Top 15 Plastic Innovations Of 2024
As the plastics industry continues to evolve, 2024 brings a wave of groundbreaking innovations that are reshaping the sector - focusing on sustainability, efficiency, and performance. From products that fire-proof buildings, get menstrual products to women in poverty, and even a revolutionary new approach to body armour, these developments are tackling challenges and saving lives in more ways than ever before.
Back by popular demand, here is the BPF's 2024 list of innovations that are changing society for the better:
- Baysgarth School: Recycled Plastics Race Track
- Loughborough University: Polmer Sintered Body Armour
- Fairgrieves: Firewall Bracket
- Glasgow School of Art: SafiCase
- Notpla & Plastek's: Seaweed Fork
- Berry: Aquafigure Bottle
- Spectra Packaging: Prevented Ocean Plastics Commitment
- Chase Plastics, Summit Systems & Ocean Integrity: Recycling Ocean Plastics
- MBA Polymers: Car Bumper Recycling Scheme
- Coveris: MonoFlexP Sausage Packaging
- Zotefoams: Sustainable Beverage Carton
- Tosca Services: The Egg RPC
- The University of Edinburgh: Plastic Waste Trash to High Value Treasure
- UAL - Central Saint Martins: Wrapatouille
- Jaguar Land Rover: Composite Cross Car Beam
1. The Baysgarth School Race Track
Ever fancied yourself to have been an amazing professional driver, if only your potential was nurtured? Well a school in North Lincolnshire is ensuring none of their students can say that again. Baysgarth School decided not to stop at a gym or extra sports field, and are building a race track for students to research, test, and develop electric cars!
They plan for the track to be made entirely from recycled plastic tarmac, with electric cars also made from recycled plastic - all of which is to be sourced from the town and beach cleans, sorted and shredded at the school, and then formed into the new useable material.
“This is a tremendous opportunity for our young people, enabling them to gain hands-on, cutting-edge experience in STEM subjects and bringing design and technology to life in the most engaging way,” said North Lincolnshire Council leader Cllr Rob Waltham.
Sounds like Lincolnshire might be the home of the next Lewis Hamilton… learn more.
2. Body Armour That Actually Fits
Loughborough University’s ‘Next-Generation Additive Manufactured Police Body Armour’ is set to revolutionise body-worn protective systems for frontline policing.
Andrew Johnson and his team at Loughborough University recognised that body armour development for frontline policing had stagnated, especially regarding knife and spike threats. They also noted that recent developments are typically with limited-to-no consideration of female users or individuals that have body shapes incompatible with traditional sizing - which leads to officers wearing body armour that is uncomfortable and less effective.
That’s exactly why the team developed and successfully demonstrated both polymer laser sintered and hybrid aramid-laser sintered body armour panels, capable of providing multi-strike protection against knife, spike, and handgun ballistic threats – in line with the UK Home Office’s Body Armour Standard. Their amazing innovation allows for the design and manufacture of bespoke protective panels capable of providing improved comfort, wearability, and overall protection to often neglected user populations, in particular female police officers.
Winner of this year's BPF Horners Award for Design and Innovaton... learn more.
3. A Firewall Bracket To Improve Fire Safety in Construction
Following the devastating loss of life in Grenfell Tower fire in 2017, improving fire safety in new developments has become a major focus for the construction industry - so Fairgrieves was tasked to develop a new firewall bracket to help improve fire safety within new developments.
These brackets are used in the assembly of firewalls as a fire-resistant barrier designed to prevent the spread of fire between different parts of a building. The brackets help contain heat and slowdown the spread of fire outbreaks - the longer their structural integrity is held, preventing building collapse, the slower the spread of fire and smoke, and more crucial time to evacuate safely.
Fairgrieves developed and brought to market a new Matrix Firewall Bracket Base capable of withstanding intense heat, fire, and smoke for up to two hours. When it went through a testing process it was found to achieve about an eight-fold improvement in performance of the firewalls for the customer.
It has ensured firewalls used by CA Group now have a much better resistance to heat and fire overall, with the product now being used in its thousands on new developments across the UK.
A product helping to make buildings safer, and ultimately saving lives by ensuring occupants are afforded more escape time… now that’s an innovation for the books.
4. Getting Reusable Sanitary Products To Women In Need
Invented by a student at the Glasgow School of Art, Isabel Payne acknowledged the need for reusable sanitary products that can be safely maintained without electricity or running water.
Payne discovered that a singular menstrual cup replaces 10 years’ worth of single-use sanitary products, and with around 500 million women relying on sanitary products being distributed monthly by charities, the menstrual cup should be an incredible alternative. However, research shows menstrual cups cannot be distributed due to the difficulties cleaning them without a large amount of clean water and a mains electrical connection – which is of course a big barrier in developing countries or areas of conflict.
That’s why Payne developed ‘Saficase’ - an all-in-one solution for both cleaning and sterilising a menstrual cup with minimal water. Made using medical grade silicone, HDPE, and PP (to create a safe sterilising environment and ensure longevity) the product uses a steam sterilising circuit powered by a modular solar battery base which only needs 15ml water and is charged with 24 hours of sunlight per month. The body of the case can also be used to mechanically ‘shake clean’ a cup with 45 ml water for convenient discrete cleaning.
An incredible innovation that has potential to bring safety and comfort to women around the globe who may need it most.
Winner of the 2024 David Williams Award... learn more.
5. A Fish & Chip Fork From The Sea
The Notpla Chip Fork was developed by Notpla and Plastek UK to meet the need for a single-use rigid utensil that could fall outside the ban on single-use plastics by successfully injection moulding Notpla’s remarkable seaweed-based natural polymer.
The use of seaweed is truly ground-breaking. Seaweed is a fast-growing natural polymer that is completely biodegradable, composting similarly to fruit peels. It grows rapidly, doesn't require arable land, fresh water or fertilisers, and has a minimal environmental footprint.
Wooden utensils often involve a resource-intensive journey from European forests to manufacturing in China and back to Europe for use. Whereas this production cycle is contained within the UK and Europe, significantly reducing overall carbon emissions, supporting local economies, and enhancing supply chain sustainability.
The intended end-of-life for Notpla Rigid cutlery is home compost, industrial compost or food waste, as it uses natural ingredients which will return to nature without leaving a trace.
Fish, chips, and a seaweed fork, anyone?
6. One Bottle – Unlimited Designs
An exciting concept in reusable water bottles, Aquafigure is a ‘bottle for life’ whose interchangeable designs can be swapped to suit changing consumer trends.
At the centre is a patented PET tag, inserted into the bottle to provide eye catching 3D artwork. Thanks to a series of licensing agreements, consumers can already choose from over 50 different designs, from elite football clubs to The Smurfs.
Key to Aquafigure’s success is the reusable bottle that keeps the image tag in place, while also ensuring it is easy for children to remove with minimal force. Whereas usually external dimensions are key, here it was the internal measurements that had to be precise to hold the insert in place regardless of angle. Development focused on fine-tuning wall thicknesses to provide a home for the insert.
The 330 ml bottle is made from BPA-free Tritan, a food approved co-polyester that is certified dishwasher proof for regular re-use. The cap is designed and produced by Berry. With sustainability vital, this has been created without the need for any wadding, enabling it to be manufactured from monomaterial PP.
Launched to great acclaim in Norway in 2023, Aquafigure has expanded into Spain, Germany, France, the UK, and Italy with further expansion already being planned.
7. Spectra Packaging’s Ocean-Plastic Commitment
A proactive solution to ocean plastic waste… Spectra Packaging has proudly transitioned to Prevented Ocean Plastics (POP) in all production lines (HDPE, PET and PP) - a turning point towards environmental stewardship.
POP is recycled plastic collected from coastal areas at risk from ocean plastic pollution. According to academia, this ocean-bound plastic is at risk of ending up in the ocean if not collected for recycling.
The initaitve:
- aligns plastic recycling standards across coastlines at risk from ocean plastic pollution
- offers an ongoing supply of high-quality recycled plastic at industry scale
- supports local communities at the forefront of ocean plastic waste in at-risk areas, including Southeast Asia, South America, the Galapagos Islands, the Mediterranean, and Central America.
Through the initiative, Spectra has helped divert over 50 million plastic bottles from entering oceans at the forefront of ocean plastic pollution, safeguarding wildlife and ecosystems while empowering coastal communities. 👏
8. Recycling Ocean Plastics – A Three-Way Partnership For The Books
The best trio since the Bee Gees…Chase Plastics has partnered with Summit Systems and Ocean Integrity (a global enterprise dedicated to recovering ocean plastics) to recycle ocean-recovered LDPE!
Step 1 was developing a feasible process for recovering ocean plastics and ensuring 100% of recovered plastics are recycled and do not end up in landfill or incineration. So, Ocean Integrity worked with Summit Systems on getting Micro Plastic Elimination Devices (MPEDs) - that retrieve microplastics down to 65 microns – into areas that need them.
Step 2 was ensuring the MPED’s were used. The initiative therefore pays indigenous fishermen in many regions of the world 3-4x the local minimum wage to collect plastics using MPEDs. Verified by independent auditors, details of all plastic collections are then securely logged onto Ocean Integrity’s app to ensure transparency and accountability.
Step 3 comes down to recycling the recovered plastic, which is when Ocean Integrity and Summit Systems secured the support and recycling expertise of Chase Plastics Ltd - who believe initiatives like this demonstrate sustainability in action.
The result? Aside from the environmental benefits, the scheme benefits indigenous communities (through deploying traditional fishing skills to help stimulate local economies) and reduces the use and transportation of virgin polymers. By recycling ocean waste, they are helping to clean the oceans and improve the marine environment…
Mother Nature called, and she’s optimistic! 🌍
9. Car Bumper Recycling Scheme
In May 2024, MBA Polymers UK launched an innovative recycling initiative to efficiently recycle car bumpers which are damaged (or due to be processed by end-of-life vehicle (ELV) recyclers) into high quality polymers for use in the automotive industry - a move which significantly advances MBA’s plans to create a fully circular economy for car bumpers in the UK.
Recycling bumpers directly (rather than reclaiming the polymers following ELV recyclers shredding processes) will enable the exploration and production of improved performance grades to complement the Automotive sector. The idea will:
- Slash the amount of plastic that ends up in landfill
- Reduce the carbon emissions required to produce its materials
- Assist car makers in meeting strict new recycling targets
- Advance the automotive industry towards a standardised circular economy
Recycling bumpers directly - rather than reclaiming the polymers following ELV recyclers shredding processes - will enable MBA Polymers UK to explore the production of improved performance grades to complement its existing offering to the Automotive sector.
10. Sustainable Sausages
With sustainability at the forefront of Coveris’ innovation, the packaging manufacturer has recently supported Lidl in transforming its fresh sausage packaging.
Moving away from a non-recyclable paper/ PET/ PE triple laminate, Lidl’s sausages are now packed in MonoFlexP, Coveris mono-material, two-ply duplex PP laminate structure. The switch from a non-recyclable triple laminate has made Lidl’s fresh sausage packaging fully recyclable through back-to-store soft plastic recycling schemes!
By updating the packaging for Lidl’s five-line sausage range, Lidl has achieved an impressive 30% packaging weight reduction. This change not only provides sustainability benefits but also enhances presentation. To create a butchers feel, a special tactile finish has been applied, giving the packs a unique paper-like appearance whilst offering substantial environmental savings.
So your next bangers and mash can deliver standout sustainability benefits.
11. The Sustainable Beverage Carton
Debuting on supermarket shelves later this year, ReZorce cartons are an alternative to standard composite beverage cartons, the majority of which are not recycled. And with 250 billion beverage cartons produced annually, a more sustainable alternative is essential.
Patented technology is used to create an innovative microcellular layered structure. The inner foamed layers inhibits the transmission of water and oxygen, creating physical barrier properties. As a mono-material, including the tethered cap, ReZorce is compatible with standard waste collection and sorting, as confirmed through testing with recyclers Biffa and Veolia.
An independent LCA demonstrates that, compared to a conventional package, a ReZorce beverage carton uses 53% less energy, 51% less water, and has a 55% lower global warming potential.
12. Eggspert’s At Tosca Services Have Some Cracking Solutions
The Egg RPC was created specifically for the egg industry as a reusable packaging solution. It provides superior strength and structural integrity to significantly reduce product damage compared to corrugated cardboard, delivering a 50% reduction in shrink.
Because it is foldable and stackable, the reusable plastic egg crate saves transport and storage space, reducing costs, improving supply chain efficiency, and reducing transportation emissions. LifeCycle Assessments have shown that using these reusable crates can reduce greenhouse gas emissions by over 60% compared to when using the cardboard alternative and that is without including emissions from the disposal of broken eggs.
Additionally at end of life, the crates are reground and incorporated back into new egg crates with over 40% recycled content currently included in all egg crates… Eggcellent! (Sorry - had to be done).
13. Plastic Waste Trash to High Value Treasure
Converting polyethylene based mixed plastic wastes into high value products is work by The University of Edinburgh that explores the use of polyethylene (PE) film-based waste mixed plastics (wMP) from packaging, waste glass fibres (wGF), and recycled carbon fibres to produce valueadded composites for various real applications.
Recyclable thermoplastic composite laminates (produced with wMP and wGF) leads to significant improvements in tensile strength, tensile modulus, flexural modulus, compressive strength, and compressive modulus - compared to unreinforced wMP. Hybrid composites - also produced with over 50 vol% of PE based mixed packaging waste - also show exceptional strength.
The wMP based laminates also exhibit excellent ballistic performance, successfully withstanding wind debris at speeds (between 103 m/s and 125 m/s) surpassing the recommended speeds of Australian and New Zealand guidelines.
These test results demonstrate that these PE waste based composites exceed the performance of globally used plywood – and instead of going to landfill, can be used as hurricane-resistant panels, cyclonic shelters, and in transport and construction sectors with the added benefit of recyclability at the end of life.
14. Binning Wrapping-Paper Made Fun
Not a cooking mouse, but an idea nearly as fun... Wrapatouille is a solution to combat wrapping-paper waste – a perfect innovation as we head into Christmas this year! Whilst embracing gifts and their wrapping, UAL - Central Saint Martins’ students designed this to extend the gifting moment and the life of wrapping-paper; and educates households on proper collection and recycling practices.
Wrapatouille mixes all the ingredients of joyous occasions (wrapping-paper, games, quality time with loved ones) and encourages consumers to cheerfully dispose of wrapping-paper.
The leaflet transforms into a basketball hoop to hold Wrapatouille bin bags and help families collect wrapping-paper post gift-giving event. Gloves with 3 compartments also help collect wrapping-paper and flatten it before being made into papier-mâché objects.
These wrapping-paper collecting tools are part of a wider campaign, which includes an informative website with activities to teach how you can verify if wrapping-paper is recyclable - the scrunch test - to check if it’s contaminated and recyclable, and show you how to repurpose discarded material into papier-mâché objects, either at home or in community centres.
Maybe keep the more competitive family members in the other room for this!
15. Jaguar Land Rover’s Composite Cross Car Beam
Some context for the non-petrolheads… a cross car beam (CCB) is the structural component (conventionally made from magnesium) which supports the instrument panel (IP) of a passenger vehicle. Jaguar Land Rover (JLR) made a project aimed at reducing the global warming potential of the current CCB without any weight increase.
They were successful in engineering an innovative assembled solution which uses steel on the driver side to support the demanding vibration requirements of the steering column, and fibre reinforced injection moulding on the passenger side to act as a functional carrier for the rest of the IP content, expected to save 180,000 tonnes of CO2e equivalent (over their life cycle) to JLR’s entire site emissions for a year.
Minimising CO2e and weight concurrently is a prevalent issue across the automotive sector as a whole, and this hybrid technology group is currently the only known solution which achieves both within a viable business case, which offers JLR the opportunity to not only deploy this on their own products, but potentially license to other suppliers, making the potential decarbonisation opportunity far greater than identified in the initial study.
If you’ve got a plastic innovation that you feel deserves to be in this list, submit it HERE for consideration — and you might even win one of next year’s BPF Horners Awards!
Author
Rebecca Shortland
*Please note that this article is not a press release. Do not use on your own website unless given specific permission from the author.
