The CytroConnect Solutions service offering from Bosch Rexroth helps recycling companies avoid high downtime costs or even contractual penalties. The customized packages of real-time monitoring, data-based analyses, and complementary spare parts management maintain the availability of hydraulic equipment such as scrap shears, shredders, and presses. At the same time, the intelligent combination of cutting-edge IoT technology and hydraulics expertise minimizes maintenance and extends machine life.
The reuse of raw materials is a permanent fixture in the economy. As part of the supply chain, however, it also leads to high deadline pressure and, not least, requires seamless availability of shredders, scrap shears and presses.
If hydraulically driven recycling machines such as shredders, scrap shears or presses fail, there is a threat of contractual penalties. If trucks, trains or ships have to wait for the load, the consequential costs quickly climb into five to six figures. Acute shortages of skilled workers and the simultaneous supervision of distributed sites cause unnecessary delays in maintenance. In addition, recycling companies lose service life, material and budget if they replace hydraulic parts on a fixed cycle as a precaution. Bosch Rexroth counteracts all these economic disadvantages and financial risks with the three service packages CytroConnect Monitor, Maintain and Predict.
Flat rate against failures at a fixed monthly price
Plant operators achieve the highest possible availability and service life of components with CytroConnect Predict. Using predictive analyses and detailed status reports, the experts make maintenance recommendations at such an early stage that the affected components can be replaced in a planned manner. This reduces the user’s previous maintenance effort by up to 50 percent. Complementary services such as complete spare parts management with guaranteed delivery within 24 hours further optimize availability. The service fees usually pay for themselves within a year, but depending on the application, they can also be recouped with a single avoided downtime, as the following real-life example shows:
Through predictive analytics and predictive maintenance of scrap shears, an international company with over 100 distributed yards can avoid high downtime costs. Previous downtime costs per case were around 600 euros, plus penalties of up to 100,000 euros per day if shiploads of steel bales did not leave for overseas on time. Wear on the shear is detected at an early stage on the basis of the pressure peaks and torques on the electric motors, so that the operator can replace the tool in a planned manner in the future. The far-flung maintenance staff is sustainably relieved and now needs less time for troubleshooting, maintenance, planning and spare parts procurement. In addition, monitoring saves electricity costs because the system avoids operation with increased energy consumption.
In another use case, a recycling company avoids unplanned shutdowns and subsequent costs through predictive analysis of waste shredders. The shredded waste has since been delivered on time again as fuel to a cement plant. Previously, frequent failures of hydraulic pumps and electric motors resulted in regular penalties and additional costs for temporary storage of the delivered waste. The maintenance department, which was suffering from a shortage of skilled workers, was relieved of this burden in the long term.
In addition to the all-inclusive CytroConnect Predict service, Bosch Rexroth also offers the basic CytroConnect Monitor package, which provides pure real-time monitoring with access to historical data from the last 24 hours. As an introduction to the topic of rule- and data-based analyses, Bosch Rexroth recommends the CytroConnect Maintain package. The service package monitors the condition of components in the background using predefined rules, warns of damage via push messages, and supports the continuous optimization of applications with regular performance and usage reports.
All three service packages already include the respective required dashboards and sensors. Recycling companies benefit quickly and easily from intelligent and sustainable failure protection.
Recycling technology to increase value of recycled aseptic cartons in Brazil
SIG today announces a BRL 10 million investment in innovative recycling technology that will enable polymers and aluminium from used aseptic carton packs to be recovered and sold separately for the first time on an industrial scale in Brazil. By expanding the range of applications for recycled materials from used aseptic cartons, SIG expects to increase their value by more than 50 percent.
“We are excited to bring to Brazil a new technology that will enable separation of aluminium and polyethylene layers from carton packs, thereby expanding the market for these materials and generating more value from the separated waste,” says Ricardo Rodriguez, President and General Manager for SIG Americas. “This project is the latest in a series of innovative collaborations led by SIG to boost collection and recycling rates for used aseptic cartons and grow the recycling chain in a sustainable way.”
Innovative recycling technology
The renewable paper board that makes up around 75 percent of aseptic carton packs on average can be separated for recycling in paper mills through Brazil’s existing recycling infrastructure. The polyethylene and aluminium mix (polyaluminium or PolyAl) left over from this process can be recycled into a robust material for purposes such as roofing, pallets and furniture.
SIG’s recycling plant will use innovative technology that makes it possible to separate the polyethylene from the aluminium in PolyAl to create a wider market and demand for these recycled materials. Developed over five years with project partner ECS Consulting, the new technology has already undergone a pilot project that proved the effectiveness of the chemical recycling process.
The new recycling plant is currently in construction in the state of Paraná. It is expected to begin operating in 2024 with an initial production capacity of 200 tonnes per month. Together with industry partners, SIG has also invested in a plant in Germany to separate polymers and aluminium from PolyAl that went into production in 2021.
Ethical collection programmes
Investing in new technology to create a wider market for recycled materials is an important step in increasing recycling rates for used aseptic cartons. SIG has already led the way with innovative programmes to support two other important steps: collection of used packaging from consumers and separation of that packaging to go into the right recycling streams.
SIG’s so+ma vantagens programme, run in partnership with NGO so+ma since 2018, enables people in underprivileged communities to collect loyalty points for bringing in waste for recycling. The points can then be exchanged for rewards, such as essential food products and skills training. SIG is now expanding this model to promote recycling and bring additional societal benefits to further municipalities in Brazil and beyond.
SIG also promotes public policies for selective waste collection in Brazil, and supports effective infrastructure and decent working conditions for waste collectors’ cooperatives as a seed investor in the Recicleiros Cidades programme. Set up with NGO Recicleiros in 2018, the programme is now operational in 13 municipalities and aims to reach 60 by 2027.
The focus on recycling in Brazil is part of SIG’s global Way Beyond Good commitment to enhance the positive environmental and social impact of its packs throughout their lifecycle.
“At SIG, we are committed to sourcing the materials that go into our packs sustainably. We are already the first aseptic carton producer to source 100 percent FSCTM-certified board and use ASI-certified aluminium,” says Isabela De Marchi, Sustainability Manager for SIG South America. “We are also determined to foster an ethical recycling chain that promotes collection and recycling of our packs after use in a way that supports communities, workers and the environment. The new recycling plant in Paraná takes us a step further on this journey by maximising the retained economic and environmental value of the materials recovered from aseptic cartons.”
Use of renewable energy
The construction of a vast solar installation at SIG’s production site in Linnich, Germany, will see SIG further extend its lead in the beverage carton industry in the use of renewable energy. The 10.25MWp system, made up of 22,300 photovoltaic solar panels, will be the largest photovoltaic system at an SIG plant to date.
“The thousands of solar panels we are installing in Linnich will double our on-site renewable energy capacity in Germany,” said Arnold Schuhwerk, Head of Category Polymers & Energy Global at SIG. “This latest investment shows that SIG is not only committed to continue making its beverage cartons with 100 percent renewable energy, but to continually improve the quality of that renewable energy through physical power purchase agreements.”
Maximising on-site capacity
SIG is already the first and only aseptic carton manufacturer to produce all its packs with 100 percent renewable energy globally since 2018.
The company recently secured physical power purchase agreements that will provide enough renewable energy capacity to power 100 percent of its carton packaging production in Germany from January 2023 – and the Linnich installation will enable more of this to come from its own sites.
Construction has begun on a gigantic ground-standing system of 20,600 panels that will occupy an 80,000 squarer meters area in front of the Linnich plant – that’s the equivalent of 11 soccer fields side by side. A further 1,700 panels will cover the plant’s rooftop to maximise potential to solar power on the site.
As the owner and operator of the Linnich photovoltaic system, Leipziger Stadtwerke will pass on the solar power generated directly to SIG through a long-term power purchase agreement. The power will go straight into the production of SIG carton packs at the site.
“Leipziger Stadtwerke is driving forward the expansion of renewable energies, including working with partners like SIG. The solar installation at the SIG plant in Linnich is another milestone towards the decarbonising of energy systems in Germany,” says Maik Piehler, Managing Director of Leipziger Stadtwerke. “We are pleased to be able to make an important contribution to this. The project is one of the largest photovoltaic self-supply systems with direct connection in Germany that is operated without using the public grid and without any subsidies on industrial land.”
Going Way Beyond Good for climate
SIG already doubled its on-site solar capacity in 2021 to 11.3MWp and plans to triple this again within the next year. The Linnich system will play a big part in this expansion, together with installations in development at other SIG plants in Germany, Saudi Arabia and Mexico.
The company’s focus on renewable energy is part of SIG’s Way Beyond Good Climate+ ambition that is driving down value chain carbon emissions for its business and its customers.
Use of renewable energy for carton packaging production has already avoided over half a million tonnes of CO2-equivalent and these savings will continue to grow. The new Linnich installation alone will generate enough renewable electricity to reduce more than 3,150 tonnes of carbon emissions a year.
Commitment to sustainability
EcoVadis, the world’s largest provider of corporate sustainability ratings, has presented Bilfinger SE with a Gold Award for sustainable, ethical and responsible business practices. The Group is thus among the top 5 percent of companies from the more than 100,000 throughout the world that EcoVadis analyzed.
“We are truly proud to receive this award. The results clearly show that the sustainability principle is firmly established in our Group structure and that it is actively embraced by our employees. At the same time, we see the award as an incentive for our future performance”, says Bilfinger Group CEO Thomas Schulz. “The impartial recognition from EcoVadis also serves as confirmation for our process industry customers that with Bilfinger they have a responsible and trustworthy partner at their side ready to help them successfully implement their own sustainability goals.”
The EcoVadis evaluation is based on a comprehensive catalog of questions in which the results of the criteria surveyed are grouped into the four topic areas including environment, labor & human rights, ethics and sustainable procurement. In the most recent survey, Bilfinger improved in both the environment category (from 70 to 80 points), in the labor & human rights category (from 60 to 70 points) and in the sustainable procurement category (from 40 to 50 points). In the ethics category, the same figure as in the previous year (60 points) was achieved. Overall, Bilfinger achieved a score of 68 from a possible 100 points in the annual survey conducted by EcoVadis. The industrial services provider thus surpassed its results from the previous year’s survey by eight points.
Bilfinger has been reporting on its sustainability activities on an annual basis since 2011 and has published an externally-audited non-financial report every year since 2018. In accordance with the Greenhouse Gas Protocol and as part of its current Annual Report, the Group has also formulated specific targets for its own carbon footprint in the form of a so-called “Sustainability Commitment”. This commitment calls for CO2 equivalents under Scope 1 and 2 to be successively reduced from around 60,000 metric tons in 2021 to ‘net zero’ by the end of 2030 at the latest.
Bilfinger is also increasingly providing its customers with valuable support to help them achieve their own sustainability goals. The Group’s customers face the challenge of securing their energy supply for the future and significantly reducing their carbon footprint. As a key component of the company’s growth strategy, Bilfinger targets an increase in revenues from energy transition and carbon reduction projects from approximately €500 million in 2021 to around €1 billion by 2024.