“Where others see challenges, we see opportunities,” says Hoang Minh Nguyen, Material and Innovation Manager for Plastics and Metals at IKEA.

The National Center for Sustainable Plastics at RISE unites industry, academia, institutes, and trade organizations with the aim of collectively achieving freedom from fossil-based plastics and strengthening the market position of the Swedish plastics industry. With 460 stores worldwide, IKEA is a player capable of significantly reducing global use of fossil-based plastics. Now, the furniture and homeware giant is joining the center.

“Reducing greenhouse gas emissions, and mitigating climate change are commitments shared by many. At IKEA, these goals are a top priority. If we are to limit global warming, it is extremely important to embrace a collective approach, involving both industrial players, institutes like RISE, and the academy. Plastics is an area in which we need to place a substantial amount of our efforts,” says Hoang Minh Nguyen.

He explains that the center has been eagerly awaited.

“Finally, we have a common platform in Sweden where we can collectively address shared challenges across industries. A key advantage is the all-in-one deal. We gain access to different technologies, material development, and a big network of organisations all working with the same issues. We've already cultivated a strong relationship with RISE and are actively collaborating on a portfolio of possible solutions in the plastics field. Hopefully, we’ll soon get to expand this collaboration to include other partners within the center.”

Plastic waste: an enabler

The pursuit of sustainable solutions to replace fossil-based plastics has been a longstanding topic on IKEA’s agenda. They are currently exploring both recycled and biobased sources, as well as the future potential of carbon capture sources.

“To reduce our overall plastic consumption, we have decided to phase out our single-use plastics. Additionally, we've incorporated recycled plastics into our product range. But recycled plastics come with certain limitations. They may not always be suitable for food or children’s products, or items requiring transparency. Hence, we need to seek out new solutions for these cases, with biobased options appearing the most promising. The challenge extends to composite plastics, which are typically difficult to recycle. Nonetheless, plastic waste also presents significant opportunities. Currently, only 9 percent of plastic waste is recycled; doubling this figure could have a tremendous impact. We want to be part of that journey,” says Hoang Minh Nguyen.

Strength in numbers

He is optimistic that the center will effectively address and generate viable solutions to these challenges.

“I believe we've reached a point where large-scale collaboration is essential, focusing on specific pathways and decisions for the future. My hope is that the center will yield several solutions in the fields of mechanical recycling and material development that we can pursue together with the industry. Creating synergies is crucial, as tackling these issues alone is beyond the capacity of any single party. Hopefully we can also jointly monitor and influence policy makers, so that they to a greater extent support the transition into sustainable plastics. IKEA’s primary focus areas are developing products with durability, circularity, and a minimal residual footprint at the end of their life cycle. I hope that these three themes will form a shared agenda for the center.”

In front of Wallenstams's headquarters in Stockholm stands the artwork "Two ants," created by the artist Torgny Larsson. When the real estate company - whose signature is a logo featuring an ant - wanted to create a smaller version of the artwork to place at a new property project, RISE was commissioned to cast the ants for the new sculpture.

"Since it is an artwork, aesthetics took precedence, but it was also important from a casting perspective to ensure the sculpture's durability and stability," says Andreas Lindberg Pruth, Research Technician at RISE.

In June 2024, the new six-meter-high artwork was installed outside of Mölnlycke Fabriker. The inauguration marked the end of a project where several experts from different fields collaborated. RISE's experience in sustainable casting became a central factor:

"Since the ants were cast in multiple parts, one challenge was designing the molds. The placement of the pouring and venting holes had to ensure that the metal flowed properly and filled the mold as well as possible. Additionally, the holes had to be positioned so that the artwork would look good after welding and painting. We examine every detail meticulously and have developed a special expertise in this over the years," says Andreas Lindberg Pruth.

Cast with recycled aluminium

The original sculpture consists of two ants cast in bronze, carrying two twelve-meter-high pine needles. The new artwork, which is half the size, is made from recycled aluminum for sustainability and cost reasons.

"The ants' bodies are solidly cast, which is a challenge to do in aluminum. It's crucial to maintain the correct casting temperature based on the size and ensure that the aluminum flows properly to avoid defects. We only had one attempt per mold, so we had to be on our toes during casting to save both time and money. We have extensive experience working with aluminum and are comfortable with the material, so everything went smoothly," says Jörgen Jernkrook, Research Technician at RISE.

At the testbed for cast materials and processes in Jönköping, Jörgen, Andreas, and their colleagues work on both research projects and assignments focused on the foundry industry.

"We specialize in cast metals and possess broad knowledge and expertise in multiple materials. Operating our fully equipped foundry, there's virtually no challenge in casting technology that we cannot tackle. Additionally, we support our clients in optimizing their casting processes, from initial designs to practical casting," explains Andreas Lindberg Pruth.

Helps the industry become more sustainable

The choice of recycled aluminum was important from a sustainability perspective.

"In this project, both we and the customer thought a lot about sustainability. It's a consideration we carry with us in everything we do, whether it's saving materials or casting as energy-efficiently as possible."

The work on the artwork lasted for just over eight months. There may be a possibility of creating more ants as Wallenstam could potentially use the sculpture as a signature in other property projects in the future.

"We are very happy and proud of how it turned out. We have worked on advanced projects before, but they are often early in a company's development process and subject to confidentiality agreements. Therefore, it's especially exciting that the ants will be exhibited and that people will see our work," says Jörgen Jernkrook.

And at Wallenstam, they are pleased with the result:

"We needed the best expertise to test, develop, and produce the ants in the right size, material, and appearance. We chose RISE, and they have solved this in an absolutely fantastic way with impressive dedication and knowledge," says Ulf Ek.

PFAS, or ‘perpetual chemicals’, can be found in a wide range of products, including waxes used on cross-country skis to improve glide, textile impregnation to resist water and dirt, bicycle oil to provide low friction, muffin tins, electronic products and frying pans.  

In 2023, Sweden, along with four other European countries, proposed a ban on the entire group of PFASs in the EU. This was based on studies which showed that PFASs cannot be broken down and can be linked to negative health effects. The issue of perpetual chemicals is also being discussed outside Europe, including in the United States.

"A lot is happening on the regulatory front right now. The broader EU proposal to regulate PFAS broadly and as a group aims to remove these substances from as many uses as possible. As a result of this development, more and more companies are becoming interested in finding out whether PFASs are present in their products, why and whether they are really needed." This is according to Lisa Skedung, researcher at RISE and project manager for POPFREE, a series of innovation projects promoting PFAS-free alternatives.

Two new analytical methods

PFAS is a large group of chemicals that includes over 10,000 industrially produced substances. It is not uncommon for these persistent chemicals to be added somewhere along a long value chain, without the knowledge of the companies placing the product on the European market. Testing for the presence of PFAS in products is therefore important. Traditional PFAS analysis can identify a number of specific substances, but it does not capture all of them, including what are known as polymeric PFAS.

"We realised that new analytical methods are needed to screen PFASs broadly and to capture polymeric PFASs that are often used to provide a function in products. "The usual analytical methods are great for finding the PFAS substances that are regulated today, but they don't catch the polymers," clarifies Lisa Skedung.

New methods catch hard-to-detect PFAS substances

A number of different methods were tested, and in the end the POPFREE team came up with two. These new methods will help companies find PFAS substances that were previously difficult to detect. The first analytical method provides the total fluorine content, which can be compared to the limit in the EU proposal.

The second method allows us to verify that there are indeed PFAS in the sample. On occasion, the first analysis shows a high concentration of total fluorine, but the verification method shows that it is inorganic fluorine that is not PFAS.

"Does not fit well with sustainability" 

It is crucial for the company that commissioned the assignment to understand what RISE has done and what the analyses show. This enables them to use the data internally and in communication with suppliers. If the analyses show that a particular product contains PFAS substances, RISE can guide the company further, for example to projects where PFAS-free alternatives are tested. RISE can also provide guidance prior to the analysis on which components in a product should be tested.  

"Many companies are seeking to anticipate the stricter legislation. This is because selling products that contain PFAS is not consistent with a sustainability profile. Companies that wait until the regulation comes into force to look for alternatives may encounter difficulties, as it may take time to replace the PFAS substances in products," says Lisa Skedung.