptake activities.
    If you selected the chain voucher, please include 3 offers from your potential suppliers.
  3. A brief description of the planned activities and an estimation of direct and/or indirect increasment of
    plastic recyclate uptake through the voucher in the production chain.

Your can find a detailed description of the application in our application guideline

DOWNLOAD
Application Template

 

DOWNLOAD
Application Guidline

(updated 29.11.2021)

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Submit your application

Fill your information into the online application form (link on the right) and submit your application until 31st of July 2022.

 Online Application Form

 

The application will be evaluated by review criteria which you can find at the bottom of this page.

If you have been granted, we will provide you with all necessary documents for the documentation. Applicants will be notified within 6 weeks if the voucher can be granted.

Relevant documents after the approval:

Di-Plast Voucher Agreement

Di-Plast Voucher Pay-out Form

If you having doubts or question regarding

a suitable voucher or the application

process, please contact us!

Sophia Botsch I
SKZ-KFE (Regional Coordinator Germany)

Erik Plaggenmarsch I
Oost NL (Regional Coordinator The Netherlands)

Download Flyer and Info-sheets

Di-Plast
Voucher Flyer

Info-sheet
German

Info-sheet
Dutch

 Flyer Voucher Voucher Info-Sheet-german Voucher Info-Sheet-dutch

 

Three types of vouchers


   Matching Voucher                                                                                          up to 1,000 €

Supports you with finding the right match for cooperation to introduce or increase recycled plastics in your production process. The following activities can be supported:

• Partner matching
• Consultancy
• Material Research
• Set up of feasibility study/proof of concept

• Testing costs
• Shipping costs
• Meeting and travel costs

 

Di-Plat Voucher-Flyer

Di-Plat Voucher-Flyer


   Expertise Voucher                                                                                           up to 4,500 €

Utilise external and specialist expertise to relise your project ideas for the (increased) use of recycled plastics.
The following activities can be supported:

• Technical engineering
• Process control
• Material quality
• Supply chain cooperation

• Innovation consultancy
• Realisation feasibility study
• Material research
• Product recipe Creation


   Chain Voucher                                                                                                  up to 7,500 €
 

Finance specific purchases to concretize projects to increase the usage of recycled plastics in your production process. Please note that you will be requested to send three tender offers with your application.
The following activities can be supported:

•External costs for (product/quality) testing
•External costs material sampling – running technical trails with state-of-the art equipment

•Process consulting services
•Procurement costs for equipment & Machinery
•Software

 

Di-Plat Voucher-Flyer

Di-Plast Pilots

 

Here you find sources with information and background about the Di-Plast Project. 

Di-Plast Flyer   Voucher Flyer

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