Envalior, as one of the world's first manufacturers of thermoplastic composites, has conducted a life cycle assessment, LCA, for a widely used lightweight composite from its Tepex family. The study concerns Tepex dynalite 104-RG600(x)/47% and was subjected to a critical review by the international testing and certification company TÜV SÜD. According to the company, the analysis provides composite processors and their customers with transparent and consistent information on the environmental aspects related to this material. Envalior states that this scope of data is intended to address growing demand from OEMs, particularly in the automotive and electrical and electronics industries, for more comprehensive product life cycle analyses to optimize sustainability.
Dr Lisa Tölle, Project Manager of Material Development at Envalior, said: "With this TÜV SÜD critical review, we go one step further than most of our competitors. We are responding to the trend among OEMs in the automotive and electrical and electronics industries to determine complete life cycle analyses for their products in order to optimize their sustainability. This requires that they receive the necessary input from their raw material manufacturers." In addition to the LCA study itself, the company has also developed a version of Tepex dynalite 104-RG600(x)/47% based exclusively on sustainable raw materials which, according to the information provided, reduces the carbon footprint by approximately 50%.
Cradle-to-gate assessment scope
Tepex dynalite 104-RG600(x)/47% is a composite with a polypropylene matrix, reinforced with continuous glass fiber rovings. The material is used primarily in lightweight automotive structures, for example in vehicle underbodies and safety-related structural components such as front-end carriers and seat pans. The results of the LCA, based on ISO 14040/44 standards, show the environmental impact of one kilogram of semi-finished composite sheet that has not yet been customized for a specific application.
The assessment was carried out in a cradle-to-gate model, from raw material sourcing to the point at which the composite leaves the Envalior factory gate. Environmental impacts arising at this stage were taken into account, including effects on soil, water, climate, resources, and human health. According to the company, the critical review conducted by TÜV SÜD confirms that the LCA study for the Tepex composite was carried out consistently in accordance with ISO standards, uses appropriate and reliable data, and provides a transparent interpretation of the results.
Variant based on sustainable raw materials
The new Tepex variant, made from 100% sustainable raw materials, contains 70% continuous glass fibers produced from glass waste. The remaining 30% of the material is derived from attributed bio-circular polypropylene. The sustainable origin of all raw materials has been verified using a certified mass-balance approach, in accordance with the ISCC Plus standard.
Envalior emphasizes that the composite is completely identical to its counterpart based solely on fossil raw materials. It has the same chemical, physical, and processing properties and the same quality, and therefore meets the same technical specifications and certification requirements without the need for requalification. As Lisa Tölle explains: "Our customers can therefore use it directly as a drop-in solution and replace the fossil-based counterpart in the ongoing production process. The substitution does not require much effort because the existing processing machines can be used under the same process parameters."
Information on Envalior materials is available in the MaterialAdvisor tool, which provides digital tools and services supporting the search, selection, and evaluation of materials.
