Special Feature

Special Feature

Ecocalmulch

We have made mechanical recycling of agricultural plastics a reality, although it had been considered difficult. This reduces the environmental impact, compared with thermal energy recovery. Effective use of plastic resources has begun on farmland.

With regard to agricultural and horticultural plastics in Japan, mechanical recycling of PVC products is increasingly becoming commonplace. This means that waste is recycled as raw materials for products. Meanwhile, most polyolefin products are discarded after use or sent for thermal energy recovery, where heat generated from incineration is collected and used.
In recent years, there have been growing demand for mechanical recycling, instead of thermal energy recovery, to use resources effectively. Under such circumstances, Okura Industrial Group worked with Sojitz Pla-Net Corporation to consider mechanical recycling of polyolefin agricultural and horticultural materials, looking to recycle them as raw materials for products. Having found the potential, we decided to use the polyolefin materials for agricultural multi-film. Our Ecocalmulch is made from used agricultural film, which is collected from farmers, cleaned to the level fit for mechanical recycling, and turned into recycled raw materials. Recycled plastics collected from farmers account for 25% or more of all plastics contained in the product. While mechanical recycling generally degrades physical properties of and have other negative impacts on products, Ecocalmulch shows performance equivalent to that of our conventional products. We have received positive feedback from users.
By turning farming waste into recycled raw materials and making it possible to use them as agricultural materials, we took the first step toward a circular economy. The Group will continue to develop and offer products that contribute to plastic resource recycling.

Trademark registration number JP6416460

The Eco Mark is a Type I environmental label given by the Japan Environment Association. The mark certifies products that have small environmental impacts throughout the life cycle, from production to disposal, and are regarded as helpful for environmental conservation. Ecocalmulch has acquired the Eco Mark for category No. 118, Plastic Products.

Behind the Development of Ecocalmulch

Developed in 2021, Ecocalmulch is a multi-film made from agricultural and horticultural plastics, mechanical recycling of which had been considered difficult.
Challenges we faced were different from those in the recycling of film waste generated in our manufacturing process, which we had been working on. The product is made from agricultural and horticultural plastics used in the market, and those plastics are made of different types of resin and have different levels of dirt on them. In addition, we needed to remove soil, sand, and other kinds of dirt that cannot be supplied to manufacturing facilities. We therefore started from considering the use of used agricultural and horticultural plastics with relatively little dirt on, which are being thermal energy recovery across Japan from Hokkaido to Kyushu. Simultaneously, we conducted research on a manufacturing method that can constantly remove dirt.
As we proceeded with the development, unexpected issues came up, such as resins other than polyethylene contained in the agricultural and horticultural plastics with relatively little dirt on. This made it necessary to not only explore the manufacturing method but also to separate and manage polyethylene, which we were trying to recycle, in used agricultural and horticultural plastics.
In addition, the quality of agricultural and horticultural plastics used in the market affects the quality of multi-film produced from them. We addressed this issue by establishing an inspection method.
To expand the range of recycling, we are now considering in the Company recycling agricultural and horticultural plastics with large amounts of dirt on. We will proceed with the consideration so that we will be able to contribute to resource recycling.
(September 21, 2022)*

*Affiliation and position are as of the publication date.

Section Chief, Environment and Energy Development Department, Research & Development Center Kenzo Takebayashi

Endo barrier™

The patient stays in a box, and the inserted continuous suction tube forms a negative pressure. This virus infection prevention system for endoscopy prevents droplets from spreading in the examination room and makes endoscopy safer.

Many endoscopic examinations of the digestive tract have been cancelled or postponed due to COVID-19, resulting in lost opportunities for early detection and treatment of cancer and other diseases. To protect not only healthcare workers but also the health of patients, we have commercialized Endo barrier™, a virus infection prevention system for endoscopy. The system was developed jointly with National University Corporation Kagawa University, which came up with a method to block the spread of aerosols emitted from patients.
Endo barrier™ not only prevents direct contact between patients and healthcare workers but also contains the spread of droplets in examination rooms. Patients can therefore safely undergo the examination. In addition, using Endo barrier™ can help healthcare workers reduce the burden of countermeasures against infection, such as cleaning, sterilizing, and preparing for those measures. The product has been adopted at medical institutions across Japan, from university hospitals and general hospitals to clinics. We have received positive feedback from them.
Okura Industrial Group will continue to actively develop and commercialize products that can contribute to society.

Design registration number JP1683900
Design registration number JP1700260
Trademark registration number JP6411558

The combination of droplet infection prevention film and purpose-made frame creates a semi-hermetic space. By forming a negative pressure in the semi-hermetic space surrounded with the film, users can minimize the spread of droplets.

Behind the Development of Endo barrier™

Endo barrier™ is a product that takes advantage of technology and knowledge held by more than one division and department of Okura Industrial. We therefore worked on the development in close collaboration with many departments and project members across divisions. Before commercialization, we also received direct feedback and request from healthcare workers and made improvements by testing prototypes on the frontline of healthcare.
We will continue to listen and respond to users’ voices and develop new products, so that we can offer our processing solutions to solve problems in the world.
(September 21, 2022)*

*Affiliation and position are as of the publication date.

Senior Staff, Product Support Section, Planning Department, New Materials Division Takumi Yamane