TY - JOUR

T1 - Screening Life Cycle Assessment comparing One-step and Two-step Injection Molding Compounding using Conservative and Optimistic Scenarios

AU - Kirschnick, Ulrike

AU - Shahroodi, Zahra

AU - Krempl, Nina

AU - Schledjewski, Ralf

PY - 2023

Y1 - 2023

N2 - One-step injection molding compounding (IMC) is an innovative process to manufacture shortfiber-reinforced polymer composites. The aim of combining compounding and injection molding into oneprocess is to enhance component quality and minimize environmental impacts. In this study, a screening LifeCycle Assessment (LCA) is conducted to evaluate and compare the environmental impacts of the IMC processwith standard two-step manufacturing. Two scenarios for the IMC are considered, each differing in terms ofmachinery requirements, energy consumption, and material usage. Mechanically recycled polypropylene andglass fiber are used, and considered in the LCA employing a simple cut-off approach without awarding creditsfor substituting (primary) materials. The functional unit is the composite produced via the respective process,assuming equal functionality. Inventory data are obtained from initial experiments, literature, and the ecoinventdatabase. The impact assessment method selected is ReCiPe2016. Results indicate that the environmentalperformance improvement achieved by the IMC compared to the reference process is minimal in theconservative scenario where energy and material usage can be reduced but machinery usage is increased.However, in an optimistic scenario, the IMC can reduce the impacts of composite manufacturing by 34 %. Thecontributions at the midpoint level vary, and metal usage and energy consumption are the main contributors inall scenarios. A variation of the energy source for manufacturing shows the dependency of environmentalimpacts of components produced in both processes on the geographical location of production and its electricitysupply. Methodological choices, such as the definition of the functional unit and modeling of recycledmaterials, have a large influence on LCA results, and alternative options are discussed.

AB - One-step injection molding compounding (IMC) is an innovative process to manufacture shortfiber-reinforced polymer composites. The aim of combining compounding and injection molding into oneprocess is to enhance component quality and minimize environmental impacts. In this study, a screening LifeCycle Assessment (LCA) is conducted to evaluate and compare the environmental impacts of the IMC processwith standard two-step manufacturing. Two scenarios for the IMC are considered, each differing in terms ofmachinery requirements, energy consumption, and material usage. Mechanically recycled polypropylene andglass fiber are used, and considered in the LCA employing a simple cut-off approach without awarding creditsfor substituting (primary) materials. The functional unit is the composite produced via the respective process,assuming equal functionality. Inventory data are obtained from initial experiments, literature, and the ecoinventdatabase. The impact assessment method selected is ReCiPe2016. Results indicate that the environmentalperformance improvement achieved by the IMC compared to the reference process is minimal in theconservative scenario where energy and material usage can be reduced but machinery usage is increased.However, in an optimistic scenario, the IMC can reduce the impacts of composite manufacturing by 34 %. Thecontributions at the midpoint level vary, and metal usage and energy consumption are the main contributors inall scenarios. A variation of the energy source for manufacturing shows the dependency of environmentalimpacts of components produced in both processes on the geographical location of production and its electricitysupply. Methodological choices, such as the definition of the functional unit and modeling of recycledmaterials, have a large influence on LCA results, and alternative options are discussed.

U2 - 10.37394/232015.2023.19.117

DO - 10.37394/232015.2023.19.117

M3 - Article

VL - 19.2023

JO - WSEAS transactions on environment and development

JF - WSEAS transactions on environment and development

SN - 2224-3496

ER -