Alve-One® improves the sustainability of plastics
In applications such as construction, footwear, automobiles, and packaging, foam plastics are everywhere. Azodicarbonamide (ADCA) is the benchmark material for the production of foamed thermoplastics in the chemical blowing agent market. However, in recent years, the European Chemical Registration, Evaluation, Authorization and Restriction (REACH) regulations listed ADCA as a "substance of high concern". Fortunately, Solvay has developed Alve-One®, a sustainable foaming alternative, based entirely on inorganic formulations. It is a 100% safe, high-performance and cost-effective alternative to ADCA in plastic foam applications. Therefore, it was recently awarded the Inovyn Solar Impulse High-Efficiency Solution Label and the Silver Award in the Innovation category, demonstrating its appeal in the PVC industry .
Alve-One® is a chemical product based on sodium bicarbonate that can be traced directly back to Solvay's creation in 1863, when Ernest and Alfred Solvay invented a new method of producing this inorganic compound. Sodium bicarbonate can be used in a variety of foods, including baking soda, animal feed, pharmaceutical applications, flue gas treatment, and many other industrial and household applications. When used as baking soda in food, it releases gas and makes cakes fluffy. This is the same principle used by the Solvay team to manufacture Alve-One® for the plastics industry.
Agile foaming agent development process
One of the challenges to be overcome for plastic foaming is its processing temperature, which will vary depending on the foamed plastic resin (PVC, PP, PE, XLPO, EPDM, EVA, etc.) and the process used (extrusion, calendering, injection molding, etc.) ) And change. Therefore, the Alve-One® team must develop a series of chemical blowing agents to adapt to such processing conditions and achieve foaming performance similar to ADCA. The final solution will have a positive impact on the factories that produce plastic foam, thereby reducing the risk of workers being exposed to potentially unsafe chemicals and benefiting the end users of this plastic foam.
It usually takes five to ten years for a new solution to enter the market, but the project was launched in 2017 and was launched in just two years. “We have adopted agile project development methods from the beginning of product development and worked closely with our customers,” said Pedro Pinto, Global Marketing Manager of Plastic Foam Solutions. “The first customer verification was carried out at the end of 2019. In the transitional phase of actual business, some initial customers have already begun to use it."
Solvay's Alve-One® foaming solution can be tailored to the needs of thermoplastic and elastomer foam producers. The automotive industry is paying great attention to this more sustainable alternative to ADCA because it enables them to reduce body weight without compromising passenger comfort, reducing carbon dioxide emissions, odors, or harmful emissions (VOC ).
Award-winning customer solutions
The Alve-One® team takes pride in its close relationship with customers and strives to better understand customer needs (product and market aspects), production processes and parameters. They engage customers in the development of tailor-made solutions from the beginning, instead of putting standardized products on the market, in order to minimize the impact of customers in product changes and get the most benefits from them. This is one of the reasons why Alve-One® is recognized as an efficient solution for Solar Impulse and the winner of the Inovyn Awards 2019.
"I hope that as more and more people and companies seek alternatives to hazardous chemicals, the market will increasingly eager to switch to safer and sustainable solutions like ours," Pedro said, "can bring Sustainable solutions that have a positive impact are good for people, the environment, and companies."