2024-11-28 15:21:00
Grupo Flexível, one of the largest national manufacturers of polyurethane technologies, has just published its first sustainability report, highlighting the development of polyol from renewable sources, which replaces petrochemical material in the polyurethane formulation. The material is already being produced on a large scale by the company.
This type of polyol, which began to be developed by the company in 2023 – is created from fatty esters, or fatty acids of vegetable origin, from seeds and agribusiness waste – without impacting food production. Together with isocyanate, the material makes up polyurethane, replacing petroleum-derived polyol in any formulation.
Quite versatile, polyol from renewable sources can be applied as a component for the manufacture of various types of products, such as rigid and flexible foams, coatings, elastomers, adhesives, sealants, among others. According to studies carried out by external consultants, this type of polyol reduces the emission of greenhouse gases into the atmosphere by up to 90% during its manufacturing process.
“Our forecast is that polyol from renewable sources will represent growth of up to 30% for the company in the national market within the next two years. It is a very adaptable product, and can make up up to 70% of polyurethane formulations, which can be adapted to meet the needs of each customer”, explains Thaize Schmitz, director of Innovation, New Business, Marketing and Sustainability.
Polyol from renewable sources is already used by companies in the footwear sector, where it makes up 64% of the formulation used to manufacture sustainable insoles. This product passed the bio-based material test carried out by the North American laboratory, Beta Analytic, and is more resistant to tears than conventional polyol. “It is a proven sustainable product that maintains characteristics such as impact absorption, comfort and flexibility”, adds Thaize.
Growth above the market
The Flexível Group has recorded significant growth, compared to the current average for the Brazilian chemical sector. According to data from Brazilian Chemical Industry Association (Abiquim) – the national market recorded a 10.1% retraction in production in 2023. To give you an idea, Grupo Flexível recorded, in the same period, a 52.7% growth in production volume, accompanied by a 53% increase in the number of employees, culminating in 29% higher revenue compared to 2022.
And the company’s growth is driven, in part, by the development of new products to meet the needs of customers in the cold chain, footwear, furniture, automotive, civil construction, industrial and sports, one of the main characteristics of the business – and which represented 13% of the company’s revenue last year. To support continuous innovation, Grupo Flexível has been continuously improving its Technological Development Center, located at the company’s headquarters. With a structure of 200 m², and a team of specialists, it is one of the most complete polyurethane technology laboratories in the country.
Decarbonization is also a focus
In addition to investing in innovation and the use of sustainable materials, Grupo Flexível also invests in reducing its carbon footprint, through the expansion of the use of raw materials from renewable sources, decarbonization of its energy matrix and also with the adoption of inputs with less impact on the environment.
The decarbonization process began in 2020, with the implementation of a system of photovoltaic panels that meets part of the energy needs of the operation in the matrix, avoiding the emission of 47.39 tons of CO2 between the years 2022 and 2023. Another point was the replacement, in 2020, of hydrochlorofluorocarbon (HCFC) gas used for foam expansion and banned in the country, with hydrofluorocarbon (HFO) – which does not generate any type of emissions and is not flammable – making it ideal for thermoacoustic applications.
In 2023, the company also reduced the volume of waste destined for landfilling by 55% – from 99.09 tons in 2022 to 44.89 tons last year. One of the actions that generated this result was the reverse logistics generated in the polyol formulation. Previously destined for landfilling, it began to be prepared for a new use as raw material.
Grupo Flexível also works on circular economy projects, promoting the mechanical and chemical recycling of post-consumer polyurethane, preparing the product for reuse.
Sustainability Report
Flexível Group’s first sustainability report marked the establishment of governance for the Sustainability area. The company now has an internal Sustainability Committee, as well as a corporate governance structure that places objectives related to environmental, social and governance (ESG) practices on the company’s strategic map.
The preparation of the document involved public consultations with various stakeholders, including suppliers, customers, employees and also the community established around the company, whose headquarters are in Jaraguá do Sul, Santa Catarina.
The document was based on the GRI – Global Reporting Initiative guidelines, and covers the years 2022 and 2023. The full report can be accessed at the following address:
1732808205
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How does Grupo Flexível’s commitment to sustainability translate into tangible benefits for its customers, beyond just environmental impact?
I’d like to welcome Thaize Schmitz, Director of Innovation and Sustainability at Grupo Flexível, to discuss the company’s recent strides in sustainable polyurethane development and their impressive growth.
Thaize, thank you for joining us. Could you tell us more about this new bio-based polyol and its potential impact on the industry?
**Thaize Schmitz:**
Thank you for having me. It’s exciting to share this news. We’ve developed a polyol derived from renewable sources like vegetable fatty acids and agribusiness waste. This replaces traditional petrochemical-based polyol, significantly reducing the carbon footprint of polyurethane production. Current studies show up to a 90% reduction in greenhouse gas emissions during the manufacturing process.
**Interviewer:**
That’s remarkable! What kind of products can incorporate this new polyol?
**Thaize Schmitz:**
The versatility of this polyol is one of its biggest strengths. It’s already being used in various applications, including rigid and flexible foams, coatings, elastomers, adhesives, and sealants. For example, it’s currently used to create sustainable insoles for footwear, replacing up to 64% of the conventional polyol in the formulation while still maintaining durability and comfort.
**Interviewer:**
Grupo Flexível has experienced impressive growth in a challenging economic climate. How has this new sustainability focus contributed to your success?
**Thaize Schmitz:**
While the Brazilian chemical industry experienced a downturn in 2023, Grupo Flexível actually saw a 52.7% jump in production volume and hired 53% more employees. We believe this growth is directly linked to our dedication to innovation and sustainability. Customers are increasingly seeking eco-friendly solutions, and our bio-based polyol allows them to reduce their environmental impact without compromising on product performance.
**Interviewer:**
Grupo Flexível is clearly taking its commitment to sustainability seriously. What are some other initiatives you have in place?
**Thaize Schmitz:**
Absolutely. Alongside the development of renewable materials, we’re actively working on decarbonizing our energy matrix. We’ve implemented a system of photovoltaic panels, which helps meet our energy needs while reducing our CO2 emissions. Additionally, we’ve switched to hydrofluorocarbon (HFO) gas for foam expansion, a much more environmentally friendly alternative.
**Interviewer:**
Thaize, thank you so much for giving us insight into Grupo Flexível’s groundbreaking work. Your dedication to innovation and sustainability is clearly paving the way for a more responsible future in the polyurethane industry.
