Recycling process for galvanized plastics

A new recycling process for galvanized plastics makes it possible to reprocess chrome-plated components in such a way that the decoated ABS plastic can be reused. A sanitary ware manufacturer brings this world first to the point where it is ready for use.

The Hansgrohe Group is using an individually developed recycling process for galvanized plastics at its production site in Offenburg/Elgersweier. The facility, which was developed in cooperation with plant manufacturer ImpulsTec GmbH, allows the production waste from chrome-plated components to be processed in such a way that the decoated ABS plastic is available for the production of new parts directly on site in the Hansgrohe plastic injection molding plant. "With this technical world first, we are closing the material cycle at the site," says Frank Semling, Deputy Chairman of the Executive Board and Chief Operations Officer of Hansgrohe SE. "Every resource that no longer needs to be extracted but can be recycled protects our ecosystems. With this innovative process, we are taking a further step on our path to green transformation."

On June 14, 2024, Frank Semling and Stefan Eisert, Managing Director of ImpulsTec GmbH, ceremoniously opened the new plastic recycling plant in the presence of media representatives, project participants and employees of the plastic injection molding plant. In his welcoming speech, the Deputy Chairman of the Executive Board emphasized the excellent cooperation between the ImpulsTec and Hansgrohe project teams: "Successful individual solutions can only be created through excellent teamwork. ImpulsTec's openness to the joint development of the process and the professional exchange between those involved made possible what was previously extremely difficult to implement both technically and economically: the recycling of chrome-plated plastics. On behalf of my colleagues on the Executive Board, I would like to thank everyone involved in the project for their outstanding achievements."

The innovative system uses electro-hydraulic shredding technology. All chrome-plated ABS scrap components, such as hand shower housings, wall rosettes or knobs and buttons, are decoated using shock wave treatment in conjunction with pre-shredding and magnetic separation. David Zapf, Surface Technology Specialist and head of the project at Hansgrohe, explains: "The result is a highly concentrated metal fraction containing mainly copper and nickel. This is then sold for smelting. This means that 100 percent of the valuable metals are returned to the raw material cycle. On the other hand, we receive the decoated ABS plastic, which we use to manufacture new parts. Here, we use the material directly on site in our plastic injection molding plant and can thus close the material cycle at the site." The processing plant was designed for an annual throughput of 100 tons of chrome-plated plastic. In purely mathematical terms, this amount of recycled ABS can be used to produce one million new hand showers. It is planned to operate for eight hours a day on around 250 working days a year.

The products from the Schiltach-based manufacturer of premium and designer products for bathrooms and kitchens are manufactured to the highest quality standards. The particularly stable bond between plastic and metal characterizes the durable products. "This is precisely why recycling became a challenge," explains David Zapf. "Thanks to the new system with its innovative shock wave treatment, we are now able to reuse around 98% of the raw materials." The chrome-plated components that were produced as rejects during the production process were also previously processed by external partners. Before the project began in 2019, the focus was on thermal recycling to recover the metal.

Becoming part of the circular economy is one of Hansgrohe's key areas of action in its sustainability strategy. "It is an urgent concern for us to focus our production on sustainability. By using or recycling products and materials for a long time, we reduce both our use of resources and transportation routes. Our new processing plant therefore offers not only ecological but also economic benefits for Hansgrohe," says Frank Semling. The hansgrohe Planet Edition product line launched in 2023 already uses recycled material: the handle of the Pulsify Planet Edition hand shower is made from recycled plastic. This alternative to petroleum-based primary plastics significantly reduces the consumption of resources and energy. (OM-6/24)