Closed circulation of polystyrene products between manufacturer and user
Circularity, Germany
A leading initiative by Sanofi.
Insulin administration devices, crucial for diabetes treatment, undergo highly automated production processes that employ polystyrene trays for device components. These trays, once used, are transformed into high-purity recyclates, contributing to a sustainable approach. In this collaborative project, we partnered with the supplier to repurpose the shredded material, resulting in raw material savings, reduced CO2eq emissions, and decreased blue water consumption.
Efficiency in Diabetes Device Production
The production of insulin administration devices involves the automatic assembly of pen assemblies and insulin cartridges. These components are processed using rectangular transport boxes, known as trays, which facilitate their assembly, packaging, transportation, and processing within the manufacturing system. These trays, crucial to the process, are crafted from polystyrene to ensure seamless, automated assembly.
From Assembly to Recycling
Trays, made of polystyrene, are manufactured by a supplier and delivered to the assembly manufacturers. After their role in the manufacturing process is fulfilled, the trays cannot be directly reused. Instead, they undergo shredding to prepare for recycling. The shredded polystyrene material is then sold in the secondary commodity market.
Closing the Recycling Loop
Our project aimed to establish a closed-loop system by returning high-quality, impurity-free shredded polystyrene material directly to the tray manufacturer. This initiative required rigorous qualification and validation processes to maintain product quality while adhering to Good Manufacturing Practice (GMP) conditions. Since its successful implementation last year, a significant portion of the polystyrene shredded material has been reintegrated into the production process.
Project Achievements
- Collaborative Circular Management: This project fostered close cooperation across European borders between the manufacturer, user, processor, and freight forwarder to establish a circular approach.
- Material Loop Closure: By keeping the polystyrene material within a closed loop, we reduce the need for new polystyrene material in tray production, conserving natural resources.
- Yearly Emission Reduction: Utilising 30% shredded material leads to an annual reduction of 840 tonnes of CO2eq emissions and a decrease in blue water consumption by 4620 cubic meters.
- Ongoing Process Optimisation: Our efforts continue to optimize the use of shredded material, targeting a 50% incorporation rate. This enhancement would result in a further reduction of 252 tonnes of CO2eq emissions and a decrease in blue water consumption by 525 cubic meters.