Increased Recycled Content In SOPRA-XPS

Generally, the construction industry is exerting more and more pressure on the environment due to the consumption of raw materials, commonly known as natural resources, and the waste of residual materials throughout the lifecycle of construction products. 

Through its SOPRALOOP initiative, SOPREMA is addressing the problem at its source by focusing on the potential provided by recycled materials. The evolution of the SOPRA-XPS line paves the way for a whole new generation of products that have been rethought in terms of both their sourcing and their end-of-life cycle. The use of recycled materials is a way to lessen the environmental footprint of construction products while reducing our dependence on fossil-based materials.

Learn how SOPREMA is implementing this form of waste reduction at source, the best approach to follow to comply with the 4R principle, which encompasses reducing at source, reusing, recycling and recovering.

Five Questions and Answers on Recycled Content

1. First of all, what does “recycled content” or “recycled material content” mean?

These are generally materials transformed so as to be reintroduced into a production cycle for the manufacture of new products. Normally, this approach prevents these materials from being sent to landfills or from being used in other more polluting recovery purposes.

2. Did you know that No. 6 plastic is recyclable?

Styrofoam cups, plates, bowls, vegetable or meat trays, and protective packaging for food, electronics and household appliances, etc. – those are some examples of polystyrene objects that are recyclable, and since they belong to the No. 6 plastic family, they represent most of the recycled polystyrene in SOPRA-XPS.

• The coveted polystyrene (PS) materials come mainly from food or protective packaging and containers made of extruded (XPS) or expanded (EPS) polystyrene. The fact that the material might be contaminated with food residues is not a problem. 

Due to consumer lack of awareness and since most recycling facilities still don’t collect them, polystyrene materials, although recyclable, tend to end up in the trash.

As a reference, between 2012 and 2016, the recycling rate of polystyrene (PS) containers and packaging from the residential sector in Québec was 21.2% ^[1]. Statistics published in 2016 show that only 18% of Quebecers would have access to a rigid polystyrene recycling service through selective collection, compared to 70% across Canada ^[2].

3.      How does SOPREMA manage to recycle polystyrene?

SOPREMA works with companies seeking to recycle polystyrene. From the arrival of recycled polystyrene at the production of insulation boards, here is an overview of the main stages of the process related to the manufacturing of SOPRA-XPS products:

Arrival of the Recyclable Polystyrene

The recyclable materials arrive at the plant in their original form, whether in bales or densified. Densified polystyrene is generally in the form of blocks, coils or ingots, which makes it easier to transport. 

Polystyrene Processing

These materials are then crushed and transformed into small plastic balls through our production line dedicated to polystyrene recycling. This is the plastic ball extrusion process. 

Insulation Board Production

The recycled plastic balls (in solid form) are mixed and heated with additives. Blowing agents are then added to the mixture in liquid form. The mixture is finally cooled and processed according to the dimensions and characteristics of the product. This is the insulation board extrusion process.

Residual Material Recovery from Production

Non-compliant products or even scraps generated during the cutting of insulation boards are systematically recovered, i.e. reintroduced into the manufacturing process to avoid waste.  

4. Did you know that the XPS plant in Sherbrooke (QC) is committed to eco-efficient production?

With a focus on internal eco-efficiency, the plant’s production process is designed to reduce material losses at all stages of the manufacturing process. More specifically, the plant can recover (reintroduce) non-conforming products and polystyrene residues by integrating these materials into the production cycle several times.

5. Did you know that SOPRA-XPS products are recyclable at the end of their useful life?

Residual materials generated on construction sites as well as products reaching the end of their useful life are recyclable. The SOPRA-XPS products now bear the No. 6 plastic classification symbol to promote their recycling. While the plant often recycles end-of-life polystyrene insulation, it is important to note that SOPREMA Canada does not currently offer a collection and recycling program for its end-of-life SOPRA-XPS products.

Recycled Content in SOPRA-XPS Products

Recycled and Recovered Content in SOPRA-XPS Products Since 2020, SOPREMA teams have been working to increase the recycled content rate in the SOPRA-XPS line. Recycled content rates are shown with and without recovery rates*.

• Recycled content validated by an independent third party ^[3]: Representing an increase of 29%, the average recycled content rate was 30% in 2020, rising to 59% in 2024.

• Recycled content including recovery: The rate of recycled content including recovery was 67% in 2020, rising to 78% in 2024, representing an increase of 11%.

The post-consumer and pre-consumer recycled content rates are validated annually by an independent third party in accordance with ISO 14020/21 standards for the products concerned. Being self-reported by SOPREMA on a voluntary basis, recovered (reintroduced) content rates have not been subject to external validation.

ISO 14020/21 and ISO 7000-1135 Standards Explained

A validated recycled content means that the manufacturer’s declaration has been verified by an independent third party in compliance with the requirements of ISO 14020/21 and ISO 7000-1135. In environmental communication, the rules put forward by these standards are recognized internationally. The results appear in a Recycled Content Certification which remains valid for a period of 12 months after its release.

These standards indicate the general principles and rules to be followed for the environmental labelling and declaration (Type II environmental labelling) of a product. This means that data and information relating to the purchase and integration of post-consumer and pre-consumer recycled materials into products has been verified. This also includes the control of formulas and suppliers. 

Explanation of the Validated Recycled Content Rates Vs. the Self-Reported Recovered Content Rates

To clarify the terminology, recycled content rates correspond to pre-consumer and post-consumer recycled material values validated by an independent third party. The recovered content rate corresponds to recovered (reintroduced) materials self-reported by SOPREMA.

• Pre-consumer: This refers to materials diverted from the waste stream during the manufacturing process. It excludes the reuse of materials, such as those resulting from reprocessing and regrinding or residues generated during a process; materials that can be recovered in the same process that generated them.

• Post-consumer: This refers to materials generated by households or commercial, industrial or institutional facilities in their role as an end user of the product, and which can no longer be used for the application for which they were designed. This includes material returns from the distribution chain.

• Recovery: This is the action of reintroducing or recovering products or residual materials generated by the products or the same manufacturing process to obtain new materials and avoid their elimination (i.e. landfill or incineration).

Depending on the requirements of ISO 14020/21 and ISO 7000-1135 standards, the method for calculating the recycled content and the certification sheet cannot include the recovery portion. Since nonconforming products and residues from the SOPRA-XPS production line originate from the same process, it is impossible to account for the portion of materials recovered (reintroduced) during product manufacture. 

For the sake of transparency, SOPREMA presents the portion of verified recycled content (according to ISO standards) separately, compared to the declared content which includes the portion of recovered materials (reintroduced) during product manufacturing. Following this same logic, the content including recovery is therefore verified separately but is not presented in the Recycled Content Certification.

Contribution to LEED Certification

The Recycled Content Certification contributes to SOPREMA’s efforts to support projects aiming for LEED™ certification. More specifically, the products covered by the Recycled Content Certification can contribute to the score and the calculation to obtain the following credits:

•  Materials and Resources (MR): Building Product Disclosure and Optimization – Sourcing of Raw Materials (1 to 2 points).

  o Recycled content validated by an independent third party in accordance with the requirements of ISO 14020/21 standards.

  o   Post-consumer = value of 0.5 

  o   Pre-consumer = value of 1.0 

About SOPRA-XPS

SOPRA-XPS is a line of extruded polystyrene insulating boards made of closed-cell foam. They are used as thermal insulation for a multitude of applications, including walls, foundations, and inverted roofs. They are also used in the civil engineering sector (under roads, airstrips, etc.).

References

[1] Recyc-Québec et Éco Entreprises Québec [ÉEQ] (2017). Caractérisation des matières résiduelles du secteur résidentiel – Résultats 2012-2016 (Characterization of residual materials in the residential sector – 2012–2016 results).

[2] Recyc-Québec (2016). Guide technique sur la mise en valeur du polystyrène postconsommation (Technical guide on the valorization of post-consumer polystyrene). 

[3] AGÉCO. (2024). Recycled content certificate: SOPRA-XPS.

Previous References:

CT Consultant. (2020). Recycled content certificate: SOPRA-XPS.

CT Consultant. (2021). Recycled content certificate: SOPRA-XPS. CT Consultant. (2022). Recycled content certificate: SOPRA-XPS.

AGÉCO. (2023). Recycled content certificate: SOPRA-XPS.