The vinyl era
Brief overview: polyvinyl chloride was synthesized from rock salt and petroleum products in the 1838th century in two laboratories. Independently of each other, in 1872, Henri Victor Regno received vinyl, and in 1913, Eugen Baumann. In 1920, the German inventor Friedrich Heinrich August Klatte patented a new plastic, but the commercial use of the material began only in the late 100s, when chemist Waldo Semon used a new synthesis technology and obtained an elastic substance capable of replacing expensive natural rubber. Light, reliable, budget material with a long service life (up to XNUMX years) made a real revolution in the construction market, comparable to the use of concrete.
First of all, polyvinyl chloride began to be used for laying communications. And in 1952, the German designer Heinz Pasche patented the first window system made of polyvinyl chloride on a steel profile — Mipolam-Elastic-Profilsystem. Double-glazed PVC windows have demonstrated new, previously unattainable insulating properties! The first window was installed in the apartment of the inventor's parents in Hamburg and served its functions properly for half a century. It is now in the plastics museum in the city of Trossdorf and still looks great.
The development of PVC window systems 70 years ago was one of the turning points in construction. An important quality of construction products made of PVC is the ability to be recycled and restored. Photo credit: Yener Torun
Today, about 600 million PVC windows are installed in houses in the EU countries, and they are still in great demand. PVC is characterized by another quality, which today, apparently, has migrated to the top of the requirements for construction products: the ability to be recycled and restored multiple times. It is called the perfect circular material or the phoenix material. Among plastics, PVC has the longest history and the most advanced level of mechanical processing.
In 2009, 18 blocks of flats in Manchester were fitted with new windows made from 98% recycled plastic. This marked the entry of fully recycled PVC frames into the global commercial market. According to the results of the experiment, the developer company Northwards Housing stated that window frames made of recycled PVC with a coating of new "skin" added to ensure color uniformity (2%) are neither functionally nor visually different from products made of the original material. In 2023, more than 820 million tons of PVC waste were recycled in the world, and window profiles accounted for half of this volume. These indicators will grow. Research and Markets forecasts that the PVC recycling market will reach $2028 billion by 4,9. And it's not just about the new business ethics of the digital world.
Secondary plastic is a valuable resource for preserving the environment and a sustainable future. The modern PVC recycling market is worth billions of dollars, and the rates of plastic recycling, including window plastic, will only grow. Photo: Christopher Schmid
EU policy: the whip and gingerbread method
People often tend to idealize reality and ignore delayed action issues. For example, against the background of growing demand for electric cars, the problem of disposal of Li-ion batteries has not yet been resolved. Yes, there are some changes, but so far, car battery cemeteries are only growing. The construction market also faces many challenges, in particular in the processes of processing. Plastic has become an integral part of architectural structures, but it is also one of the main environmental problems.
From the point of view of CO₂ emissions, the production of PVC has a minimal impact on the environment compared to the energy-intensive process of glass and metal production. However, the melting of traditional materials is a historically established process, but plastic, due to its cheapness and resistance to oxidation and decomposition, turned out to be a real curse for the ecology of the planet. In just a few decades, from 1950 to 2017, people produced 9,5 billion tons of plastic products. And by 2017, only 8% of this volume was disposed of. Plastic was usually burned, causing toxic emissions into the air. It was buried underground, forming huge cemeteries of plastic waste. But then it turned out that these cemeteries caused the poisoning of the oceans with microplastic particles that were washed away by groundwater.
The United States and rich European countries have solved the problems of overflowing landfills by sending plastic waste to China and third world countries. But in the past few years, one by one, Asian, African and island nations have declared that they are not trash and imposed restrictions on the import of plastic waste.
In the countries of the European Union, environmental standards are becoming more stringent every year, and it is obvious that this course will continue. In February 2024, the European Commission outlined the EU's 2040 climate target to reduce greenhouse gas emissions by 90% by 2040 compared to 1990.
Concern VEKA AG as part of EPPA (the European trade association representing manufacturers of PVC window systems and related products) joins the goals of sustainable development in the field of PVC profiles. VEKA is a pioneer in recycling and a partner of the VinylPlus® and Rewindo initiatives, participates in programs for the introduction of sustainable practices and innovations in the use of PVC at all stages of production. Photo: Christopher Schmid
The European VinylPlus® initiative has brought together more than 200 major manufacturers of PVC products who have made a voluntary commitment to minimize the carbon footprint throughout the material's life cycle and ensure its complete recycling. Since the profiles are non-biodegradable, they will forever take up a lot of space in a landfill. Germany and other EU countries have already banned the removal of such bulky waste to landfills. Recovinyl® was founded in 2003 to promote recycling. It evolved into a certification and audit program aimed at creating an "attractive market" for recycling. If the auditors find violations of the rules, this can lead not only to fines, but also to a ban on construction or production.
In addition to certification according to the famous LEED and BREEAM standards, European real estate investors compete for the prestigious Green Globes and Living Building Challenge certificates, which also increase the value of buildings. Green Globes and Living Building Challenge candidates are required, in particular, to reduce emissions and minimize waste.
The reputation of an environmentally responsible company brings many benefits: subsidies from the government and international funds, capitalization of real estate and other image benefits.
"Requirements for the processing of production waste are increasing every year. Previously, for example, a manufacturer of window systems had to use 10–15% recycled material. But this norm is increasing, and I do not rule out that soon we will be obliged to switch to a completely closed cycle. All enterprises from all industries participate in this transformation, so there will be no exceptions. Ukraine is on the European path, and we will inevitably reach the ratification of all European norms," Dmytro Firsov believes.
Dmytro Firsov, expert of the VEKA Ukraine company
Pioneers in recycling
Previously, PRAGMATIKA.MEDIA already talked about the role of modern windows in the energy efficiency of buildings using the example of VEKA products. The leading German developer and manufacturer of plastic window and door systems, VEKA AG, is also a pioneer in the recycling of plastic windows and a partner of the VinylPlus® and Rewindo initiatives.
"Burning plastic waste is the worst option for the environment. PVC window profiles are too expensive and relatively clean material to neglect its thorough processing, says Dmytro Firsov, representative of the VEKA Ukraine company. — Previously, broken frames were simply taken to landfills for garbage. The cost of removal fell on the end user, the manufacturer did not pay anything. But the management of the VEKA AG concern took a course on waste processing back in 1993."
Every year, VEKA enterprises in Europe and Britain process about 100 tons of window and door plastic profiles and window blinds. Photo: Christopher Schmid
The first processing plant was commissioned back in 1993 in Beringen. The production experiment proved that this initiative is economically profitable and environmentally justified: during the production of regranulate (granules from recycled vinyl), CO₂ emissions are reduced by 90% compared to the synthesis of new PVC. Soon, the concern opened two more factories in Great Britain and France. VEKA enterprises process about 100 tons of window and door plastic profiles, as well as window blinds, per year.
Delivery to the factory and shredding of used plastic windows and doors is only the first stage of processing. At the second stage, metals are extracted from the ground mass with the help of powerful magnets. In the third stage, the PVC particles are separated from the glass and rubber using a series of sieves and scales. Next, PVC is granulated, undergoes quality control and is sent to manufacturers of profile systems.
The processing technology developed by VEKA allows you to obtain PVC granules that can be immediately used in the production of new window and door profiles. VEKA assures that the final degree of cleaning is so perfect that the regranulates are in no way inferior to the primary raw materials for window profiles. This distinguishes VEKA from other companies that process plastic profiles into products of a different quality, such as sewer pipes. VEKA profiles are made of hard PVC (Unplasticized PVC or PVC-U) and do not contain plasticizers and phthalates that are potentially dangerous for the environment.
Processing of PVC has its own problems, for example, the degree of cleaning, separation of colored parts or reinforcement, collection and delivery of raw materials to processing plants. In this regard, VEKA has developed its own techniques, which are constantly being improved. Photo: Christopher Schmidt
Dmytro Firsov: "Functionally, a window made of recycled plastic is no different from a product made from primary raw materials. We can recycle it 10 times. If a window serves 30-40 years, and then is recycled and used again, it is not difficult to calculate that the total estimated service life of the products is up to 400 years. And I'm sure that soon technologists will invent something new to increase the number of cycles even more. The process is constantly being improved. Previously, there were issues with the separation of colored parts of the window, now that VEKA has developed its own technology, such problems no longer exist.
Although new challenges are emerging. Currently, there are profile manufacturing technologies with various materials that replace steel reinforcement. The idea is good, but we immediately have to take into account - will we be able to separate these materials from PVC at the recycling stage? It may be necessary to change something in technology. But we have faced similar challenges more than once, so I am sure that everything will be solved."
VEKA manufacturers treat old, out-of-service windows not as garbage, but as raw materials. Photo: Christopher Schmid
Logistics and VEKA Umwelttechnik
Since VEKA manufacturers treat old, decommissioned windows not as garbage, but as raw materials, the processes of logistics and supply of processing plants were refined in parallel with the improvement of technology. Windows and doors are bulky waste, and its collection and delivery to a landfill or a special site is a problem for consumers and collectors of PVC raw materials.
Today, VEKA partners and end users can contribute to recycling without any additional costs or worries. VEKA Umwelttechnik is a company that offers the service of providing a special container for the collection and removal of old windows. A window manufacturer or installation company simply orders a container, based on the volume of waste, and when everything is filled, it is taken directly to the factory.
The collection and delivery of bulky waste to the site of the processing plant is a problem for consumers and collectors of PVC raw materials. The VEKA Umwelttechnik service in Europe offers containers for collecting old windows and taking them to factories. Photo: Christopher Schmidt
Today, VEKA UT cooperates with more than 2300 specialized companies that manufacture or install PVC windows and doors.
"For example, the company received an order for the reconstruction of a residential building, as well as the manufacture and installation of new windows. They brought the order to the facility, installed new windows, doors or showcases, and packed the old ones into a VEKA UT container, which then went to the recycling plant. A similar container is installed somewhere on the territory of the factory, there is a shortage or leftovers from production. This is an established system that is used by almost everyone, and each participant receives his bonuses," explains Dmytro Firsov.
According to the laws of the EU countries, any company is obliged to contribute to the reduction of CO₂ emissions: materials should be reused, disposed of for energy or recycled. Attention has been increased to the construction sector, because construction is still one of the most ecologically dirty processes. As proof that waste has been properly disposed of or sent for recycling, companies must provide appropriate evidence. For example, acts of acceptance and transfer of garbage. VEKA Umwelttechnik customers receive a complete package of supporting documents for each shipment.
In Ukraine, the problem of disposal of construction debris, which was formed as a result of destruction and hostilities, is discussed at various levels and should be defined by law. It is simply necessary to organize a full-fledged processing of the remains of windows and polyvinyl chloride. Photo courtesy of VEKA Ukraine
The Ukrainian perspective
In Ukraine, the problem of waste disposal, which was formed as a result of hostilities, is discussed at different levels. What to do with the debris of destroyed buildings? Some of the materials could be reused, including the remains of plastic windows. But for now, unfortunately, the VEKA Umwelttechnik service is not available on the territory of Ukraine.
Dmytro Firsov: "So far we do not have a clear legislative course on this issue, but of course everyone is thinking about what to do with the processing of construction material that appears as a result of destruction. In the total volume, windows occupy a smaller share, but still there are a lot of them. Now they are all taken to landfills. Glass and metal are taken away immediately, but PVC is not needed by anyone yet or is used in a completely different direction than it is needed."
The processing technology developed by VEKA makes it possible to obtain PVC regranulate, which is not inferior in quality to the primary raw material. It can be used immediately in the production of new window and door profiles. Photo: Christopher Schmid
VEKA Ukraine is a member of the Active House Alliance and has undertaken to strive for the creation of a circular economy.
According to Dmytro Firsov, the company's management is calculating options for the organization of full processing of polyvinyl chloride in Ukraine, assessing risks and opportunities.
"Today, PVC processing is possible in Ukraine, but this is what is called coarse processing, when the granules are used for the production of window sills or other profiles. However, the cost of clean material in old windows is still high, and it is advisable to use it effectively. This is not so much a matter of economy as of ecology. For this, we have two ways: to establish a logistics chain from sending raw materials to the nearest factory in Germany, or to build a similar factory in Ukraine.
The average service life of a PVC window is 30-40 years. It can be recycled up to 10 times. Each participant — the producer, the consumer, and the state — receives their benefits from an established recycling system. Photo: Christopher Schmidt
Even before the large-scale invasion of the Russian Federation, we collected waste and later planned to set up a system like VEKA Umwelttechnik. But the economic crisis and logistical problems affected these plans.
If we take the raw materials to Germany, we have to prepare them — not to take the windows whole, but to sort and grind them in advance. Do a rework. And only then send. But new problems arise here, since an environmental permit is required for the import of waste — and formally it is not raw materials, but waste — to EU countries. Agreement is needed in the ministries of ecology of Ukraine and Germany, Poland's consent to transit. And, of course, the delivery of goods over such a distance — more than 1000 kilometers — is a significant transportation cost.
For truly ecological recycling of PVC, logistics chains and a correct map of the location of specialized processing enterprises are important. The management of VEKA Ukraine is calculating the options for the organization of full PVC processing in Ukraine. Photo: Christopher Schmid
In my opinion, the idea of building a specialized PVC processing plant is a more justified way. However, without assistance from the government, without investments, we cannot implement it. I have no doubt that the construction of the factory and closing of the production cycle is a question of the future. The only problem is whether it is in the near future or in the distant future," concluded Dmytro Firsov.
At the end of May, the VinylPlus 2024 sustainable development forum will be held in Cologne, where representatives of European companies — manufacturers of polyvinyl chloride products — will gather. The activity of world markets and the growing demand for window systems made of recycled material leave no doubt that PVC recycling is one of the priority and promising directions.
