CLIENTS AND CASES
Changing a culture and revolutionizing the market
One day, the plastic requeijão cheese spread cup was born in a market previously dominated by glass containers. In partnership with Huhtamaki of Brazil, now Dixie Toga, Braskem has developed a plastic resin to replace glass packaging for requeijão, a popular cheese spread in Brazil. More practical and safer than conventional materials, the plastic resin has revolutionized the market. Today, 80% of requeijão cheese spread manufacturers use polypropylene cups to package their brands. The main advantages for them are lower weight, ease of transportation and, especially, low cost, among others.
Braskem envisioned an opportunity to expand the use of transparent copolymers in a new application for the market. That innovation has benefited everyone involved. Braskem's technical support and monitoring were essential to speeding up approval of the level of PP used in the new molds for packaging production. Clients have benefited by winning a new market, and the public has gained safer, reclosable packaging. The product also has sustainable advantages: it is lighter, which reduces CO2 released during transport, does not break, reducing losses from leaks up to arrival at the consumer's home, and is 100% recyclable.
A new concept in logistics
PackLess is a company that offers solutions for its clients' logistics chains. Their innovative spirit brought PackLess and Braskem together, and Braskem saw the project as a unique opportunity for the logistics chain. It is the "pack less" system developed for cargo handling, made of 100% PP, which weighs only 3 kg and supports a dynamic load of 1,500kg. In addition to being resistant, according to a report issued by the Institute for Technological Research (IPT), the "pack less" system has several benefits, such as improved hygiene, reduced mass (up to 10 times lighter), reduced storage space and the possibility of in-house assembly of the pallet.
A life-cycle assessment made by the Espaço Eco Foundation comparing pack less and the traditional alternative used for cargo handling, showed that PP pallets have fewer environmental impacts in all the dimensions considered in the study. An important point raised was the reduction in fuel consumption for transportation and consequently CO2 emissions thanks to the lightness of the pallet. The Espaço Eco Foundation also found that this reduction in CO2 emissions can reach 85% depending on the logistics operation.
Although it was initially developed for handling products packaged in sacks and big bags, pack less is extremely versatile and can be adapted and applied in various types of packaging and operations. To help PackLess develop this project, Braskem brought in heavy-weight partners: Propex, a world leader in the production of synthetic fabrics and thermoplastic resins and Cartonale, the largest manufacturer of corrugated plastic solutions in Latin America.
The Client's competitiveness in the field
Increased productivity. That was the goal set by CSI when it turned to Braskem, a partner of over ten years with a long history of joint projects, for support. An important player in the world market for bottle tops for carbonated and non-carbonated beverages, CSI needed to increase the productivity of its machines in the process of compression molding to reduce manufacturing costs, thereby increasing competitiveness. However the performance of the bottle tops being produced conflicted with their quality requirements.
Committed to providing a solution that met CSI's needs, Braskem sent its entire team into the field to develop a plastic resin with higher productivity. A meeting with Braskem's technical team at CSI's headquarters in the United States was key to delivering the ideal solution and meet the Client's expectations. Thanks to this development, CSI has achieved its goal of producing bottle tops with excellent mechanical properties and good productivity without changing the cost of inputs, while reducing loss of materials during the production process, which makes the company more competitive.
Automotive Industry surrenders to plastics
The use of plastic in the automotive industry started in the 60s and significantly increased in the 90s, mainly providing weight reduction and design flexibility, with bolder, more rounded lines. Containing an average of 50 kg of PP compounds, Brazilian cars have plastic parts in their interiors, exteriors and close to the engine compartment. Because of their versatility and low weight, these PP parts are increasingly used, allowing design flexibility, integration of parts and cost reduction.
To grow this market, Braskem and Produmaster have teamed up to introduce a new solution using a PP compound with very low contraction to use in compounds for manufacturing car bumpers. A major player in the compounds segment, Produmaster has tested and approved Zero Gap compound at auto manufacturers' facilities. The main characteristics of this compound include small percentages of minerals and lower density, meeting and exceeding the requirements for the product.
In addition to meeting the mechanical and processing requirements for large auto parts, the Produmaster compound made the Braskem's plastic resin enables production of bumpers with very low shrinkage that fit snugly to the body of the car. Thanks to the lower weight of this product, cars are lighter and use less fuel per mile, as well as producing fewer emissions. In addition, plastic parts simplify processes and require less energy to manufacture. An environmentally responsible partnership. This joint development project with Produmaster has opened up a brand new market.
The best solution for the refrigeration segment
Seeking to improve the plastic resin used in packaging applications for frozen chicken, Braskem, in partnership with Plascon and Maxiplast, has developed the best solution for the refrigeration segment, which could be recognized as a benchmark. That's how Braskem arrived at Pluris 6301 - a plastic resin with good processability, sealing and excellent puncture resistance and stretchability. Thanks to these features, the company managed to overcome one of the biggest challenges for plastic packaging, which used to be perforated by the sharp points of frozen chicken. The new packaging has already been launched outside Brazil and has promising prospects in the domestic market.
Plastic reaches the roof
This was the slogan that led Precon, a leading manufacturer in the Brazilian roofing industry, to request Braskem's help in the development of PVC roof tile, from its conception to the purchase of technology and machinery. The project's main goal was to find a solution for the production and marketing of PVC roof tile that would make it the market's preferred choice as an alternative to fiber-cement, ceramics and aluminum, among other materials. The roofing model is competitively priced compared to conventional materials, and its technical performance is compatible with the needs of the Brazilian market. Once this potential was confirmed, the two companies went on to develop the plans for this product, which, shortly after the launch, was already found on the roofs of homes around Brazil.
With PVC roof tiles, Braskem has developed a new application for this plastic resin, expanding its reach in the construction market, and Precon has diversified its range of market service options, introducing PVC roof tile for the first time in this country. Besides the technical differences inherent in the plastic resin, such as resistance to chemicals, light weight and durability, PVC roof tiles are stable in storms, hail and other inclement weather, in addition to having low rates of thermal expansion. Its resistance to variations in temperature, size stability and color are superior to conventional roof tiles. In addition, the product is environmentally friendly, since PVC is fully recyclable.
One more step toward sustainability
With a focus on expanding the sustainability of its business, Tetra Pak, a world leader in food processing and packaging, has once again partnered up with Braskem to develop a grade of green polyethylene to produce plastic lids for beverage cartons. To find the optimal solution and meet the Client's needs, Braskem's Innovation & Technology Center in Triunfo, Rio Grande do Sul, has developed a high density polyethylene (HDPE) that meets all specifications for the application at the global level.
This partnership was essential to placing green polyethylene in the food and beverages industry. The use of green plastic in Tetra Pak's products will help reduce global emissions of greenhouse gases. Here's what makes green plastic sustainable: for every tonne of green polyethylene produced, up to 2.5 tonnes of CO2 are captured and secured from the atmosphere. Another advantage is that green plastic is 100% recyclable using currently existing processes.