Tackling the global plastics problem by bolstering circularity processes

By Christophe de Maistre, Segment President for Energies and Chemicals at Schneider Electric

Following a fifth round of negotiations, nations have not been able to reach a significant agreement on The United Nations Global Plastics Treaty, despite growing concerns that plastics pollution is one of the biggest challenges threatening human health, biodiversity, and the environment.

With global plastic production increasing to almost 460 million tonnes annually since 1950 and less than 10% of the plastic produced globally being recycled since that very same year, excessive production and improper disposal of plastics continue to have hazardous environmental effects.

In fact, 19% has been incinerated and 79% ends up in landfills or in nature. What’s more, with 90% of emissions from plastics coming from production alone, it is clear that plastic recycling is just one half of the current plastics problem.

With plastic production now responsible for four times more greenhouse gas emissions than the aviation industry, reducing single use plastic production is of the upmost importance, and this must be met alongside improved recycling efforts.

As such, the way we use, consume and dispose of plastics needs to change, and this must be a top priority despite not having a treaty in place.

With this in mind, let’s explore what businesses can do to drive forward circularity efforts whilst reducing plastics usage across their operations and processes.

The current plastics outlook

When looking at the global plastics problem it’s important to identity the industries that are the biggest users and ‘abusers’ of plastic and where the biggest impact can be made.

And unsurprisingly, the chemical sector is one of the largest plastic consumers.

Not only is the chemical sector renowned for leveraging plastic for packaging, cleaning and storage, but the sector is heavily dependent on petrochemicals, chemicals which are used to create plastics and other materials like rubber and glass.

The production of petrochemicals, which are often taken from fossil fuels, not only contribute to the plastic pollution crisis, but also is a large contributor of carbon emissions, responsible for around 10% of global greenhouse gas emissions.

Have you read?
Turning wastewater into energy: a story of hydrogen and circularity
Embedding circularity and sustainability for profitable business models

As chemical producers are challenged to decarbonise the energy-intensive processes in plastics production, the industry is also facing increasing pressure to transition to more circular recycling processes.

This combination of inefficient production and recycling processes highlight how crucial it is for the chemical industry to implement new, innovative solutions that enable more sustainable operations.

So, how can the industry lean into digital technologies and automation to accelerate its transition to a more circular plastics economy?

Building a circular plastics economy

While a ‘plastics-free' world is unrealistic, the chemical industry has a vital role to play in minimising the harmful impact of plastics production through more efficient processes, underpinned by digital technologies and automation.

The development of new chemical recycling methods and improved mechanical recycling will prove critical. Plastic products should be designed with circularity in mind. Industry leaders must consider eco-design and the circular economy of plastic products to not only extend their life and improve their recyclability but also to provide safer options for people and ecosystems.

For instance, industry leaders could use digital twin software for plastics product design, creating modular designs for process, electrical, automation, and digital systems to further optimise costs, enhance speed of deployment, and increase operational efficiency. Businesses can even use open automation platforms that enable multiple project stakeholders to collaborate while minimising error.

Then, to help end-users reduce their consumption, it is important to work closely and early on with suppliers of recycled material to test recycled plastic and become an early adopter. This is especially true for high-performance plastic products for electronics and electrical applications, as well as medical and construction applications.

On the software and automation side, picking partners that specialise in circular transformation is crucial to successful planning and implementation. Vendors who provide modular, agnostic software are paramount, giving chemical companies the freedom to choose the optimal technology for their plant and easily scale to new sites.

Finally, transitioning to more circular recycling models requires industry leaders to build a seamless connection between recycling facilities, infrastructure and the supply chain.

Developing a reverse supply chain means taking back products from regional operations, customers, partners, to reuse and recycle. This is only possible with a digitalised, fully-connected supply chain that ensures the quality and availability of materials and products.

The role of digitalisation and automation

As we continue to innovate in plastics processes, the solution set to make a monumental impact is software-defined automation.

Software-defined automation systems decouple hardware from software, allowing devices and equipment to be freely connected across architecture layers, regardless of manufacturer. It acts as the digital backbone of industrial operations, providing the foundation to make more informed decisions.

This new generation of automation systems intertwines OT and IT, enabling the exploitation of advanced functionalities for operations management and data analytics – crucial to find future ways to evolve plastics production, recycling, and reuse.

Also of interest:
The role of circularity in decarbonising copper
Resin made from biomass aids recycling of wind turbine blades finds NREL

This approach enables industry leaders to effectively de-risk operations and push the boundaries of their technology. Specifically, this is possible through the reconfiguration of systems to optimise efficiency, while avoiding supply chain issues due to the hardware-agnostic nature of the system.

For instance, GR3N has successfully demonstrated how this technology will be used to transform plastic recycling processes. Working in partnership with Schneider Electric, GR3N expects to treat over 40,000 tonne/year of Polyethylene terephthalate (PET) waste, making it the first plastic recycling plant to use the shared automation runtime managed by Universal Automation, based on the IEC 61499 standard.

The modular design of their control software, supported by digital continuity across the whole plant lifecycle with automation-focused decision-making happening at conception, reduces human error at the development stage by 40%. What’s more, GR3N can expect a 30% reduction in engineering costs linked to automation thanks to the software-defined approach.

Looking ahead

If we want to overcome the scale of plastic waste, there are certain non-negotiables. We must see integration across the whole product cycle, modularisation to optimise and standardise engineering processes, as well as software-defined automation solutions that deliver scalability, break siloes and act as a gateway to advanced analytics.

Furthermore, industry and businesses at large should also look to limit consumption of single use plastics.

At Schneider Electric, we are committed to achieving 100% of our primary and secondary packaging, free from single-use plastic and use only recycled cardboard by 2025. To achieve this requires making a systemic shift from the traditional linear model of "take-make-dispose" to a regenerative approach that involves designing and utilising products that are durable, repairable, and recyclable. Encouraging this paradigm shift in industry, alongside driving collaboration to support growth of the advanced recycling sector will be key to reducing plastic consumption and waste.

Above all, success will depend on digitalisation, forging partnerships, and setting up a reverse supply chain. Only by using plastics better, longer and again can we start to see a real difference made in the way we drive plastic circularity.

In order to do that, we need a more digitalised way of working. Innovative technology that is underpinned by software-defined automation will be the catalyst for more environmentally responsible, efficient and profitable operations.