Kinnarps reported a total CO2 emission reduction of 86% for the base frame of a desk pedestal after implementing two material changes developed with Polykemi and the injection moulder Nolato. The project examined the effect of switching from an original PA6 to high-crystalline PP, both virgin grades, and then to a recycled PP formulation supplied by Polykemi. According to the company, the first switch delivered the largest impact on the component’s footprint, and the second change further decreased emissions while maintaining production performance.
Polykemi describes the initial outcome as a strong example of the leverage available through polymer selection. "By choosing a high-crystalline PP instead of a PA6, both based on virgin materials, they were able to reduce their emissions by 74 percent. It’s a great example of how major improvements can be achieved even without using recycled plastics," said Area Sales Manager, Johan Sonesson. After validating the first step without changing the process or compromising quality, the team moved to a recycled alternative. "In the second step, they switched to our REPRO PP, which is based on recycled plastic, and reduced emissions by an additional 45 percent, resulting in a total emission reduction of 86% compared to the original material," added Sonesson.
Beyond the carbon footprint, the material transitions influenced cost and mass efficiency. PP offers lower raw material cost and lower density compared to PA6, which can increase output per kilogram of feedstock and reduce transport-related emissions per part. The companies state that these gains were achieved within the existing production setup.
Cost and processing implications
The switch from PA6 to PP combined environmental and economic effects. Polykemi highlights that PP’s lower density enables more components from the same amount of supplied material, while the reduced weight supports lower transport emissions per component. "For Kinnarps and Nolato, choosing PP also has the benefit of producing more plastic components from the same amount of supplied material, due to the lower density. In addition, the lower weight also reduces transport emissions per part," said Sonesson.
Material selection was approached as a balance between performance, functionality and environmental impact. Polykemi underlines the importance of defining requirements before substitution. "As a material supplier, our role in these material transitions is to determine what requirements the material must meet in both production and the final product, in order to identify alternatives that result in lower emissions," said Sonesson.
Collaboration and technical support
Polykemi reports close coordination with Kinnarps and Nolato throughout the project, including direct engagement with sales and technical specialists, on-site support during implementation, and adjustments to fine-tune the material where needed. "Throughout the process, Nolato and Kinnarps have been in direct contact with both sales and technical experts from us at Polykemi. We’ve been on-site in production during implementation, listening to the customer, providing training, and fine-tuning the material when needed. It’s rewarding to see our customers experience these kinds of positive effects, and it strengthens us as a supplier to see that this is possible," said Sonesson.
