Molten salts technology is attracting intensive R&D efforts and emerging in the circular economy. It is leading advancements in renewable electricity generation and heat storage as a safe, green alternative to conventional technologies. 

The demand for molten salts for thermal energy storage alone was worth 8.6 billion USD in 2024 and is expected to have a CAGR of 9.4% in the same year. Molten salts technology is also being developed for recycling critical resources and hazardous tire waste, and its advantages are driving more usage across different industries, which we will cover in this article, along with: 

• The many properties of molten salts technology,
• What the uses of molten salts in various industries are, 
• And how molten salts are used to recycle important resources.

Subscribe to the Contec Monthly on our LinkedIn Page and gain relevant insights into circularity and sustainable business models.

What is a molten salts mixture? 

Molten salts are simple inorganic compounds, such as fluorides, chlorides, and nitrates. A common example is sodium chloride or table salt. The standard molten salts mixture in industrial settings is 60 per cent sodium nitrate (NaNO3) and 40 per cent potassium nitrate (KNO3). 

Molten salts are phase change materials that are solid at room temperature and atmospheric pressure. High temperatures, specific to the salt, melt them to produce stable liquids made of positively- and negatively-charged ions. For example, sodium nitrate, potassium nitrate, and sodium chloride all melt at different temperatures of 306.5°C, 334°C, and 801°C, respectively. The 60 per cent sodium nitrate + 40 per cent potassium nitrate mix remains a liquid only at high temperatures of 220-600°C. 

How and what molten salts are used for depend on their following properties:

• Fluid stability: Molten salts have a viscosity similar to water at high temperatures and the ability to flow, which is useful in heat transfer applications. When the molten salts cool, they solidify and contract unlike water that expands when frozen and can burst pipes.
• High heat capacity: Molten salts have a higher latent heat capacity than conventional materials and store the heat applied to melt them. They can store heat over 700°C making them suitable as a heat transfer or storage medium. 
• Electricity conductivity: In the liquid state where the chemicals are ionic in form, molten salts conduct electricity.
• Solvent: Molten salts act as solvents and can be used as alternatives to toxic volatile organic compounds (VOC). They can dissolve or dilute several organic and inorganic materials, such as metal oxides, or crystallise basic oxides at their freezing points. 
• Catalysts: Some molten salts are catalysts and used in the synthesis of chemicals.

Molten salts are used in various applications, including direct heating, baths, and circulation. They are nonflammable and nonvolatile, making them ideal for industrial applications as a safe and environmentally friendly technology.

What are molten salts used for? 

Several standard industrial processes use molten salts technology, such as nuclear reactors, heat transfer, electrochemistry, etc. The first use of molten salts was in 1950 to develop and test a nuclear-powered aircraft in the USA! 

Molten salts as a heat transfer medium      

Currently, one of the main uses of molten salts is as a heat transfer medium. Molten salts’ high heat capacity and viscosity are useful in transferring high temperatures in many energy systems for storing or producing energy, according to a 2022 review (Roper et al.).

A few examples are:  

• Thermal energy storage: Renewable energy storage has been a challenge that molten salts address. Molten salts as thermal energy storage and heat transfer fluids are integral to new concentrating solar power (CSP) plants. Molten salts absorb heat from solar radiation that is focused by mirrors and lenses on a small receiver. Molten salts store the heat up to 600ºC for extended periods for later use. When required, the heat stored in molten salts is transferred using a heat exchanger to generate steam to turn a steam turbine for electricity production. Nitrate-nitrite molten salts are common in solar applications. Molten salts technology increases efficiency and storing capacity of solar power plants.
• Nuclear reactors:  Molten salts cool solid fuels in nuclear reactors due to their heat transfer capabilities. Molten salts can also be used as fuel salts in nuclear reactors. Since the molten salts remain liquid even under low atmospheric pressures, it is an advantage that allows for use of systems that have relatively thin walls.
• Pyrolysis: The use of molten salts as heat transfer mediums has been further extended by integration into end-of-life tire (ELT) pyrolysis. Pyrolysis is a thermo-chemical process that uses high temperatures between 400-700ºC to break down the complex mix of substances in tires into simpler components that provide a range of secondary recycled products that can narrow the material loop to produce new tires, rubber, and paints. 

Molten Salts Pyroprocessing of Non-Ferrous Metals 

Pyroprocessing extracts non-ferrous metals by dissolving them in a molten salt bath. For example, metal ores like titanium oxide are combined with chlorine and carbon, and the resultant compound titanium tetrachloride (TiCl4) is smelted in molten salts. Once melted, the metal is boiled and then distilled to separate it from impurities to give pure TiCl4. 

Using molten salt electrolysis for metal production is a more common method.

Molten Salts in Electrolytics and Fuel Cells 

Molten salts are popular for electrolysis because their electrical conductivity is several times higher than aqueous and organic electrolysis. Molten salts’ high temperatures support rapid electrode reactions, therefore a higher voltage, though this property can be a disadvantage at times.  

Examples of molten salts in electrolytics include:

• Metal extraction: Molten salts with high melting points, electrical conductivity, and electrochemical stability are useful in extracting aluminium and titanium from raw ores. 
• Critical resources recovery: Molten salts electrolysis can help in the recovery of critical resources and metals from waste/secondary resources such as abandoned rare earth metals, spent lithium batteries, waste cemented in carbide scrap, and spent fuel. With the rise of renewable energy, demand for critical metals is increasing. The metals are considered critical as they are essential to the security and economy of a country and their supply chains are fragile, since they are sourced from regions with less government control. Molten salts address challenges in conventional aqueous solution electrolysis. They provide anhydrous and oxygen-free conditions and inhibit hydrogen production that interferes with the electrodeposition of metals. Therefore, molten salt electrolysis is preferred for extracting, purifying, and resource recycling of rare earth metals, alkali, aluminium, and magnesium. 
• Fuel Cells: Molten salts are used as electrolytes with other compounds in batteries called fuel cells that use electrochemical conversion to convert chemical energy to electrical energy. This process is used with carbon-containing fuels, including biofuels, to generate electricity. These Molten Carbonate Fuel Cells (MCFCs), can operate at high temperatures of 580-700oC. However, electrolyte vaporisation and corrosion can be disadvantages.

Molten Salts Cleaning for Remanufacturing 

Cleaning secondary and reusable materials is essential during remanufacturing. Cleaning helps detect repair needs during processing and assembly. Molten salts combinations of sodium nitrite/nitrate baths are used to strip metals of impurities like carbon compounds, oil, and metal depositions. Cleaning with high quality molten salts uses their catalytic and oxidative properties and does not deform surfaces. However, corrosion must be tackled. For example, appliance manufacturers use molten salts baths to clean paint from items that fail quality tests in order to reuse materials again.

Molten Salts Oxidation (MSO)

The many uses of molten salts shows their versatility. Among thermal methods, molten salts oxidation (MSO) is a non-flame process that can destroy several kinds of wastes while retaining items of interest like inorganic or radioactive materials. MSO can oxidise several categories of waste, such as hazardous, mixed plastics, and medicinal wastes. It is also used to destroy biological and chemical weapons, munitions, explosives, and rocket fuel. 

In this process, waste and air are sent to a molten sodium carbonate bath and the only emissions are steam, oxygen, carbon dioxide, and nitrogen. Conventional technologies use acidic gases that react with waste material, while MSO is stable and non-reactive. 

MSO technology was pioneered for nuclear processing and applied for coal gasification initially. In the future, it could become a viable recycling method for challenging waste streams like plastics.

How are molten salts used in tire pyrolysis?  

Contec is the only company in the world that uses molten salts as a heat transfer medium in ELT pyrolysis to produce circular secondary raw materials. Contec developed the patented technology after five years of R&D efforts in close collaboration with the Warsaw University of Technology and engineers.

Molten®, Contec’s proprietary technology, uses a commercial mix of sodium nitrate and potassium nitrate. The molten salts are heated, melted, and pumped into a jacket that keeps circulating them in a loop around the reactor containing ELT rubber granules. This thermal treatment of rubber is even and without hotspot formation due to heat transfer from the molten salts and an auger that rotates the rubber granules. As a result, the tire waste is broken down to yield high quality Recovered Carbon Black.

Contec has found various other advantages in using molten salts. The medium requires less energy to melt and retains its high temperature, considerably reducing the energy requirement and carbon footprint of pyrolysis. Moreover, using molten salts as a heat transfer medium prevents the buildup of pressure and avoids accidents and explosions, for which pyrolysis plants are notorious.

Molten® has helped to make Contec’s tire pyrolysis process safe, efficient, and environmentally friendly. Its pilot plant situated in Szczecin, Poland has two pyrolysis plants and the company aims to triple its capacity soon following successful fundraising in 2023.

Improving circularity with molten salts

Several new technologies are emerging to usher in the circular economy. Molten salt technology is one of them. Molten salts are used to produce and store renewable energy and help recover critical resources. The long list of molten salts’ properties is also increasing how, where, and what molten salts are used for in industrial waste reduction. 

At Contec, we’re dedicated to advancing molten salt technology for the circular economy. We provide sustainable and circular products such as recovered Carbon Black (ConBlack®), recovered Tire Pyrolysis Oil (ConPyro®), and recovered Steel (ConWire®), applying molten salts.

If you liked reading this article, we recommend the following content:

• Explore Contec’s registered Molten® technology
• Pyrolysis: 5 heat transfer systems
• Making plastics circular: what is chemcycling?

Molten salts are a heat storage solution with a great potential to help enable the manufacturing industry to transition to carbon neutrality.

The demand for molten salt storage is expected to grow at a compound annual growth rate (CAGR) of 9.4% in 2024, reaching 8.6 billion USD in the same year. 

Thermal energy companies are especially interested in molten salts for their applications in the renewable energy industry. However, molten salt applications can extend beyond this industry!

Heat storage materials have limited capacities, which makes thermal heat storage one of the biggest challenges in the renewable energy industry. Efficiency depends on a properly designed system to ensure energy extraction at a constant temperature.

Molten salts are one of the upcoming technologies that will help thermal energy companies succeed.

In this article, you will learn:

• What molten salt storage is,
• How molten salt storage works, and
• The pros and cons of this technology.

Subscribe to the Contec Monthly on our LinkedIn Page and gain relevant insights into circularity and sustainable business models.

What is molten salt storage?

Molten salt storage uses molten salts as a heat storage medium. This promising technology addresses the challenge of an energy storage that is safe, consistent, and sustainable for several manufacturing processes.

Currently, this technology is primarily used with concentrated solar power (CSP) plants, but it has potential applications in other forms of renewable energy and industrial processes. Molten salt storage can:

• Enhance the efficiency and reliability of CSP plants by allowing them to generate electricity even when it’s not sunny.
• Increase grid stability with a consistent power output.
• Integrate hybrid systems with other renewable energy technologies (solar PV, wind) and energy storage systems (batteries) to maximise energy availability.
• Serve as a backup power source for critical infrastructure, providing energy during periods of high demand.
• Provide a consistent and safe heat transfer for tire pyrolysis.

With plenty of business opportunities available for this technology, it’s essential to understand how molten salt storage works, which will prompt even more research and development.

How does molten salt storage work?

Molten salts, typically a mixture of sodium nitrate and potassium nitrate, have a high heat capacity and thermal stability. They remain liquid even at high temperatures (between 220°C and 560°C), making them excellent for storing and transferring heat.

In CSP plants, molten salt storage works in the following steps:

• Mirrors concentrate solar radiation onto a receiver.
• Molten salts absorb heat from the receiver.
• The heated molten salt is stored in insulated tanks.
• When electricity is needed, the hot molten salt is pumped to a conventional steam generator.
• The steam drives turbines to generate electricity.

Molten salts can store up to 600ºC of heat for extended periods of time, addressing one of the main concerns regarding CSP plants: heat storage. However, despite its many impressive benefits, molten salt storage has some disadvantages.

What are the pros and cons of molten salt storage?

Molten salt storage is a promising technology with significant benefits, particularly in large-scale and high-temperature applications.

• Molten salts have a high heat capacity, allowing for efficient heat storage and thermal energy transfer of around 90%.
• Molten salt storage systems can be scaled up for large operations and are suitable for utility-scale applications like CSP plants.
• Molten salts can store energy for several hours to days, increasing the reliability of CSP plants even when it’s not sunny.
• The materials used to make molten salts (sodium nitrate and potassium nitrate) are inexpensive and commercially available.
• Molten salts are stable at high temperatures, typically from 220°C to 550°C.
• Molten salt storage systems can have a long operational life with proper maintenance, often exceeding 20-30 years.

Despite the benefits of molten salt storage, there are some drawbacks to this technology.

• The upfront costs for setting up molten salt storage systems, including infrastructure and installation, can be high. This can be a barrier in smaller applications or regions with limited financial resources.
• Molten salts can be corrosive to certain materials, necessitating specialised, often more expensive, materials for containment and heat exchange. Molten salt systems require regular maintenance and monitoring to prevent and manage corrosion-related issues.
• Handling and storing large quantities of molten salts pose safety risks, including the potential for leaks and burns.
• The optimal use of molten salt storage is typically in regions with high levels of solar radiation, limiting its applicability in less sunny areas.
• Despite molten salt storage’s high efficiency, some energy is still lost during conversion from thermal to electrical energy, which can affect overall system efficiency.

The advantages and disadvantages of molten salt storage influence its adoption and effectiveness in different applications. As technology advances and more teams invest in R&D surrounding molten salts, these drawbacks could be mitigated, making molten salt storage more attractive for several industries.

Molten salts at Contec

Molten®, Contec’s proprietary technology, uses a commercial mix of sodium and potassium nitrate—a patented technology developed after five years of R&D efforts in close collaboration with the Warsaw University of Technology.

Contec is currently the only company that uses molten salts as a heat transfer medium in end-of-life tire pyrolysis to produce circular secondary raw materials. Molten® has helped to make Contec’s tire pyrolysis process safe, efficient, and environmentally friendly. 

At Contec, we’re dedicated to advancing molten salt technology for the circular economy. We provide sustainable and circular products such as recovered Carbon Black (ConBlack®), recovered Tire Pyrolysis Oil (ConPyro®), and recovered Steel (ConWire®), applying molten salts.

If you liked reading this article, we recommend the following content:

• Molten salts: Why they’re an excellent heat transfer medium
• Explore Contec’s registered Molten® technology
• What are the SDGs: A sustainable transformation in manufacturing

We welcome Dominika Żelazek to the Contec team.

Dominika Żelazek joins Contec S.A. as Chief Financial Officer (CFO) and a member of the Management Board. This strategic move underscores Contec’s commitment to innovation and sustainable growth as it prepares for international expansion and fundraising efforts.

Dominika Żelazek’s expertise and strategic role

Dominika brings over 20 years of financial management experience in demanding and regulated sectors. Her previous roles include key positions at Arriva Poland, where she oversaw finance, IT, communication, and external relations as Vice President of the Management Board and CFO.

As Contec focuses on strengthening competencies and developing products using its unique Molten® technology, Dominika will play a crucial role in supporting the company’s growth, enhancing management capabilities, and driving fundraising initiatives for new plant construction and product development.  

For the last 15 years, she’s held key positions at Arriva Polska, supervising finance, IT, communication, and external relations as the Vice President of the Management Board and Financial Director. 

Joining Contec as CFO and Member of the Management Board represents an exciting challenge for me and an opportunity to leverage my financial and executive expertise to advance the company’s strategic expansion. Contec’s clearly defined goals and our commitment to sustainable development position us as a formidable player in the rapidly evolving Clean Tech industry.

– Dominia Żelazek, CFO and Member of the Management Board

Contec’s Recent Milestones and Future Plans  

Contec recently completed the expansion of its plant in Szczecin, Poland,  marking a significant step in its growth trajectory. Dominika’s role as CFO and board member is integral to Contec’s broader strategy. The company seeks to strengthen its position in both Polish and international markets, attract new investors, and build on its successful €15 million funding round in 2023.

Krzysztof Wróblewski, CEO of Contec, emphasises the company’s unique value proposition and the importance of the new appointment.

Sustainable raw materials produced by Contec have significantly lower carbon footprint in comparison with their conventional, virgin counterparts. This makes us an ideal partner for companies seeking sustainable solutions and aiming to decarbonize their supply chains. With Dominika joining our executive team as CFO and Management Board Member, we’re well-positioned to capitalize on these opportunities and drive our financial and strategic objectives forward, addressing the growing demand for our products and building our part in the circular ecosystem of tire manufacturing.

– Krzysztof Wróblewski, CEO

We’re looking forward to working with Dominika. Welcome to the team!

Download the press release in English or Polish. For media inquiries, please contact Anna Goławska at a.golawska@contec.tech.

Manufacturing and production are responsible for one-fifth of global emissions.

High carbon footprints aren’t limited to specific industries; they’re characteristic across sectors providing raw, processed, and intermediary materials. Given the pervasive nature of carbon emissions, developing strategies and solutions applicable across sectors is necessary. Let’s dive into what the carbon footprint of manufacturing is.

In this article, we will:

• Learn the existing patterns in the carbon footprint of the manufacturing sector,
• Explore some standard solutions,
• Discuss the efficacy of the circular economy model, and
• Demonstrate the benefits of cooperation and collaboration. 

Subscribe to the Contec Monthly on our LinkedIn Page and gain relevant insights into circularity and sustainable business models.

What is the Carbon Footprint of Manufacturing?

Manufacturing includes industries that physically, chemically, or mechanically transform materials into new products.

The manufacturing sector drives economic growth, contributing 16 per cent of the global GDP, and directly provides 35 million jobs in the European Union (EU). However, manufacturing is also a significant contributor to climate change and other environmental issues.

The manufacturing sector’s carbon dioxide and other greenhouse gas (GHG) emissions are caused by using fossil fuels for energy, transportation, and raw materials for industrial processes. Carbon footprint of manufacturing constitutes around 21 per cent of total emissions.

Thecarbon footprint of the manufacturing sector needs to be reduced to meet national climate targets. To this end, the EU has set ambitious reduction targets of 55 per cent below 1990 levels by 2030.

So, what can manufacturers do to achieve this goal?

6 Strategies to Reduce Carbon Footprint in Manufacturing

Businesses should realise that cutting the carbon footprint of manufacturing will benefit them.

Adopting carbon reduction technologies will increase efficiency and decrease waste. Businesses that meet their ESG compliance goals will avoid costly fines and penalties. Moreover, as consumers seek more sustainable products, cutting emissions will help companies stay competitive and retain their markets.  

Among the broad spectrum changes that industries can make are increasing energy efficiency, choosing renewable and eco-friendly materials, and implementing circular design. 

1. Optimise Production Processes 

Regardless of the industry, production processes can be optimised using lean manufacturing principles to improve efficiency and reduce waste.

Waste is any unused material, process, or work time that doesn’t add value for which customers will pay. Eliminating waste can reduce lead time/manufacturing time and operating costs while increasing quality through the supply chain.

The production and services sectors follow specific manufacturing principles to reduce waste. The five principles of lean manufacturing are

• Determining value by evaluating what the customer is prepared to pay,
• Map the value stream throughout a product’s lifecycle by analysing resource use,
• Create a flow for constant delivery by removing barriers to production,
• Establish a pull system to manufacture only in response to demand instead of preplanning that leads to over or under-production, and
• Pursue perfection through ongoing assessment and process improvements. 

Some examples of lean manufacturing practices that produce direct benefits for companies include

• Switching off unused machines to reduce energy usage, 
• Implement control systems for processes to increase energy efficiency,
• Invest in maintenance and efficient equipment to improve production efficiency,
• Choose sustainable product designs and new manufacturing processes to decrease material use, and
• Reduce, reuse, recycle, and recover materials to reduce waste. 

2. Embrace Renewable Energy Sources 

The manufacturing sector uses 54 per cent of global power.

In 2022, manufacturing industries were the third largest source of carbon emissions (19.6 per cent, in the EU, after power generation and domestic transportation. 

Most of the carbon footprint of manufacturing comes from energy generated from non-renewable carbon-rich fossil fuels like coal, oil, and natural gas. Switching to renewable energy, which is obtained from replenishing sources and doesn’t generate carbon emissions, can help manufacturers reach net zero emissions targets by 2050.

Some of the renewable energy sources available for manufacturers in the EU are

• Solar and wind energy,
• Hydropower of varying sizes that is flexible and has storage potential,
• Bioenergy produced from biomass and biofuels to reduce GHG, and
• Offshore energy generated by ocean-based resources like tidal, wave, wind, or thermal energy.

As manufacturers substitute fossil fuels with these renewables, they will be able to reduce carbon footprint of manufacturingby avoiding certain classes of emissions, like

• Scope 1 emissions from onsite operation and production processes or vehicles can be avoided through recovered heating, heat pumps, and bioenergy.
• Scope 2 emissions, accrued indirectly from energy or electricity purchased for heating and cooling, can be reduced by choosing solar, wind, hydro, geothermal, or offshore energy providers.

Manufacturers can choose energy providers that show Renewable Energy Certificates (RECs) or Guarantees of Origin (GOs) to ensure validity.

3. Reduce Transportation Emissions 

Domestic transportation (23.1 per cent) in the EU is the second largest source of GHG emissions.

Manufacturers emit them not only through vehicle use and travel by staff but also through upstream and downstream transportation of raw materials and finished goods. Businesses can look for options that cut carbon footprint of manufacturing and save money, such as:

• Sourcing raw materials locally instead of globally,
• Grouping deliveries to save trips, and
• Encouraging staff to use public transport, trains, and roads to avoid air travel.

Transportation emissions can also be cut by adopting circular economy principles. 

4. Adopting Circular Economy Principles 

Circular economy principles reduce material use by avoiding losses in the product life cycle.

A circular economy model emphasises using product design to encourage the reuse and recycling of materials in end-of-life items and incorporate them in remanufacturing new products. This keeps materials in circulation as long as possible and prevents the extraction and processing of new materials. 

As a result, the energy used for processing raw materials and their transport is decreased. Reduction in carbon footprint of manufacturing are more significant when recycling and material recovery centres are locally or regionally situated. Waste is also reduced. The circular economy’s waste hierarchy prioritises cutting emissions and pollution through reducing, reusing, refurbishing, recycling, and recovering over incineration and disposal.

For example, instead of incinerating or landfilling end-of-life tires (ELTs), mechanical and chemical recycling by Contec produces valuable secondary products for open-loop and closed-loop applications.

According to the Circularity Gap Report 2021, only 8.6% per cent of the manufacturing used circular materials. The report says that manufacturing emits 80 billion tonnes of GHG with ‘business as usual’ practices. It’s possible to reduce emissions to zero if manufacturers educe reliance on extracting new minerals, metals, and fossil fuels by doubling circularity to 17 per cent. According to the Circularity Gap Report 2024, unfortunately, in 2023, circularity dropped to 7.2 per cent.Moreover, resource use in the past six years was reported to be half a trillion tonnes of material equal to that consumed in the previous century.

Individual manufacturers cannot achieve the transition to circularity in isolation. They must collaborate across the supply chain to make the circular economy a reality. 

5. Collaborating Across the Supply Chain (And Stakeholders)

Supply chain emissions are 11 times higher than operational carbon footprints, so manufacturers have to focus on their processes and other stakeholders they deal with.

Even if manufacturers use circular, novel designs that prioritise recycled materials or components, they still need reliable recycling partners in the supply chain. Sourcing sustainable materials from like-minded suppliers interested in reducing carbon emissions and environmental impact can be an asset for manufacturers. These could be already eco-friendly sources or ready to change to reduce carbon footprint of manufacturing.

Similarly, a business can help other stakeholders by producing materials or products with low carbon footprints. For example, Contec produces Recovered Carbon Black (rCB), whose carbon footprint is 80 per cent lower than virgin Carbon Black from fossil fuels. The rCB is produced by collecting ELTs and processing them in their novel tire pyrolysis plant. Contec’s rCB can be used instead of virgin grades to make new tires and reduce the carbon footprint of tire manufacturing and the automobile industry supply chain.

Krzysztof Wróblewski, the CEO of Contec, says,

“Sustainability brings integrity to the manufacturing industry. Of course, it’s also a collective effort: every team member contributes. Collaboration accelerates the transition to circularity by supplying sustainable raw materials to the rubber industry. With such a new product, like recovered Carbon Black, you must teach your clients the best application use cases.”

6. Reducing Scope 3 Emissions

Carbon emissions reductions throughout the supply chain will also address Scope 3 emissions of an industry.

It’s now apparent that Scope 3 emissions from upstream and downstream operations are far higher than the combined Scope 1 and 2 emissions. Scope 3 emissions comprise around 70 per cent of a product’s carbon footprint, and reducing Scope 3 emissions is industry-specific.

Upstream reduction can be achieved by increasing the content of recycled raw materials procured from suppliers.

Reducing packaging or using reusable materials is one way of reducing waste and carbon footprint of manufacturing. Through circular design, manufacturers can determine emissions linked to product use and treatment of end-of-life products. Designing for easy disassembly and recycling will reduce Extended Producer Responsibility costs, help increase circularity, and eliminate emissions.

One of the current challenges is the lack of information on the carbon footprint of raw materials and finished products. This makes calculating Scope 3 emissions difficult, and without measurement, improvements are hard to make. Lack of carbon information is one of many challenges industries face in cutting emissions.

An Opportunity In The Making

Manufacturers are also challenged by ever-changing regulations, which are growing stricter and increasing compliance requirements. The 2030 deadline for cutting carbon emissions by 55 per cent isn’t far. As Martin Chilcott points out, manufacturing needs to make dramatic changes to increase sustainability. Fortunately, significant changes have already been achieved through efficiency improvement and the size reduction of mobiles reducing the size of cars.

Therefore, rather than considering carbon reduction compliance a burden, it should be treated as an opportunity to innovate and improve efficiency, ROI, brand image, and reputation. Energy efficiency reduces emissions and results in long-term savings through improved productivity. Supply chain optimisation can build stronger partnerships and resilient material flow.

The EU compliance requirements to cut the carbon footprint of manufacturing will require a change in mindset to reach 2030 targets. However, adopting one or more reduction strategies like production and supply chain optimisation, use of renewable energy, cutting transportation emissions, using circular principles, and collaboration in the supply chain will make any manufacturing sector more competitive and profitable. Minimising material use and reducing waste will be critical to the process.

In this regard, Contec can be a valuable partner for cutting carbon footprint of manufacturing rubber products and tires. At Contec, we’re dedicated to accelerating this transformation by providing sustainable and circular products such as recovered Carbon Black (ConBlack®), recovered Tire Pyrolysis Oil (ConPyro®), and recovered Steel (ConWire®). Contec uses a proprietary pyrolysis process to turn end-of-life tires into new commodities. Learn more about our process.

If you liked reading this article, we recommend the following content:

• The automotive industry and circular cars
• SDGs in manufacturing
• Why is circularity crucial in manufacturing?

Plastic is ubiquitous. Production of plastics has grown exponentially by 19,000 per cent since 1950, and over half of today’s plastic products are designed to be single-use.

Of the colossal volumes of plastic waste produced globally, only 9 per cent is recycled, 12 per cent is incinerated, and the rest is disposed of in landfills or becomes litter.

Current plastic waste treatment methods pollute seas, air, and food, with adverse environmental and health impacts on people and wildlife. The situation with plastic waste is expected to worsen as plastic production is predicted to double by 2050. 

The European Union (EU) is introducing several measures to reduce plastic waste by encouraging recycling and circular production. Read this article to find out about:

• What the EU’s Plastics Strategy is,
• What regulations were introduced to reduce plastic consumption,
• How circular production can minimise plastic waste, and
• What technologies can provide circular solutions.

Subscribe to the Contec Monthly on our LinkedIn Page and gain relevant insights into circularity and sustainable business models.

The European Union’s Plastics Strategy 

A 2018 report, European Strategy For Plastics In A Circular Economy, notes that in 2015, Europe generated 25.8 million tonnes of plastic waste, of which only 30 per cent was collected for recycling. 31 per cent of the plastic waste was landfilled, and the remaining 39 per cent was incinerated, respectively. By 2022, Europe’s plastic waste volumes had increased to 32.3 Mt.

In 2019, plastic production and incineration released 850 million tonnes of carbon emissions, and plastics are responsible for 80 per cent of marine pollution.

The EU has taken several steps to combat the plastic problem, as detailed in the 2018 report:

• In 2015, the European Commission (EC) recognised the urgency of the plastic waste problem when it adopted the “First Circular Economy Action Plan.” 
• In 2017, the EC set the goal of making all plastic packaging recyclable by 2030. 
• In 2018, the EC adopted the “European Strategy for Plastics in a Circular Economy.” This strategy promotes the production of plastics through innovative and sustainable manufacturing that integrates circular design, which respects and enables reuse, repair, and recycling to increase jobs and reduce plastic consumption, carbon emissions, and dependence on imported fossil fuels in the EU.

The EU has since supported this strategy by passing several regulations to reduce plastic consumption and encourage investment and innovation in circular solutions.

Regulations to Reduce Plastic Consumption

One of the main aims of the European Strategy for Plastics is to reduce plastic consumption, prevent production problems, and minimise waste. The EU has implemented several regulations to help reduce plastic consumption and boost demand for recycled plastics, including:

• Packaging and Packaging Waste Directive (PPWD): The latest amendment to the PPWD in 2018 stipulates that the Extended Producer Responsibility should be enforced by the end of 2024 for packaging producers and sets recycling targets of 50 per cent and 55 per cent by 2025 and 2030, respectively.
• European Green Deal: The European Green Deal has introduced mandatory targets of reducing packaging waste by 15 per cent from 2018 numbers by 2040. To achieve this aim, the European Green Deal promotes reusable and refillable packages, transparency in the labelling of recyclable packaging, avoiding unnecessary packaging, making packaging completely recyclable by 2030, and setting mandatory rates of recycled content in plastic packaging.
• Ban on single-use plastics: On 3rd July 2021, the EU ban on the top 10 single-use plastic items and fishing gear came into force. These banned items account for 70 per cent of marine pollution in the EU and include cotton buds, plates, cutlery, straws, balloons, food containers, beverage cups, cigarette butts, plastic bags, packets, wrappers, wet wipes, and sanitary items. For items without sustainable alternatives like PET bottles, the Directive on single-use plastics has set specific recycling targets. Design, labelling, and waste clean-up obligations such as  Extended Producer Responsibility (EPR) were also introduced.
• Zero Pollution Action Plan: The Zero Pollution Action Plan was adopted on 12th May 2021. It aims to reduce marine plastic litter by 5 per cent, microplastics in the environment by 30 per cent, and municipal waste by 50 per cent.
• Waste Export: On 17Th November 2023, the EU and EC reached a political agreement that export of plastic waste from the EU to non-OCED nations would be prohibited within 2.5 years of the regulation. Prior to this agreement, in 2021 the EU exported over one million tonnes of plastic waste to non-OCED countries where it was burnt or landfilled. This waste is now available for EU recyclers as feedstock to boost the circular economy.

Transitioning to a Circular Economy for Plastics

The circular economy extends the value of materials after products are no longer used through reuse, recycling, and recovery. Also called remanufacturing, this approach keeps materials in circulation longer and eschews the need to extract and process new raw materials. 

Circularity in plastic production can reduce fossil fuel use and divert post-consumer plastics from landfilling and incineration. According to the  Plastics Europe 2024 Report, circularity is the fastest, most cost-effective means to diminish plastic waste, meet greenhouse gas (GHG) emissions reduction targets of 28 per cent by 2030, and reach net zero by 2050.

The Plastics Europe 2024 Report says that 26.9 per cent of European plastics were recycled in 2022, more than the waste landfilled. 

According to the Report, the industry is transitioning to circularity. Recycled plastics use has increased by 70 per cent since 2018, and circular plastic accounts for 13.5 per cent of the total plastic produced in Europe. 

The Report also points out the challenges the industry faces to reach the 25 per cent circular plastic goal by 2030:  

• Progress in circularity is not uniform throughout the plastics value chain. Content rates of recycled plastic are higher in sectors like packaging (9.7 per cent), construction (22.7 per cent), and agriculture (37.5 per cent). However, other industries are lagging behind, such as the automotive industry, which only uses 4.6 per cent recycled plastic, and the electricals and electronics industry, which uses even less, at 3.2 per cent.
• Plastic waste incineration has increased by 18 per cent since 2018, and around 25 per cent of plastic waste was still landfilled in 2022. Better collection and sorting of plastic waste is necessary to prevent incineration and landfilling of mixed plastics and divert them to meet demands for circular feedstocks.
• Recycled plastics are still in low demand. Low prices and manufacturers’ concerns about quality are major reasons for poor demand, discouraging investment and innovation in plastic recycling.
• Most plastic recycling is currently done at small and regional facilities. Standardisation and upscaling of recycling and recovery efforts are necessary, especially to tackle the plastic waste that the EU used to export. 

Plastic manufacturers want more intervention from the EU and national governments to overcome these challenges and accelerate the transition to circularity. 

The EC is working to remove these hurdles through regulations and partnerships with the plastics industry and the European Committee for Standardisation to develop standards for sorted waste and recycled plastics.

Innovations and Technologies Driving Circular Solutions

However, the transition to circularity in the plastics industry will be impossible without innovation and the development of new technology to meet the demands of design changes and allow for efficient recycling and material recovery from post-consumer plastic waste. 

Several technologies can increase circularity in the plastics industry by providing feedstock or supporting the use of recycled materials, such as:

• Mechanical recycling: This standard method remains popular and accounts for 13.2 per cent of secondary plastic material, according to the Plastics Europe 2024 report. It involves shredding and melting plastic into flakes or pellets that are useful as feedstock.
• Chemical recycling: According to the Plastics Europe 2024 report, chemical recycling, also known as chemcycling, can help complete transition to circular plastics but currently provides only 0.1 per cent of the feedstock for plastics. It involves chemically breaking down waste into its molecular components, which can be used to make virgin-quality plastics.
• Pyrolysis: Pyrolysis is a thermo-chemical process that breaks down plastic polymers; for example, in waste tires, to produce recovered oil, gases, and carbon black. These secondary products can be used as feedstock for plastics and other products. 
• Bioplastics: Bioplastics are produced from renewable and biomass feedstocks. Some are also biodegradable and are sustainable alternatives to fossil-fuel-derived products. According to the Plastics Europe 2024 report, bioplastics account for 1 per cent of European plastic production.
• Repurposing: Plastic waste is upcycled and repurposed to produce high-value products without treatment.
• Additive manufacturing: Additive manufacturing technologies, such as 3D printing, boost demand for recycled plastic as raw materials.
• Traceability solutions: Blockchain and other traceability technologies can increase transparency and accountability in plastic recycling and reuse.

As the standardisation of plastic waste and recycled materials improves, the market for recycled feedstock should also grow. 

Moreover, assured demand can also be increased through collaboration between manufacturers, suppliers, and recyclers in the plastics value chain, which will encourage innovations. To help with collaboration, the EC wants to integrate recyclers into the plastics value chain, tap into their expertise and experience to create higher-quality recycled plastics, and provide manufacturers with a steady feedstock supply. Most circular transitions have only been possible through collaboration between stakeholders throughout a supply chain.

Contec uses a proprietary pyrolysis process to turn end-of-life tires into new commodities. Learn more about our process.

Better Product Design Makes Plastic Recycling Easier 

Another critical step in increasing circularity is product design. 

According to Sustainable Design, manufacturers incorporating circularity at the design stage can influence the entire value chain. Circular design involves material choice, planning for recycling post-consumer goods, and determining how materials can be brought back into the economy. 

Material choice is a critical design decision, and manufacturers can increase circularity by choosing recycled plastic or feedstock. Designing products for easy separation of component parts will also increase reuse, refurbishing, repurposing, and recycling. By increasing the demand for recycled plastics, it is possible to encourage better collection, sorting, and recycling of post-consumer plastics.

“Product design is also key in increasing circularity, as rethinking the design of many everyday items (like tires) can help minimise waste. Product design can irreversibly affect the ease of separating components for later reuse and recycling, which causes circularity to involve considerable technology and energy. Component separation is a recycling challenge that reduces tire material recycling, repurposing, and economic circulation. The difficulty of tire disassembly means nearly 50 per cent of ELTs are incinerated.”

Krzysztof Wróblewski, CEO at Contec

Contec treats end-of-life tires (ELTs) through pyrolysis, and knows firsthand that easy separation of component parts can make recycling more efficient. Tires are made of several components, a high proportion of which is synthetic rubber produced from plastic polymers. Contec separates the rubber from other components and produces rubber granules, which it then uses in its pyrolysis plant to create secondary oil, gas, and carbon black. 

Design improvements are crucial to reaching the recycling goals set by PPWD in 2018 for plastic packaging of 50 per cent and 55 per cent by 2025 and 2030, respectively.

Driven by EU regulations and consumer demand for change, Europe has started transitioning to more circular plastic production methods. While significant progress has been made in improving the recycling rate of plastics, more needs to be done. Individuals can do their part by avoiding single-use plastics. Incentives and investments to encourage upscaling of plastics recycling are also urgently needed. With the introduction of better waste management by EU countries and broader adoption of circular principles, the plastics industry can hopefully reach its 2030 recycling targets. 

At Contec, we enable tire manufacturers interested in transitioning to a circular economy by providing recovered Carbon Black (ConBlack®), recovered Tire Pyrolysis Oil (ConPyro®), and recovered Steel (ConWire®) from ELTs as sustainable alternatives to current industrial production.

Get in touch to learn more about our solutions.

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Contec S.A. is breaking ground for our next phase of growth. After collaborating as a team, we’re ready to introduce our revised company values!

Our long-term dedication to product quality excellence, process safety, and innovation remains — but with newly written values to reflect our current journey. We embody four major values: Leadership, Partnership, Innovation, and Quality.

Values are the building blocks to achieving our vision and mission at Contec. Our revised values — Leadership, Partnership, Innovation, and Quality — will set the tone and direction for the next phase in our development.

– Krzysztof Wróblewski, CEO at Contec S.A.

Leadership

We boldly head in the direction we’ve set. We’re proactive and methodical in our approach.

In achieving our goals, we take on the leadership role and influence change in the perception of pyrolysis.

We take full responsibility.

Partnership

Collaboration and good relationships are the foundation of our approach. We care about the environment in which we operate.

We support each other and our partners, so that by implementing our vision and mission, we can achieve success together.

Innovation

Research curiosity and ingenuity are key to our development. In our approach, we’re constantly looking for new solutions that make us better.

We draw conclusions and learn from our mistakes. We treat failure as a learning opportunity.

Quality

We value high quality, which is reflected in the continued improvement of the safety and excellence of our processes.

We provide solutions and products that set standards in the industry. Our superior work reflects our continuous dedication to operational efficiency and customer satisfaction.

Transforming manufacturing with circular solutions

At Contec, we accelerate the transformation of the manufacturing industry to carbon neutrality. We’re helping to replace petroleum-derived products with high-quality and low-carbon solutions. We use our protected pyrolysis technology to implement the idea of ​​a closed-loop economy, eliminating the use of petroleum-based raw materials.

We’re dedicated to accelerating the transformation towards a circular economy by creating circular products from waste tires, applying sustainability across our operations, and limiting our carbon footprint. Learn more about our process.

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In 2020, the European Union generated an astounding 2.2 billion metric tonnes of waste, highlighting the urgent need for more efficient waste management strategies. 

Waste represents a significant loss of resources and can have serious environmental impacts, such as pollution and harmful emissions from landfills and incineration. European Union (EU) policies aim to reduce waste generation, enhance recycling, and ensure safe disposal to improve resource efficiency. Waste reduction in manufacturing can minimise their environmental footprint and conserve valuable resources.

In this article, we will:

• Gain a better understanding of the manufacturing waste landscape,
• Explore strategies for effectively reducing waste in manufacturing and promoting a more sustainable and efficient industry, and
• Understand the importance of preventing waste altogether.

Subscribe to the Contec Monthly on our LinkedIn Page and gain relevant insights into circularity and sustainable business models.

Understanding the Manufacturing Waste Landscape

In 2020, the EU generated 2.2 billion metric tonnes of waste from all economic activities and households, amounting to 4,815 kg per person.

This enormous quantity of waste underscores the importance of effective waste management strategies. Here is the breakdown of waste by sector:

• 212 million tonnes were generated by waste and water services
• 196 million tonnes by households
• 167 million tonnes by manufacturing activities

Notably, while waste generation from waste and water services and households increased significantly between 2004 and 2020, manufacturing waste decreased by 30.5%.

About 2.0 billion tonnes of waste were treated in the EU in 2020. There are two main categories of waste treatment: recovery and disposal. Recovery encompasses recycling, energy recovery, and backfilling, where waste fills excavated areas like gravel pits and underground mines. Disposal involves landfilling and incineration.

According to Eurostat, in 2020:

• 39.9% of the treated waste was recycled, 12.7% was backfilled, and 6.5% underwent energy recovery. 
• The remaining 40.9% were managed through landfills (32.2%), incineration without energy recovery (0.5%), or other disposal methods (8.2%).

Understanding these trends is crucial for developing effective waste management strategies and promoting sustainability in manufacturing, guaranteeing the efficient use of resources and minimising waste.

Let’s explore common strategies for waste reduction in manufacturing.

1. Optimise Production Processes

Rethinking the production process is a great strategy for waste reduction in manufacturing.

When companies identify inefficiencies and areas for improvement, they can significantly enhance their sustainability efforts. One effective method is to incorporate lean manufacturing principles, such as Just-in-Time manufacturing or Total Quality Management. These techniques focus on minimising waste at every stage of production. For instance, Just-in-Time manufacturing reduces inventory waste by receiving goods only as needed in production. At the same time, Total Quality Management aims to improve quality and reduce defects.

Advanced technologies like automation and robotics can also optimise production. These technologies streamline operations, reduce reliance on manual labour, and improve precision, contributing to less waste. 

Analysing and streamlining production processes also helps manufacturers reduce energy and material consumption, enhance productivity, and minimise waste. This helps to conserve resources and improve the bottom line, making the manufacturing process more sustainable and cost-effective.

2. Implement Sustainable Packaging

Waste reduction in manufacturing requires a holistic approach throughout the product lifecycle, and packaging plays a pivotal role in this effort. Some effective strategies include:

• Reduce packaging: Minimise the amount of packaging used by opting for lightweight materials like cardboard or paper, which are easier to recycle than heavier plastics or metals. Streamlined designs that eliminate unnecessary packaging layers or components can further reduce the volume of materials used without compromising product safety.

• Introduce eco-friendly packaging materials: Incorporate reusable or easily recyclable options, such as air packs made from recycled plastic or corn-based packing peanuts, to provide necessary cushioning while being environmentally friendly. Biodegradable materials, like organic fibres or biodegradable plastics, break down naturally over time, reducing long-term waste.

• Reduce packaging size: Optimise packaging size to efficiently use space in storage and transportation, leading to lower carbon emissions. Streamlined designs that use minimal material necessary can save costs during production, transportation, and waste disposal.

3. Embrace Digitalisation and Technology

Another effective strategy for waste reduction in manufacturing production is to use digital technology and data analytics to optimise manufacturing processes. 

Introducing digital tools for waste tracking, monitoring, and management provides significant sustainability benefits. When manufacturers track production data, they identify inefficiencies and areas for improvement, enabling the implementation of targeted measures to reduce waste. These insights help streamline operations, minimise errors, and ensure resources are used more effectively.

4. Utilise Recycled Materials

Incorporating recycled materials into the manufacturing supply chain is a highly effective strategy for reducing waste.

Material recycling involves reclaiming and reprocessing materials to create new products, which reduces waste in landfills and the need for virgin resources. Additionally, using recycled materials is a cost-effective way to reduce manufacturing costs, particularly in industries heavily dependent on virgin materials.

Contec is a prime example of a company embracing this strategy with circular products. By transforming waste tires into valuable resources, Contec offers innovative products such as recovered Carbon Black (ConBlack®), recovered Tire Pyrolysis Oil (ConPyro®), and recovered Steel (ConWire®), exemplifying sustainable options that support a circular economy. Learn more about Contec’s circular products.

5. Collaborate with Suppliers and Stakeholders

Collaborating to tackle waste management challenges leads to various benefits. 

When stakeholders communicate to share their resources and expertise, they increase innovation and problem-solving. Working closely with suppliers ensures that sustainability goals are aligned across the supply chain, leading to more effective waste management strategies. 

Contec exemplifies the importance of such collaborations through its R&D efforts and industry partnerships:

• Cooperation with universities: Contec maintains complete control over its research process and cooperates with technical universities, making its R&D process uniquely robust. This enables Contec to drive advancements in sustainable materials.
• ASTM Committee: Recognising the absence of existing quality standards for recovered Carbon Black (rCB), Contec joined the ASTM Committee D36 to help formulate quality standards and testing methods for rCB. By leveraging its extensive knowledge from years of R&D, Contec continuously improves its product quality and contributes to industry-wide advancements.
• Waste Management and Recycling Cluster: Contec is a member of the Waste Management and Recycling Cluster, which includes over 136 members, such as SMEs, universities, and NGOs. This cluster fosters an industrial ecosystem that promotes cooperation between waste management businesses and companies providing consultancy services, research, and development. 

6. Use Resources More Efficiently

Waste reduction in manufacturing is also about using resources more efficiently, including water and energy.

Close monitoring of inventory levels enables manufacturers to decrease waste and minimise production delays by reducing unused resources and ensuring the timely availability of required components.

At Contec, we demonstrate our commitment to efficient resource utilisation by powering our Szczecin plant with renewable energy from the thermal energy produced during pyrolysis. 

7. Continuously Measure and Improve

It’s crucial to implement key performance indicators (KPIs) that track progress in waste reduction. These KPIs serve as benchmarks, guiding efforts towards continuous improvement.

Efficient machine and process monitoring is pivotal in transitioning to lean manufacturing. By gathering accurate data on current processes, manufacturers can identify waste areas and make targeted improvements.

Moreover, this approach empowers the workforce to monitor performance and recognise productivity norms. This promotes uniform, standardised working practices and fosters a culture of continuous improvement within the workforce.

Preventing Waste Altogether

The EU’s Waste Framework Directive establishes preventing waste as the foremost priority in waste management. It encourages a 5-step hierarchical approach, beginning with waste prevention and followed by re-use, recycling, and other forms of recovery, with disposal as a last resort. 

This directive highlights the need to reduce waste at its source, divert materials from landfills through recycling and re-use, and limit incineration to non-recyclable materials.

Efforts to prevent waste are key to sustainable manufacturing. By reducing waste generation and maximising recycling and reuse, manufacturers can minimise environmental impact and conserve resources. 

Przemyslaw Rakoczy, Business Development Director at Contec S.A., reinforces this perspective, stating:

“The directive is a major step towards improving the operating conditions for recycling companies and moving circularity in manufacturing to another level.”

Taking Action Today

The necessity for waste reduction in manufacturing is more apparent than ever. Waste is being generated at an unprecedented scale, underscoring the urgent need for sustainable practices within the industry.

From optimising production processes to embracing digitalisation, implementing sustainable packaging, and collaborating across the supply chain, businesses can use numerous actionable strategies to reduce waste. These strategies align with regulatory demands, increase competitiveness, and appeal to conscientious consumers.

Manufacturing leaders have the power to drive significant change by taking action today. At Contec, we’re dedicated to accelerating the transformation towards a circular economy by creating circular products from waste tires, applying sustainability across our operations, and limiting our carbon footprint. Learn more about our process.

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Sustainable manufacturing is revolutionising industries worldwide.

Public and governmental pressure to increase sustainability means industries must navigate the complexities of manufacturing while minimising environmental impact and maximising efficiency. Did you know that by 2040, transitioning to more circular business models could create savings of over US$4.5 trillion? 

In this article, you will learn:

• The concept and significance of sustainable manufacturing,
• Key principles guiding sustainable manufacturing practices,
• The benefits of adopting sustainable manufacturing methods, and
• Challenges hindering widespread adoption of sustainability.

Subscribe to the Contec Monthly on our LinkedIn Page and gain relevant insights into circularity and sustainable business models.

What is Sustainable Manufacturing?

Sustainable manufacturing is when goods are produced with processes that reduce negative environmental impacts and preserve resources, all while prioritising safety for employees, communities, and the products themselves.

This means managing manufacturing operations in an environmentally and socially responsible manner. It also aims to mitigate business risks while capitalising on opportunities for process and product enhancement. 

Why is Sustainable Manufacturing Important?

Sustainable manufacturing is vital because industry and the environment are closely connected. It boosts operational efficiency by cutting costs and waste. It also helps companies adapt to changing consumer preferences, safeguards brand reputation, and ensures long-term business viability. Moreover, sustainable manufacturing addresses pressing global challenges like climate change and plastic pollution.

In recent decades, population growth and an escalating demand for goods and services have led to a sharp increase in energy use, resulting in a higher collective carbon footprint. Annual global greenhouse gas emissions have surged by 50% over the past 30 years. Plastic pollution has also increased, resulting in social and economic costs totalling US $600 billion at the end of 2023.

Companies across many different industry sectors are transitioning towards more circular business models where resources are used more efficiently. Projections suggest that by 2040, this shift could create a savings of more than US$4.5 trillion. 

In the automotive industry, for instance, water consumption has been a significant concern, as large amounts of water are traditionally required for process and production stages. However, through sustainable initiatives and technological advancements, the automotive sector has made remarkable strides in reducing its water consumption. This success story serves as an example of how industries can mitigate their environmental impact through conscious efforts.

What are the Key Principles of Sustainable Manufacturing?

Understanding the fundamental principles of sustainable manufacturing is crucial to ensuring environmental responsibility, economic efficiency, and social well-being within manufacturing practices.

The key principles of sustainable manufacturing are:

1. Natural resources are used efficiently by implementing resource-efficient practices and circular economy principles to safeguard resources for future generations. At Contec, our circular products such as recovered Carbon Black, recovered Pyrolysis Oil, and recovered Steel from end-of-life tires (ELTs) provide an alternative to virgin materials, thus reducing the environmental impact of raw material production.
2. Sustainability begins at product conception. Considering the entire life cycle of a product, from sourcing raw materials to manufacturing, use, and end-of-life disposal or recycling, leads to more eco-friendly designs that are durable, repairable, and recyclable.
3. Committing to minimising pollution and waste generation and promoting eco-friendly alternatives to hazardous materials.
4. Embracing clean and renewable energy sources, transitioning away from fossil fuels, and aiming to reduce carbon emissions.
5. The safety and well-being of all employees are priorities achieved through safe working conditions, fair labour practices, and employee recognition and empowerment.
6. The surrounding communities are respected and enhanced economically, socially, culturally, and physically.

Sustainable Manufacturing Core Benefits

As companies worldwide face increasing pressure to reduce carbon emissions and enhance sustainability efforts, the importance of sustainable manufacturing has never been more evident.

With more than 6,000 companies setting science-based targets for emissions reduction and the EU’s Corporate Sustainability Reporting Directive mandating sustainability reporting for almost 50,000 companies, the spotlight on sustainable practices continues to intensify.

In this context, exploring the key benefits of sustainable manufacturing becomes imperative:

• Revenue growth: Companies integrating environmental, social, and corporate governance (ESG) priorities into their growth strategies were twice as likely to achieve a 10% increase in revenue compared to their peers, a study found. Embracing sustainable practices where efficient equipment and methods are integrated into the manufacturing process can promote optimal resource use. This can lower production costs and maximise profit margins.
• Promoting innovation: Upgrading to more efficient equipment and production processes may initially seem costly, but the long-term benefits are considerable. Integrating sustainability into innovation can enhance efficiency, reduce operational costs, and contribute to environmental preservation. For example, industries globally stand to save $437 billion annually by 2030 through improved energy efficiency.
• Increase sales: As the preference for sustainable products rises steadily, more customers seek brands aligned with their values. Many are willing to pay extra for eco-friendly options, driving demand. By adopting green practices, businesses can attract a broader customer base and ultimately increase sales. 
• Increase trust: Embracing sustainability can significantly improve a company’s reputation and brand identity. By integrating eco-friendly practices into operations, businesses stand out from competitors and gain a competitive edge. This builds trust among customers and reflects a commitment to environmental responsibility and community values, contributing to long-term success and growth.

Challenges and Obstacles to Sustainable Manufacturing

Despite its promising benefits, sustainable manufacturing presents its own set of obstacles, including unclear standards, upfront costs, supply chain dynamics, and more.

Manufacturers may encounter several common challenges while navigating the complex landscape of sustainable implementation.

• Initial investment: Upfront costs, such as energy-efficient technology or facility upgrades, can be significant when coupled with challenges in securing funding.
• Complexity of change: Substantial transformations, like supply chain adjustments, can disrupt operations and require a steep learning curve.
• Supply chain constraints: Limited options for sustainable materials may lead to availability issues or increased costs.
• Lack of clear standards: Industry-wide certifications and standards for sustainability are still evolving, making it difficult to benchmark progress or communicate efforts effectively.
• Resistance to change: People often resist change due to fear of the unknown, limited awareness of the need for sustainability, conflicting interests, and low motivation. Overcoming ingrained mindsets and resistance can be a formidable challenge.
• Balancing performance and sustainability: Businesses must ensure that sustainability initiatives don’t compromise product quality or production output. 

Industry Lens: Sustainable Manufacturing in the Automotive and Tire Industries

The automotive and tire industries have embraced innovative solutions to minimise environmental impact while maintaining competitiveness.

Some tire manufacturers, such as Michelin and Bridgestone, have incorporated recycled Carbon Black (rCB) derived from end-of-life tires into their tire production processes. This approach significantly reduces reliance on virgin materials and lowers their environmental footprint. 

Similarly, material recycling initiatives by companies like Contec divert end-of-life tires from landfills, repurposing them into new products or materials. Through innovative recycling technologies and strategic partnerships, Contec is committed to delivering top-notch, low-carbon products for the manufacturing industry.

Embracing Sustainable Manufacturing

Our exploration of sustainable manufacturing has underscored its important role in shaping the future of industries worldwide.

From recognising its significance in minimising environmental impact while maximising efficiency to exploring innovative solutions like rCB and tire recycling initiatives, the message is clear: sustainable manufacturing can be a strong ally in improving the well-being and longevity of our industries.

At Contec, we’re dedicated to accelerating this transformation by providing sustainable and circular products such as recovered Carbon Black (ConBlack®), recovered Tire Pyrolysis Oil (ConPyro®), and recovered Steel (ConWire®). Contec uses a proprietary pyrolysis process to turn end-of-life tires into new commodities. Learn more about our process.

With these solutions, we empower manufacturers to reduce their carbon footprint and contribute to a more sustainable future.

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We warmly welcome Wojciech Paruzel to the Contec team.

After a successful funding round of 15 million EUR in 2023, we’re taking the next step in its expansion plans by onboarding Wojciech Paruzel as Chief Operations Officer. 

Wojciech Paruzel is an electrical engineer and a Wrocław University of Science and Technology graduate with an MBA in Business Management. His career spans over 25 years, with experience in the construction, automotive, and technology industries.  He was previously the COO of the J.S. Hamilton Group, where he improved operational efficiency with selected strategies across Central and Eastern Europe.

Previously, Wojciech Paruzel established operational standards in plants in Poland, China, Mexico, and Germany. His latest collaboration with teams from Lithuania, Latvia, Romania, Serbia, and Croatia confirms his experience with international teams, a skill that he’s eager to expand with Contec as the company prepares for the completion of our plant expansion work in Szczecin and further European expansion. His accolades include the Forbes’ Diamond, Silver, Gold, and Platinum Laurel of Skills and Competences awarded by the Opole Chamber of Commerce.

We talked to Wojciech about his new role and motivation for joining our team. 

Why did you join Contec?

I joined Contec because I admire their innovative approach to solving the problem of how recycled end-of-life tires can add value to emerging products in various industries. I see the potential in Contec to introduce groundbreaking technologies and strategies that can truly change how we interact with our natural environment.

What do you do at Contec?

As COO at Contec, my main responsibility is to ensure the smooth and effective operational performance of the company. Together with the team, I supervise daily operations, ensuring that all processes run smoothly and in accordance with defined quality standards. Together, we develop and implement activities aimed at optimizing operational efficiency. My work also involves identifying areas where improvements can be made to increase Contec’s efficiency and profitability.

What do you like most about this job?

What I value most in my role as COO at Contec is the opportunity to influence the efficiency and effectiveness of the entire operational structure of the company. I enjoy the challenge of optimizing processes and striving for operational excellence. Seeing how my actions contribute to the company’s more efficient operation and increased profitability, I feel satisfied with the goals achieved.

Despite many years of experience in various industries, working in such a dynamic and innovative operating environment allows me to continue developing and expanding my skills, which is another reason for my satisfaction with my role at Contec.

“I am excited to work with such talented people, contribute my knowledge and experience to the company’s development, and achieve joint successes.”

Wojciech Paruzel, Contec’s COO

Our team is lucky to have him!

“Paruzel brings extensive experience and knowledge to the team, which are crucial for our ambitious development plans. His collaborative vision to operational challenges will allow us to continue working on innovations and strengthen our position as a leader in tire recycling on a global scale.” 

Krzysztof Wróblewski, Contec’s CEO

As we aim to accelerate the transformation of the manufacturing industry towards carbon neutrality, Paruzel’s expertise in scaling businesses, serving customers, and fostering inclusive environments for employees will be key to support during the next phase of our growth plans. 

We’re looking forward to working with him.

Welcome to the team!

Download the press release in English or Polish.

For media inquiries, please contact Anna Goławska at a.golawska@contec.tech.