Food-contact compliant, regenerated by-product pilot program

 At Vikan, we're committed to manufacturing all of our products from recycled materials as they become available and scalable. This not only reduces our reliance on newly manufactured plastic, it also creates a more sustainable future. As a step toward this ambition, we are excited to announce a new pilot program utilizing regenerated polypropylene by-product in our food-contact compliant tools. This program will reduce CO2 emissions versus traditional manufacturing processes, and it reflects considerable investments in developing supplier partnerships and expanding manufacturing capabilities.

The food contact challenge

As a supplier to the food manufacturing industry, many of Vikan’s tools come into direct contact with food and food-contact surfaces. Because of this, most tools in our Hygiene Range are produced from food-contact compliant raw materials as required by EU and US regulations.

European food-contact compliance requires rigorous testing by independent laboratories to ensure that any plastics that may come into contact with food or food contact surfaces don’t transfer harmful substances to the food. Our materials are subjected to various tests that simulate real-world conditions with different food types (acidic, watery, fatty) at varying temperatures and durations to ensure safety.

At present, these testing requirements, along with other regulations, make it difficult to produce food contact compliant tools from post-consumer recycled polypropylene. While there is an abundance of other post-consumer materials like those used in PET water bottles and packaging, reliable sources of post-consumer polypropylene (our primary raw material) are not yet available. As more manufacturers demand post-consumer polypropylene, we expect regulations to change and supplies to increase.

In anticipation of regulatory changes, we continuously monitor industry developments and proposed updates to EU 10/2011. We also monitor legislation and regulations in other markets like the United States, the United Kingdom, and Australia.

About our pilot program

Through our continued focus on using recycled and renewable raw materials, we identified a way to reduce our CO2 impact now while regulations and materials adapt to changing demands. In this process, our partners convert manufacturing by-products from other food-grade polypropylene products into new raw materials for Vikan.

Manufacturing by-products consist of cutoffs, out-of-spec parts, process start-up parts, and test parts that otherwise cannot be used by the original manufacturer. These by-products are segregated, collected, ground, and mixed to Vikan’s specifications, and then submitted for batch migration testing to confirm compliance with food contact regulations. Once testing establishes compliance, the material is released to Vikan molders for use in our Hygiene Range. Full documentation from suppliers ensures traceability and guarantees food contact compliance.

Pilot program rollout

To achieve the greatest possible reduction in overall CO2 emissions, we will incorporate regenerated raw materials into our most popular products containing the highest percentage of polypropylene. For example, we will be using this material in the blocks of squeegees with removable cassettes. We will also transition to this material for the hand grips of several aluminum and fiberglass handles. The transition will take place over the next six months, and there will be no visible or functional difference between products.

Quality testing of the materials and finished products has been successfully completed and manufacturing is in progress. However, due to limited and fluctuating supplies, we can’t guarantee that a specific part has a defined amount of by-product in it.

As the project progresses and more regenerated polypropylene by-product becomes available, this program could expand to more Vikan products. This first step will measurably reduce our use of newly manufactured material and reduce CO2 emissions by around 30% for these tools.

This project is just one way that we are reducing our environmental impact. We are also piloting a product takeback program in Europe where worn or broken tools are returned to us for recycling. Find out more here.

 More about manufacturing by-products

Under current regulations, manufacturing by-products can be regenerated and used by Vikan because the material was initially food-contact compliant; it was segregated by the original manufacturer; and the regenerated material passed additional migration testing.

According to Directive 2008/98/EC, “by-product” is defined when the following conditions are met:

• The material is certain to be used in other processes
• The material can be used without processing that would not be industrial practice
• The material originates from an integral part of the production process
• The use of the material is lawful in the application chosen

By-product- Include language from EU 10/2011. Proposal for 10/2011, Article 10 Section 2 (a)-(d)

Use of regenerated material is possible when it comes from cut-offs and scraps that were initially food contact compliant and meet the definition of by-product from Article 5 of Directive 2008/98/EC.

FAQ

How will I know when we get the products in stock? 

We are incorporating the by-product materials into our normal feedstock for select products. Because the products are identical in all aspects, there will not be any recognizable difference. We will not have special markings or stock numbers for these items. 

Based on the limited availability of the by-product materials, we cannot guarantee that an individual unit of a specific item contains the by-product material. We currently view this pilot project from the standpoint of total CO2 reduction in Vikan’s manufacturing process rather than a reduction on one specific product. 

Will you mark the products with a “CO2 friendly” mark? 

No, there will not be special markings on the tools or packaging. We will not have different stock numbers for these items. The lower CO2 effect from this project will be kept at a company level. 

Are there separate Declarations of Compliance for these tools? 

No, with migration testing on the batch level, the Declarations of Compliance remain the same. Testing validates that all materials are safe for food contact. 

Which Vikan products are included in this program? 

The pilot program includes plastic components for two different groups of items. We will use by-product material in the handgrips of aluminum, stainless steel, and fiberglass handles. We will also manufacture the blocks for our squeegees with removable cassettes (foam and double-blade squeegees) with the by-product material.   

What is the scale of the pilot program? 

The current scale of the pilot program is quite narrow due to the availability of by-product material. As the broader plastics industry incorporates more by-product collection programs, we expect the supply to increase. This will, in turn, mean that we could expand the program to additional products. 

Will there be a cost difference? 

No, our prices to distributors will not change for the pilot program. There are significant added costs to using by-product materials in our production process, but Vikan will absorb the additional costs. 

What are by-products? 

Manufacturing by-products consist of excess materials that otherwise cannot be used by the original manufacturer of food contact compliant products. These by-products are segregated, collected, ground, and mixed to Vikan’s specifications, and then submitted for batch migration testing to confirm compliance with food contact regulations. Once testing establishes compliance, the material is released to Vikan for use in our Hygiene Range. 

Why is Vikan using by-products instead of post-consumer recycled polypropylene? 

In short, the use of regenerated by-products instead of post-consumer recycled polypropylene in the Vikan Hygiene range comes down to availability and regulations. Products intended for food contact must meet strict legal requirements. Recycled polypropylene currently does not meet these standards. Vikan Transport and Classic ranges already incorporate recycled polypropylene – you can see the percentages of recycled material used in these ranges in the product listings on our website. The post-consumer recycled material challenge is also described in greater detail on our website.