TBM is pleased to announce that it has developed "CirculeX," a high-performance recycled material made from post-consumer recycled (PCR) plastics. Using household-sourced plastic containers and packaging as a feedstock and leveraging TBM's proprietary compounding and melt-kneading technologies cultivated through its materials development, TBM has overcome two key barriers associated with PCR materials: deterioration in material properties and unpleasant odor. In terms of bending strength and impact strength, CirculeX delivers performance that exceeds conventional PCR materials and even surpasses virgin plastics.
Demand for plastic circularity is rising globally amid strong concerns over marine litter and CO2 reduction guidelines, driven by regulations and industry such as Europe's 2025 draft ELV regulation and the entry into force of the PPWR. Interest in recycled plastics is also growing in Japan, and the market is expanding worldwide. TBM will establish mass production of CirculeX this year at its Yokosuka Circular Factory and roll it out beyond traditional PCR/PIR applications into areas currently dominated by price-competitive virgin plastics.
Development Overview
Regulations to promote plastic circularity are tightening worldwide. In the EU, the Packaging and Packaging Waste Regulation (PPWR) sets a target to recycle 55% of packaging waste by 2030.* 1 In the UK, the Plastic Packaging Tax applies to plastic packaging containing less than 30% recycled plastic.* 2 In Japan, waste plastics are still heavily reliant on incineration and the material recycling rate remains around 20%.* 3 Under the Act on Promotion of Resource Circulation for Plastics (the Plastic Resource Circulation Act), Japan has set a goal of doubling the use of recycled plastics by 2030.* 4 Against this backdrop, Japan's recycled plastics market is expected to grow from around $1.12 billion in 2024 to around $2.13 billion in 2040,* 5 while the global market is projected to expand from around $89.54 billion in 2025 to around $154.90 billion in 2032.* 6 As demand surges, high-quality recycled materials derived from industrial waste waste (PIR) face tightening supply, rising procurement difficulty, and price increases. Meanwhile, PCR materials made from post-consumer plastics still suffer from issues such as odor from food residues and insufficient strength mainly, limiting domestic applications to one-way pallets and fillers for civil engineering and construction materials; although collection volumes are expected to rise to 1.7 million tons by 2030 due to expanded collection items,* 7 the market remains supply-constrained.
*1 Delegation of Japan to the European Union: Overview of the EU's PPWR (Packaging and Packaging Waste Regulation)
*2 JETRO (Japan External Trade Organization): Plastic packaging measures moving forward, government to introduce packaging tax from April 2022 (UK)
*3 Plastic Waste Management Association: Status of production, disposal, recycling and treatment of plastic products in 2024
*4 Ministry of the Environment: Plastic Resource Recycling Strategy
*5 Fuji Keizai Co., Ltd.: Survey of markets for recycled plastics and biomass plastics
*6 MarketsandMarkets: Recycled Plastics Market
*7 Plastic Journal PJ: [Column] Issues and prospects for integrated operation of the Containers and Packaging Recycling Act and the New Plastics Act
In response to these market conditions, TBM has developed "CirculeX," a high-performance recycled material applicable to PIR and virgin-plastic applications facing supply constraints and rising prices. By leveraging proprietary compounding and melt-kneading technologies from its LIMEX business and process improvements at the Yokosuka Circular Factory, TBM has fundamentally addressed key PCR quality issues, including insufficient strength and strong odor.
Features of "CirculeX"
Delivers strength exceeding conventional PCR made from plastic containers and packaging and virgin plastics
Using TBM's proprietary compounding and melt-kneading technology, CirculeX is a PCR material made from plastic containers and packaging, yet achieves a 126% increase in bending strength compared with conventional PCR and a 47% increase compared with virgin plastics. It also delivers a 76% increase in impact strength compared with conventional PCR and a 29% increase compared with virgin plastics. This enables use in durability-demanding applications such as construction materials, materials logistics, and automotive parts.
* Calculation method: Evaluation results from tests conforming to JIS K 7171 (bending strength) and JIS K 7111 (Charpy impact strength) (in-house research). Physical properties are representative values and not guaranteed values.
Reduces odor by approximately 60% versus conventional PCR made from plastic containers and packaging
Through improvements to the washing process, TBM reduced odor by approximately 60% compared with conventional PCR made from plastic containers and packaging. This expands potential applications to a wide range of indoor and outdoor products, including furniture, home appliance components, and automotive interior materials.
* Test method: Odor level of molded samples was measured after heating at 80 degrees C for 1 hour using a hot-wire semiconductor sensor (in-house testing). Physical properties are representative values and not guaranteed values.
・Reduces greenhouse gas emissions by approximately 61% compared to virgin plastic
Used plastics that cannot be material-recycled have traditionally been incinerated through "thermal recovery," where they are burned mainly for use as fuel and the resulting heat is recovered. Compared with virgin plastics, CirculeX reduces CO2 emissions by up to 6.43 kg per 1 kg (up to 61%).
Calculation method: Calculated across the full lifecycle from raw material procurement through manufacturing and incineration for disposal. Compared against the use of 100% virgin plastics, assuming effectively 100% renewable electricity is used in the manufacturing process at the Yokosuka Circular Factory.
・CirculeX grade lineup
TBM can flexibly propose options tailored to customer needs, including a "High strength + Low odor grade," a "High strength grade," and a "Low odor grade." Mechanical strength and flowability can also be adjusted to suit specific applications.
| Item | High strength + Low odor grade | High strength grade | Low odor grade |
|---|---|---|---|
| Product Features | [Strength and low odor]This high-end grade material combines high strength with low odor. It is ideal as a replacement for virgin plastic or PIR materials where odor generation is a concern indoors and strength is also required.*Strength can be adjusted to suit the application. | [Strength exceeds virgin plastic]Our unique compounding technology overcomes the lack of strength that is an issue with regularly recycled material (PCR materials). It has strength characteristics that exceed those of virgin plastic.*Strength can be adjusted according to the application. | [Reduces odors characteristic of plastic containers and packaging by approximately 60%]Advanced cleaning and treatment processes significantly reduce unpleasant odors caused by food residue, etc., making it possible to use PCR materials in indoor areas where they have previously been avoided due to their odor. |
| Application | ・Furniture and fixtures: chair core material, desk interior ・Home appliances: base plates, backs, internal parts - Automotive interiors: Internal structural materials covered with upholstery materials and carpets | ・Construction: Resin materials Logistics and industry: for heavy items and automated warehouses (returnable) ・Automobiles: suspension parts (mud and stone chip resistant) | Logistics and industry : indoor containers |