Plastics in OPHARDT
Plastics play a crucial role in the design and functionality of OPHARDT’S products, from durable dispensing systems to single-use pumps in medical settings. The right selection directly impacts product performance, hygiene, and sustainability. While they offer durability and safety, they also present environmental challenges. At OPHARDT, it is important for us to balance the need for high-performance materials with our commitment to sustainability by exploring eco-friendly alternatives, responsible material sourcing and being aware of innovations in the market place that could lead us to be more sustainable as an organisation.
Understanding Plastics: Properties and Selection
The selection of materials for product manufacturing is contingent upon several factors, including the specific application of the product, the functional requirements of each component, and the intended user demographic. These considerations influence the choice of polymers based on their mechanical properties, thermal stability, chemical resistance, and biocompatibility, among other criteria.
Polyethylene (PE), available in high-density (HDPE) and low-density (LDPE) variations, is favoured for its chemical resistance and durability. Acrylonitrile Butadiene Styrene (ABS) is widely used due to its strength, impact resistance, and ease of processing. Polypropylene and HDPE make up a significant portion of our product portfolio, available in both virgin and post-consumer recycled (PCR) forms. Our engineering team has experimented with bioplastics. Unlike traditional plastics, which are derived from petroleum, bioplastics are obtained from renewable resources, and some bioplastics are biodegradable.
HDPE stands out for its rigidity and chemical resistance, making it ideal for high-strength applications such as detergent bottles and dispensing systems. In contrast, LDPE is more flexible, softer, and often used in squeeze bottles and liners. Nylon and PET are selected for their superior strength and resistance to chemicals. Fluoropolymers, used in some very specific applications, are being phased out in favour of more environmentally friendly alternatives. Unlike thermosetting plastic, which cannot be recycled after moulding, OPHARDT exclusively uses thermoplastics, allowing for regrinding and reuse in production.
Plastics in OPHARDT Products
While European customers have historically preferred metal dispensing systems for their aesthetic and long-lasting qualities, North American and other global markets have often favoured plastic dispensers, particularly in healthcare settings where single-use pumps help maintain strict hygiene standards.
Medical-grade plastics play a critical role in these settings, requiring precision moulding to ensure consistent performance. To reinforce sustainability efforts, our DHP pump has undergone third-party recyclability testing and certification within Germany’s waste management system, although hospital waste disposal practices vary.
Balancing Hygiene and Sustainability
OPHARDT is committed to integrating recycled materials where feasible while maintaining the high hygiene standards required in medical applications. While medical-grade plastic must be virgin to ensure safety and compliance, other products / components incorporate PCR plastics. The X10 series pumps, for instance, feature PCR resin in the pump cylinder, with over 55% of the material coming from recycled sources. The SP10 dispenser contains up to 64% PCR resin, while the BTF pump consists of as much as 77%. Additionally, our PET bottles are produced with up to 100% recycled content.
Changing to PCR, however, presents challenges. Colour consistency can be difficult to achieve, as recycled materials often have a grey tint, making colour matching costly and complex. Material inconsistencies also pose challenges for high-precision moulding, and many commercially available products we make with PCR, cannot withstand the cleaning and or sterilisation cycles required for medical applications.
To overcome these challenges, OPHARDT has successfully moulded products such as the Ingo-Top dispenser and the ERT in bio-based polymers and continues testing alternative recycled and non-fossil-based materials to assess their viability. There are issues with sanitizers reacting with bioplastics, leading to leaching however, for products/ components we produce that are not in contact with the sanitizer there is the potential to replace them with bio-plastics. We are also working to reduce fluoropolymer usage and replace them with environmentally friendly alternatives.
Growth in Sustainable Materials
OPHARDT’S efforts to expand the use of sustainable materials are already yielding significant results. Between 2022 and 2023, our use of PCR plastics doubled from 8,000 kg to 16,000 kg, with further increases expected as high-quality recycled materials become more widely available. We also prioritise recyclability in product design by ensuring clear material separation to facilitate sorting and waste management. Our collaboration with Interzero allows us to evaluate and improve the recyclability of our products in Canada and Ireland.
Future Trends: Innovations in Sustainable Plastics
As sustainability becomes a growing priority for customers, OPHARDT is responding by designing products with longer lifespans, improved recyclability, and greater use of alternative materials.
We are developing new products designed specifically for PCR compatibility while maintaining performance and hygiene standards. At the same time, we are testing bio-based and non-fossil materials to explore their potential for meeting the stringent requirements of medical applications.
Conclusion
Due to their hygienic and durable qualities, plastics will continue to be used in OPHARDT’s product portfolio in order to meet healthcare guidelines. We are committed to using this material thoughtfully, recognizing the environmental challenges associated with plastic use and using the latest technology to process these materials in the most sustainable way.
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