Sika has established itself as a leader in macrofiber extrusion with its latest generation of production lines, setting new benchmarks in energy efficiency. Over the years, systematic improvements have significantly reduced energy consumption per kilogram of fiber produced. This achievement is driven by the implementation of innovative energy-saving measures, including: enhanced insulation and efficient drive systems in new extrusion lines, advanced chilled water management integrating free-cooling and chiller technology These advancements not only reduce energy consumption but also contribute to a more sustainable production process, aligning with global sustainability goals.
The Role of Concrete Fibers in Sustainable Construction
Concrete fibers play a critical role in modern construction by reinforcing concrete and replacing traditional reinforcement methods like non-structural rebar and welded-wire mesh. The benefits include:
- Reduction or elimination of saw-cut joints, minimizing stress and shrinkage cracks
- Prevention of rusting issues associated with rebar and welded-wire mesh
- Lower embodied carbon footprint compared to steel-based reinforcement, significantly reducing the environmental impact
Achieving Zero Waste with a Closed-Loop System
In this context, Sika Peru is committed to minimizing waste through an innovative closed-loop material handling system, ensuring that over 90% of production scrap is collected and reprocessed externally. Key initiatives include:
- Implementation of internal regrind processing by 2025
- Integration of external post-industrial recycled (PIR) and post-consumer recycled (PCR) materials into the material feeding unit
This approach significantly reduces waste, optimizing raw material efficiency and driving the company closer to achieving zero-waste production.
Sustainability in Macrofiber Production
Sika Peru's macrofiber production is setting new industry standards for sustainability by focusing on:
- Scope 1 & 2: Adoption of state-of-the-art production equipment for energy-efficient operations
- Scope 3: Maximized raw material efficiency through reprocessing of internal production and cut-off waste
- Sustainable Packaging: Introduction of award-winning water-soluble paper bags, ensuring zero waste at construction sites
The Human Factor in Sustainable Innovation
The success of this sustainable macrofiber production reflects a collaborative approach with contributions from:
- Highly motivated specialists in operations, R&D, and quality control
- Strong local development and troubleshooting capabilities
- Effective guidance from global support teams, leading to prompt implementation of best practices
Looking ahead, Sika is set to expand its capabilities with new products, increased production capacity, and continuous innovation, reinforcing its commitment to energy optimization and sustainability in fiber production.
Through a combination of cutting-edge technology, waste reduction strategies, and a committed team, Sika is leading the charge in sustainable macrofiber production. By optimizing energy use, implementing closed-loop recycling, and continuously improving manufacturing efficiency, the company is paving the way for a greener and more resource-efficient future.