Envalior

Making electric vehicles Safer, Lighter and more Sustainable

The future of mobility is rapidly changing. The era of internal combustion engines as a single power source is ending, indicating a transformation that makes vehicles cleaner. To realize this transformation, automotive OEMs need advanced materials that make electric vehicles safer, lighter and more sustainable.

Our portfolio of tough yet lightweight materials enable manufacturers to produce automotive components that are extremely light, reduce friction and operate in extreme environments – particularly at very high temperatures – with drastically smaller carbon footprints.

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EV Charging Plugs and Sockets
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HV Connectors
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IGBT Frame
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Bus Bar
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Capacitor Housing
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Fuel Cells
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Hydrogen and Gasoline Tanks
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Electric Water Pump (Housing and Impellers)
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Thermal Management Module (TMM)
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Coolant Connectors
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High-Speed Bearing Cages
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E-Motor Resolver
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E-Motor Oil Distribution Ring
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Sensors
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ADAS Housings and Brackets (i.e. Radar or Camera)
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FAKRA & HSD Connectors (corrosion-resistant)
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Low Voltage Connectors
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Coolant Expansion Tank
EV Charging Plugs and Sockets
EV Charging System
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Government-mandated targets to reduce
fossil fuel emissions drive commercial
vehicle brands to invest in hybrid and EV
technology. Safe and reliable EV charging
plugs require insulating materials that
withstand up to 800V and more.
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HV Connectors
EV Charging System
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Vehicles require safe and reliable connectors to
enable a growing number of critical active
safety and driver assistance systems. Our
materials are trusted for manufacturing
high-performance connectors for millions of
new vehicles. We recently launched an
industry-first Arnite® PBT compound that
achieves a CTI of 600V and UL94-V0 at 0.8mm, as
well as hydrolysis resistance and a silicon
compression set well below any PA alternative.
Unlike competing PBTs that easily become
brittle, our Arnite® solution offers an elongation
at break comparable to PA66. As a polyester, its
orange color remains very stable after long-term
aging – unlike PAs prone to discoloration.
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IGBT Frame
EV Charging System
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Automakers continue to focus on high
voltage charging systems that increasingly
use high-power IGBT components with
dedicated frames – which need to offer high
dimensional stability, and resist extreme
temperatures and electro corrosion. We offer
a complete portfolio of Arnite® PBT, ForTii®
PPA and Xytron™ PPS compounds that
ensure UL94-V0 flame retardancy and
excellent insulative properties from -40°C up
to 180°C. Xytron offers high bonding strength
with silicon gels, excellent dimensional
stability and creep resistance, and ionic
content of less than 50ppm to reduce the
risk of electro corrosion.
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Bus Bar
EV Charging System
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Bus bars are an essential interconnection
system for various high voltage components
of EVs, such as the connection between the
inverter and the e-motor. These parts need to
be robust and offer high temperature and
thermal crack resistance. Our broad material
portfolio offers grades ideal for challenging
bus bar requirements. We also provide design
support to mitigate CTE mismatch issues with
copper and optimize glass fiber orientation –
ensuring the lowest thermal stress is
generated at the edges of copper strips.
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Capacitor Housing
EV Charging System
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Capacitor housings are essential components
in every high voltage system. Xytron™ PPS
grades enable these parts to achieve
best-in-class performance. The material
offers unmatched electrical insulative
properties, as well as a CTI of <175V to reduce
the risk of electrical tracking.
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Fuel Cells
Fuel System
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Ultra-pure materials that prevent ion
leaching and hydrolytic and heat aging
improve the efficiency and service lifetimes
of fuel cells. Our Xytron™ PPS compounds
demonstrate very low ionic leaching and
high mechanical strength to enhance the
lifetime efficiency of vehicles.
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Hydrogen and Gasoline Tanks
Fuel System
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Gasoline and hydrogen tanks for hybrid or
fuel cell vehicles need to withstand extreme
temperatures and offer strong barrier
properties to keep passengers safe. Akulon®
Fuel Lock is superior to traditional HDPE and
metal solutions due to its high strength, low
permeation and easy processing behaviour.
Our advanced bio-based EcoPaXX® PA410
material is ideal for producing more
sustainable tanks that offer increased
chemical resistance and exceed gasoline
permeation requirements set by EURO VII
and Carb III standards.
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Electric Water Pump (Housing and Impellers)
Thermal Management System
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In EVs, thermal management systems (TMS)
are critical to keeping battery packs within
the optimal temperature range – to ensure
EVs are safe and improve engine efficiency
and service lifetimes. XytronTM is ideal for
developing TMS components such as electric
water pump housings and impellers that
require the highest hydrolysis and heat aging
resistance. ForTii® PPA and EcoPaXX® PA410
also offer proven performance in TMS
components.
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Thermal Management Module (TMM)
Thermal Management System
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In EVs, thermal management systems (TMS) are
critical to keeping battery packs within the
optimal temperature range – to ensure EVs are
safe and improve engine efficiency and service
lifetimes. XytronTM is ideal for developing TMS
components such as thermal management
modules that require the highest hydrolysis
and heat aging resistance. ForTii® PPA and
EcoPaXX® PA410 also offer proven performance
in TMS components.

 

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Coolant Connectors
Thermal Management System
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In EVs, thermal management systems (TMS)
are critical to keeping battery packs within
the optimal temperature range – to ensure
EVs are safe and improve engine efficiency
and service lifetimes. XytronTM is ideal for
developing TMS components such as coolant
connectors that require the highest
hydrolysis and heat aging resistance. ForTii®
PPA and EcoPaXX® PA410 also offer proven
performance in TMS components.
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High-Speed Bearing Cages
E-Powertrain System
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Vehicle electrification trends are changing
performance requirements for high-speed
bearing cages. To develop lighter, smaller
e-motors that generate the right amount of
power, designers need to reduce torque while
boosting rotation speeds. Downsizing the e-axle
requires miniaturized, thin-walled bearing
cages. Thinner bearings that operate at faster
speeds need to offer higher stiffness over a
wider temperature range to prevent part
damage. Materials like PA66 offer limited
resistance to high-temperature grease that
lubricates high-speed bearings. Stanyl® PA46
offers proven high-performance for e-motor
applications due to its excellent strength,
stiffness and thermal properties – tested and
approved by leading Tier 1s and OEMs.
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E-Motor Resolver
E-Powertrain System
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Vehicle electrification trends are changing
performance requirements for e-motor
resolvers. Xytron™ PPS and ForTii® PPA
offer best-in-class thermal resistance, as
well as excellent creep and thermal shock
resistance. Dedicated electro-friendly
compounds with a controlled ionic content
of less than 50ppm minimize the risk of
electro corrosion.
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E-Motor Oil Distribution Ring
E-Powertrain System
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As the EV market grows, demand for
high-quality e-drive lubricants is increasing.
Vehicle electrification trends are also
changing performance requirements for
e-motor oil distribution rings. As electric
motors and reduction gears that EVs use
become more compact, new energy efficiency,
heat removal and speed drive gear oil
formulation requirements need to be met.
Materials for oil distribution rings need to
retain more than 60% of their mechanical
performance after oil aging, high dimensional
stability and low warpage to minimize the risk
of oil leakage. Akulon® PA66, ForTii® PPA and
Xytron™ PPS provide these capabilities.
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Sensors
Electrical and Electronics System
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Sensors and microelectromechanical systems
(MEMS) are key components in many
electronic interfaces. They manage internal
and external controls and require materials
proven to meet the most stringent
performance requirements. Over-molded
components, including solenoids and sensors,
rely on advanced materials that withstand
extreme temperatures, and can be processed
at low pressure to avoid electronic component
displacement.
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ADAS Housings and Brackets (i.e. Radar or Camera)
Connected Car System
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To enable driver assistance functions, ADAS
housings need to be dimensionally stable, offer
high chemical and UV resistance, conduct high
thermal loads, and prevent signal interruptions.
Radomes for radar sensors need to show a high
level of RF transparency. Our advanced material
portfolio fulfills these requirements and prevents
electro corrosion in critical ADAS components
to lower the risk of safety system failures.
Dedicated laser-weldable PBT compounds support
low cycle times – reducing manufacturing
costs. Electrically conductive compounds enable
excellent EMI shielding above 50dB across the
entire frequency range, while providing thermal
conductivity of roughly 1W/mK to disperse heat
from hot spots.
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FAKRA & HSD Connectors (corrosion-resistant)
Connected Car System
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Connected cars are driving demand for
high-speed data (HSD) and FAKRA
connectors. As a vital link to the brain of the
vehicle, connectors link coaxial cables to
receivers and transceivers for
communications and entertainment systems.
Connectors also play a key role in passenger
safety. ForTii® Ace eliminates the risk of
FAKRA connectors blistering during reflow
assembly – even after long shelf times with
open bags of non-assemble connector rails
or resin bags. ForTii Ace is free of halides and
metallic ions to avoid the risk of electro
corrosion under constant DC bias for metals
in sensitive electronics.
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Low Voltage Connectors
Electrical and Electronics System
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Vehicles require safe and reliable connectors
to enable a growing number of critical active
safety and driver assistance systems. Akulon®,
Arnite®, EcoPaXX®, ForTii® and Stanyl® are
trusted materials for manufacturing
high-performance connectors for millions of
new vehicles.
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Coolant Expansion Tank
Thermal Management System
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In EVs, thermal management systems (TMS)
are critical to keeping battery packs within
the optimal temperature range – to ensure
EVs are safe and improve engine efficiency
and service lifetimes. XytronTM is ideal for
developing TMS components such as coolant
expansion tanks that require the highest
hydrolysis and heat aging resistance. ForTii®
PPA and EcoPaXX® PA410 also offer proven
performance in TMS components.
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Air Springs
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FRP Center Tunnel
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Cross Car Beam
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E-Motor Mount
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E-Parking Brake Pedals
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Complex Die Cast Components
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Front End Module
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Seating Materials
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Battery Management System
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Battery Lids and Housings
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ATF Oil Filter Housing
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Wiring Harness
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Actuators (Electric Parking Brake, Electric Brake Booster, Electric Power Steering, Comfort Actuators, Chassis Actuators,..)
Air Springs
Suspension System
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When it comes to air spring applications,
OEMs need to meet consumer demand for
comfort, comply with government
regulations to reduce emissions, and
embrace sustainable manufacturing
processes and materials. Our materials for
these applications significantly impact the
overall performance and weight of the
entire suspension system. Our Akulon®
PA66, Akulon PA6 and Arnitel® TPC
solutions enable manufacturers to meet
key performance, sustainability and
lightweighting requirements.
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FRP Center Tunnel
Structural Parts System
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Innovative chassis and structural body
designs enable manufacturers to improve
vehicle safety and performance while
reducing total weight and costs. Our
next-generation thermoplastics can replace
traditional metal materials and outperform
alternative plastics and rubbers. Akulon®
enables manufacturers to produce complex
structural body components that are
lightweight and can successfully replace or
augment metal components.
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Cross Car Beam
Structural Parts System
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Innovative chassis and structural body
designs enable manufacturers to improve
vehicle safety and performance while
reducing total weight and costs. Our
next-generation thermoplastics can replace
traditional metal materials and outperform
alternative plastics and rubbers.
Our portfolio of injection molding grades can
be combined with advanced thermoplastic
composite solutions or metal inserts.
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E-Motor Mount
Structural Parts System
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E-motor mounts need to be made of
materials that offer excellent mechanical
strength and high temperature resistance,
such as PA6 or PPA. Akulon® PA6 and ForTii®
PPA offer excellent mechanical performance
and the lowest potential system costs, due
to their ability to reduce part wall thickness
by 20-40%.
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E-Parking Brake Pedals
Structural Parts System
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E-parking brake pedals are traditionally made
from PA6, yet this material lacks the fatigue
lifetime and impact resistance these parts
require. Our Akulon® material for metal
replacement enables manufacturers to
produce lightweight e-parking brake pedals
that offer greater design flexibility, component
consolidation and lower costs.
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Complex Die Cast Components
Structural Parts System
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Innovative chassis and structural body
designs enable manufacturers to improve
vehicle safety and performance while
reducing total weight and costs. Our
next-generation thermoplastics can replace
traditional metal materials and outperform
alternative plastics and rubbers. ForTii® offers
excellent processability and high mechanical
performance over a wide temperature range,
as well as numerous advantages over die-cast
aluminum and zinc.
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Front End Module
Structural Parts System
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Innovative chassis and structural body designs
enable manufacturers to improve vehicle safety
and performance while reducing total weight
and costs. Our next-generation thermoplastics
replace traditional metal materials and
outperform alternative plastics and rubbers. In
front end module designs, our injection
molding grades can be combined with
advanced thermoplastic composite solutions or
metal inserts. Akulon® PA6 is ideal for this
application, as it offers higher temperature
resistance than polypropylene (PP) and a
better surface appearance than PA66.
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Seating Materials
Interior System
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Replacing metal used to manufacture
seating components with advanced
engineering plastics can drive weight
savings of up to 50% without
compromising passenger safety.
Bio-based versions of our advanced
materials are also available.
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Battery Management System
E-Powertrain
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Designs for e-powertrain housings such as the
battery management system (BMS) often use
metal. However, EV producers are increasingly
focused on reducing vehicle weight. Heavier
EVs are less comfortable to drive and
accelerate tire wear – which generates micro
particles of <2.5€m that can penetrate lung
tissue. Upcoming EURO VII standards will
restrict permissible levels of fine particles. We
have a proven track record of helping BMS
housings manufacturers successfully replace
metal with Akulon® FR compounds.
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Battery Lids and Housings
E-Powertrain
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Structural parts in batteries such as the
housing or lid need to achieve UL94-V0 and
offer excellent mechanical strength and
dimensional stability. They also require
electrical insulation, as well as resistance to
extreme temperatures and high mechanical
stress generated over vehicle lifetimes.
Manufacturers also look to reduce vehicle
weight by replacing metal material solutions
for various powertrain components.
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ATF Oil Filter Housing
E-Powertrain
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E-powertrain parts need to offer excellent
wear performance, as they are perpetually in
motion. They require electrical insulation, as
well as resistance to extreme temperatures
and high mechanical stress generated over
vehicle lifetimes. Manufacturers also look to
reduce vehicle weight by replacing metal
material solutions for various powertrain
components.
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Wiring Harness
Electrical System
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Lightweighting EV components can save
manufacturing costs without compromising
on vehicle safety. Our broad portfolio of
materials offers grades specifically suited to
every application, including control modules,
connectors and much more. Our materials
provide best-in-class thermal performance
and the high-flow properties required to
design thin-walled parts with halogen-free
flame retardancy.
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Actuators (Electric Parking Brake, Electric Brake Booster, Electric Power Steering, Comfort Actuators, Chassis Actuators,..)
Actuation System
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Extremely thin and durable gears enhance
actuator performance and drive substantial
weight and cost savings. Our design miniaturization
experts can help you develop light,
reliable gears for actuation systems such as
EV electric brake boosters and parking brakes.
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Bio - Based
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Bio-mass balancing
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Post - Consumer Recycling
Bio - Based
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Ourbio-based solutions support the transition from depleting fossil energy source stousing renewableenergy ones,sources and, while also reduceing the carbon footprint of our entire material portfolio–enabling us tos.By reducing the carbon foot printof the materials in our portfolio,we help our customers meet reduce their own sustainability goals carbon footprint
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Bio-mass balancing
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Bio-based mass balancing solutions enable customers to lower their carbon footprint without having to requalify parts–,as these materials offer the same mechanical properties as 100% fossil-based alternatives. Our mass balancing approach complies with ISCC+ standards, a globally recognized sustainability certification. Stanyl®B-MB is will be certified under ISCC+
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Post - Consumer Recycling
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We work closely with partners, customers and suppliers to realize implement value chains that lead to a more sustainable value chain and economiesy. Our high-performance certified circular polyamide Akulon® CRC-MB is made of post-consumer plastics, which would otherwise be discarded invial and fills or incineratedation. We By lleverageing advanced recycling processes to convert, used plasticis converted into new feedstock, which then enters the production chain to delivernew virgin-quality materials. Every year, roughly 650kt offishing nets are discarded in ocean–equivalent to almost 400,000 vehicles.Akulon PA6 Re-Purposed is based made from on recycled fishingernets, which DSM ,together with its partners, is collectsing from the Indian and Arabian Ooceans. The While being recycle, the performance of this such compound is comparable tos are almost at the level of virgin PA6. Every year about 650kt off is hernet is discarded in oceans, this is an equivalent of almost 400,000 vehicles that we be dumped into the oceans every year
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