Schneider Electric, recognized as the leading sustainable company globally and a pioneer in the digital transformation of energy management and automation, has teamed up with GR3N, a specialist in Polyethylene Terephthalate (PET) chemical recycling. Together, they are developing the first open automation system tailored for the advanced plastic recycling sector.
With 50% of global plastic waste being disposed of in landfills and only 9% being recycled, GR3N has introduced MADE, a Microwave Assisted DEpolymerization solution. This innovative process decomposes PET into its chemical building blocks, which can then be reconstituted into new PET pellets of virgin-like quality suitable for packaging and textiles, effectively addressing the challenge of recycling hard-to-process plastics. The technology leverages alkaline hydrolysis and is capable of handling a greater volume of impurities than current methods.
In March 2024, GR3N showcased MADE alongside Schneider Electric’s open automation technology, EcoStruxure Automation Expert, at its demonstration site in Italy. The MADE plant is designed to utilize all technologies that will ultimately be implemented in the first industrial-scale facility, anticipated to be established in Spain with a processing capacity exceeding 40,000 tons per year of PET waste. GR3N’s modular recycling process has enabled MADE to become the first plastic recycling facility to employ a shared automation runtime governed by Universal Automation, compliant with the IEC 61499 standard.
This software-defined automation system separates hardware from software, permitting devices and equipment to connect seamlessly across various architecture layers, irrespective of the manufacturer. It serves as the digital backbone of operations at the plant, allowing for more informed decision-making. This framework positions MADE as a technological showcase for a new wave of automation systems, where the integration of operational technology (OT) and information technology (IT) unlocks enhanced functionalities for operational management and data analysis.
Fabio Silvestri, GR3N’s Head of Marketing and Business Development, stated, “Our software-defined automation and hardware independence have allowed us to mitigate operational risks and expand our technological capabilities. We can quickly adjust our systems to enhance efficiency while circumventing supply chain challenges due to the system's hardware-agnostic design. This approach is essential for scaling advanced plastic recycling.”
Thanks to the modular and agnostic nature of EcoStruxure Automation Expert, GR3N could select the best technology for the demonstration plant and easily expand to new locations. Key benefits include:
Industrial Scalability: This minimizes investment risks during the scale-up of GR3N's technology for the First of a Kind (FOAK) industrial facility while providing a novel way to safeguard intellectual property as a process licensor. Design Flexibility: The vendor-agnostic system enables GR3N to develop the optimal solution without the constraints of vendor lock-in or supply chain disruptions. Reduced Engineering Time and Time-to-Market: The modular design of the control software, supported by digital continuity throughout the plant's lifecycle, reduces human error during development by 40%. Simplified Control: Independence from specific vendors allows for controls to be either distributed or centralized based on requirements. New Opportunities: Integrating OT and IT opens new avenues for efficiency and optimization across the value chain through advanced data analytics. Cost Reduction: The software-defined automation approach is projected to decrease engineering expenses by 30%. Attracting Next-Gen Workforce: The system's similarities to IT environments appeal to the new generation of workers. With 50% of global plastic waste being disposed of in landfills and only 9% being recycled, GR3N has introduced MADE, a Microwave Assisted DEpolymerization solution. This innovative process decomposes PET into its chemical building blocks, which can then be reconstituted into new PET pellets of virgin-like quality suitable for packaging and textiles, effectively addressing the challenge of recycling hard-to-process plastics. The technology leverages alkaline hydrolysis and is capable of handling a greater volume of impurities than current methods.
In March 2024, GR3N showcased MADE alongside Schneider Electric’s open automation technology, EcoStruxure Automation Expert, at its demonstration site in Italy. The MADE plant is designed to utilize all technologies that will ultimately be implemented in the first industrial-scale facility, anticipated to be established in Spain with a processing capacity exceeding 40,000 tons per year of PET waste. GR3N’s modular recycling process has enabled MADE to become the first plastic recycling facility to employ a shared automation runtime governed by Universal Automation, compliant with the IEC 61499 standard.
This software-defined automation system separates hardware from software, permitting devices and equipment to connect seamlessly across various architecture layers, irrespective of the manufacturer. It serves as the digital backbone of operations at the plant, allowing for more informed decision-making. This framework positions MADE as a technological showcase for a new wave of automation systems, where the integration of operational technology (OT) and information technology (IT) unlocks enhanced functionalities for operational management and data analysis.
Fabio Silvestri, GR3N’s Head of Marketing and Business Development, stated, “Our software-defined automation and hardware independence have allowed us to mitigate operational risks and expand our technological capabilities. We can quickly adjust our systems to enhance efficiency while circumventing supply chain challenges due to the system's hardware-agnostic design. This approach is essential for scaling advanced plastic recycling.”
Thanks to the modular and agnostic nature of EcoStruxure Automation Expert, GR3N could select the best technology for the demonstration plant and easily expand to new locations. Key benefits include:
As global plastic demand is expected to triple by 2060, with ocean plastic projected to surpass fish populations, addressing this demand while minimizing pollution and achieving net-zero emissions by 2050 necessitates a fundamental shift in consumption models.
The collaboration between GR3N and Schneider Electric, formalized through a Memorandum of Understanding, aims to enable the chemical recycler to rapidly and cost-effectively expand operations to new sites. The solution is on track to reach industrial scale by 2027, with plans for a 35-40kt plant that will encompass pre-treatment, depolymerization, and repolymerization processes.
Christophe de Maistre, President of Energy & Chemicals for Industrial Automation at Schneider Electric, remarked, “Approximately 460 million tons of plastic are produced annually, with about 70% ending up in landfills or poorly managed. To effectively tackle plastic waste at scale, integration across the entire product lifecycle, modularization for optimizing engineering processes, and software-defined automation solutions for scalability and advanced analytics are essential. This project with GR3N exemplifies these principles, enhancing flexibility, scalability, and efficiency, enabling growth to an industrial scale.”