7/20/2021

The first mantle film with recycled content: get ready for a sustainable future!

Say hello to our newest product, meant to help sustainable farming forward: the first mantle film with recycled content! The best thing about it: it's made of PCR, post-consumer recycled content.

We've been producing stretch film with PIR, post-industrial recycled content, for quite some time now. PCR was the next logical step. Including PCR in our products is quite revolutionary, as this is what creates circularity. In 2019 we already successfully introduced bale wrap with PCR content. Mantle film (or net replacement film) compresses the bale before wrapping. By adding mantle film with PCR to our product range, we've developed a total solution for a more sustainable way of farming!

 

Reduced carbon footprint by at least 40 percent

The new mantle film contains at 30 percent PCR. The use of recycled content reduces the carbon footprint of the product by at least 25 percent. On top of that, the new product is thinner than a conventional film. By decreasing the thickness from 20µm to 16µm, less material is used on the bale. Combined with the recycled content this results in a total decreased impact on the footprint of at least 40 percent, when calculated per bale, compared with conventional virgin products.

“This makes us quite unique in the market”, Trioworld product manager Anders Larsson says. “We do LCA calculations on our products, which demonstrate there is a lower carbon footprint.” Our life-cycle assessment (LCA) model quantifies the carbon footprint of different types of films, from the moment the raw material (either oil, recycled film or plant material) is extracted, to the moment the finished product  leaves our plant (cradle to gate).

 

Added benefits: efficiency and profitability

A bale wrapped in both PCR mantle film and PCR bale wrap benefits the end user in a number of ways:

  • Handling the bales is more efficient: it's easy to cut through both films in one go as they're both made of the same material.
  • Thinner film means more metres on the reel, and more bales per reel of film. This is efficient and it also reduces the carbon footprint significantly.
  • Increased quality of the silage due to the properties of the film, which benefits the animals and therefore also the product.
  • The bale wrap and the mantle film can be recycled in one go.

As you can see, it creates a more sustainable silage production and a healthy agricultural business. Businesses are then ready for a sustainable future!

 

Step-by-step revolution

Developing mantle film with PCR has certain challenges. Obviously, with virgin components we have a long history and all the data on how to produce a stable quality of raw material. When it comes to PCR, it's a whole new market. You need to find out how to source materials, how to produce them and how to evaluate and develop them. Plus, a lot of the players are new, dealing with new products and applications.

However, we believe this is the only way towards a sustainable way of farming. In 2019 we applied for a patent on our PCR products including mantle film.

It's a step-by-step revolution. After developing a prototype and testing it in our labs, we performed field trials with farmers. Currently, our new mantle film is in a broad evaluation phase, with more farmers and end users doing the final evaluation of the product. This is where we see how it works on different machines, crops, in different climates, so we know for certain it performs without fail.

“When it comes to both performance and silage quality, the results have been positive”, Anders Larsson comments. “The product now completes our sustainable assortment which enables farmers and contractors to wrap bales solely with products based on recycled content.” We plan to launch our new mantle film officially in 2022.