The UK-based plastic recycling company Itero is scaling up its circular solutions in the Netherlands. In the Dutch chemicals ecosystem, Itero is developing a state-of-the-art demonstration facility that converts hard-to-recycle plastic waste. Bringing a more sustainable world a step closer by.
Itero works at the forefront of sustainable circular solutions. Most of the world’s mixed plastic waste finds its way into landfill, incinerators, or our environment. But Itero’s pyrolysis technology can convert such waste into recycled waxes and pyrolysis oils, which are then used to create virgin-quality recycled plastic – reducing the demand to extract oil. CTO Geoff Smith, from chemical recycling pioneers Itero, explains his secret to success – from starting up in the UK to scaling up in the Netherlands.
As Geoff explains, “We focus on plastic waste that can’t be processed by current recycling methods. And by maximizing the circularity of our process, we offset the virgin oil used to produce new plastics. Effectively, we close the loop for plastics.”
The business has been running its West London pilot plant since 2020. But expansion plans are now focused on a 27,000 tonnes/year capacity demonstration plant taking shape at Brightlands Chemelot Campus in Limburg, the Netherlands.
A scientific process that works
A chartered Chemical Engineer, Geoff has overseen Itero’s engineering function for nearly six years now. “Before I joined Itero I was a Research Scientist at the National Physical Laboratory, which sets the physical standards for British industry. It also shaped my passion for testing and iteration – which then inspired the rebrand of our business in 2020.
“The rebrand was part of a new strategic direction we took when our CEO, Simon Hansford, came on board. Everyone on the senior team believed iteration was the key to constant improvement. We also felt it would naturally help people properly pronounce ‘Itero’!”
The business is fulfilling its mantra. In the London Pilot Plant, an iterative approach not only puts their technology through its paces, but purposefully pushes beyond its operating limits. “By making problems for ourselves”, Geoff continues, “we can fully grasp the technology’s limits, understand what to troubleshoot, and where to design out problems.”
Iteration that sparks true progression
Geoff expands further: “It’s a constant, circular process. Sure, you can solely try and make your technology work as well as possible. But we want to look past best-case scenarios, test its limits – and see how different parameters affect those limits.
“A great example is the inlet transition to our pyrolysis reactor – effectively a pipe. Initially, it seemed obvious we should cool it in some way, so that plastic waste would only melt once it entered the reactor. Yet because we tested the system and looked for failure modes – to understand where cooling would be needed – we learnt it was superfluous for many feedstock types and throughputs. In fact, cooling could even cause problems.
“Even then, we didn’t pat ourselves on the back and move on. We kept on testing and iterating, and found certain feedstocks do require cooling. The result? We’ve deepened our understanding of the system, and are better prepared for the next step in our journey.”
Itero putting everything into practice in Brightlands, Netherlands
Excitingly, this learning is driving the design of Itero’s new demonstration plant at Brightlands Chemelot Campus. The science park, described as the home of ‘Tomorrow’s Chemistry & Materials’, is Europe’s first Circular Hub, specializing in circular materials, sustainable processes, and biomedical solutions for a more sustainable world.
Over 100 companies and institutes are already based there – a community of 3,000 professionals and 1,200 students. And together, they’ve delivered innovations and products ranging from fully recyclable drinks and food packaging to lignin that can be used to fuel ships, to COVID-19 vaccines, cell culture and patient specific implants.
A new home built on collaboration
As well as the obvious benefits of running a larger operation at the demonstration plant, Itero’s expansion to the Netherlands will open doors to leading talent, knowledge, infrastructure and entrepreneurship. Not to mention the country’s famous opportunities to develop unique connections across the business community, knowledge institutions and government.
Itero’s new Limburg home will be the perfect breeding ground for their materials science and innovation activities. “It will connect the work we do at our West London Plant to the bigger picture and help us achieve our long-term ambitions”, Geoff surmises. “Really, it’s a new start. One we’ll test and iterate as we go – and prepare our technology and people for even faster and more ambitious growth.”
