When manufacturers and converters look for ways to reduce CO₂ emissions, they often focus on using fully or partially bio-based materials, incorporating recycled content, improving energy efficiency, optimising processes, or streamlining logistics. These are all valid and effective strategies for lowering the carbon footprint of an application, but they are not the only options.
What is often overlooked is that the polymer base itself can account for up to 80% of a thermoplastic compound’s total CO₂ emissions. By taking a closer look at the polymers suitable for your specific part and technical application, you may discover that switching to a lower-impact compound can significantly enhance your sustainability efforts and goals.
Material substitution for lower-impact alternatives
Compounds are incredibly versatile, which makes material substitution both practical and efficient. In many cases, it’s possible to switch to an alternative compound without sacrificing key performance characteristics such as strength, flexibility, flame resistance, or processability. Often, these lower-impact alternatives incorporate recycled content, bio-based materials, or more carbon-efficient polymers.
This last one is precisely the point we want to emphasise here.
If you are not actively reviewing the thermoplastics compound or better the polymer base of the compound your application is made of, you might be missing a clear opportunity to:
- Lower your product’s environmental footprint
- Improve recyclability or circular potential
- Meet growing customer and regulatory demands
- Strengthen your sustainability strategy without compromising performance
The good news is, these changes can often be implemented within your existing tool designs and production processes.
Smart compound selection
Revisiting your compound choices does not always require a full redesign, just a fresh perspective. With the right partner and data, you can identify smarter materials that help reduce CO₂ while continuing to deliver on technical and commercial goals.
 
|
“Optimising compound selection is just one piece of the puzzle in being truly sustainable. Along with the shift towards recycled and biobased content, making the right material choices helps to significantly lower overall environmental impact,” says Giacomo Sciarra, Sales and Product Manager at IMCD Advanced Materials. |
Every product and application comes with its own technical requirements, and not all compounds will meet these needs while reducing environmental impact. Our team is here to guide you through these considerations. We specialise in two key strategies:
1. Compound substitution: By identifying polymers with a lower environmental impact suitable for your application and its technical requirements.
Carbon footprint of polymers
2. Metal to polymer replacement: By replacing metal components with high-performance polymers to not only lower CO₂ emissions but also reduce weight.
Material substitution in action
It’s a matter of comparison: a certain compound can be the right solution, but you need to evaluate and compare the options. This mindset applies across all market segments. In the following, two examples illustrate how this way of thinking can be applied wherever converters are active.
Polymer upgrade
A European automotive parts manufacturer replaced a conventional polymer with a polyketone compound for the production of cooling valves in a thermal management application. This switch cut the carbon footprint by approximately 30%, while maintaining high mechanical properties, chemical strength and excellent weld line. The change was implemented without modifying existing production lines, demonstrating how material substitution can yield sustainability gains.
Metal replacement
An automotive manufacturer successfully redesigned a carrying arm by replacing the traditional aluminium die-cast metal with a high-performance compound, achieving a 31% weight reduction and cutting the CO₂ footprint to just one-eighth of the original (- 87% CO₂eq/part). The new part incorporated 30% recycled carbon fibre, combining lighter weight with improved strength, demonstrating how material substitution can drive both sustainability and performance gains.
"Sustainability begins at the molecular level, the right compound choice can transform your product’s environmental impact," Giacomo concludes.
How can we support you?
Optimising your polymer selection is a practical and effective way to lower CO₂ emissions. Whether switching to lower-impact polymers or replacing metals with advanced compounds, you can enhance sustainability without compromising quality.
Comparison is key
Let’s collaborate to find solutions tailored to your technical requirements and sustainability ambitions. Contact our team today to take the next step toward a greener future.