The graphic shows a stylized infinity symbol representing the concept of a circular economy. The two loops of the infinity shape illustrate continuous material cycles, in which resources are kept in use and circulate over time. At the center of the infinity symbol, a diamond shape is positioned. This diamond represents the Make phase, i.e. the industrial production and processing stage. In this phase, different raw material sources – including fossil, recycled, or alternative feedstocks – are brought together and transformed into new materials or products. The central placement of the diamond highlights the key role of production within the circular economy. It connects both loops of the cycle and enables materials to be reintroduced into high-value applications. Overall, the graphic illustrates that the circular economy is not a linear process, but an integrated system in which the Make phase acts as a central and value-creating element.
Plastics & Rubber
Plastics Hub
MAKE - Targeting zero emissions by changing the way we make plastics
MAKE - Targeting zero emissions by changing the way we make plastics

Plastics & Rubber

Managing carbon differently: pathways to lower CO₂ emissions in plastics

Reducing CO₂ emissions in plastics production requires concrete measures across the entire value chain. BASF is taking an integrated approach that brings together technologies, energy sources, and raw materials. By combining these levers, transformation becomes not only possible but also achievable on an industrial scale—and measurable.

Nachtopname krakkers © michel@wiegandt.be www.michelwiegandt.be 0475/480.743

The BASF integrated system: Enabling transformation on a large scale

A key driver of this transformation is the BASF Verbund—the company’s integrated production network. It links raw materials, energy flows, and chemical plants across the entire value chain—from basic chemicals to more than 40,000 commercial products.

This integration enables BASF to

  • efficiently reuse energy and materials,
  • introduce new low-emission technologies, and
  • incorporate sustainable raw materials at multiple points.

The Verbund allows BASF to balance energy sources and raw materials within an integrated production system. This enables alternative resources to be integrated at various interfaces, which simultaneously increases flexibility in response to changing market and resource conditions.

By linking processes together rather than optimizing them in isolation, resources are used more efficiently overall. This higher resource efficiency means that less energy and fewer raw materials are required per unit of production—which directly leads to lower CO₂ emissions along the entire production chain.

In this way, CO₂ reduction becomes systemically scalable and measurable, rather than being limited to individual process steps. One area where this approach is applied in practice is plastics production.

Image of an already existing Vattenfall wind farm. (Vattenfall)

Technology and process transformation: Reducing emissions at the source

Plastics production is energy-intensive. Therefore, the energy supply and the production technologies used are key levers for reducing CO₂ emissions.

At BASF, this means transitioning from fossil fuels to renewable electricity and low-emission steam, and electrifying energy-intensive process steps wherever possible.

Examples of technological levers include:

electric furnaces (E-Furnace),

water electrolysis,

heat pumps,

renewable electricity,

low-emission steam, 

carbon capture and storage (CCS).

Some of these technologies are already in use, while others are still being tested. Overall, they help reduce emissions while ensuring high product quality and process stability.

In BASF’s ChemCyclingTM project, plastic waste is transformed into pyrolysis oil using a thermochemical process. The oil can be fed in the BASF Verbund, replacing fossil resources. Using a mass balance approach, new products are manufactured with it. These have the same properties as products from fossil raw materials. BASF works together with partners such as Quantafuel, a start-up headquartered in Oslo, Norway. Quantafuel is specialized in the pyrolysis of mixed plastic waste and the integrated purification of the resulting oil.Rasmus Kærsgaard (left), Plant Director, Quantafuel, and Dr. Michael Bachtler (right), who is working on BASF’s ChemCyclingTM project, in Quantafuel’s pyrolysis and purification plant in Skive, Denmark.

Raw material transformation: Circular Feedstocks keep carbon in the cycle

In addition to energy and technology, raw materials play a crucial role in the carbon footprint of plastics. BASF is increasingly replacing fossil-based raw materials with renewable and recycled alternatives, leveraging the flexibility of its Verbund to reduce dependence on finite resources.

A key approach to this transition is mass balance. It enables renewable and recycled raw materials to be integrated into existing production systems and assigned to specific products—without changing established processes or compromising performance.

Sustainable raw materials in plastics production

Various sustainable feedstocks can be integrated into existing production processes and allocated to specific products via mass balance, including:

  • renewable and recycled raw materials,
  • blue and green hydrogen,
  • blue and green methanol,
  • and captured carbon.

This approach supports circular material flows by keeping carbon within the system and helps reduce the product carbon footprint of plastics—without compromising on the quality, reliability, or performance expected of plastics in a wide range of applications.

Transparency through Product Carbon Footprints (PCF)

Product Carbon Footprints (PCFs) show how much greenhouse gas emissions are associated with a product before it leaves the factory (“cradle to gate”). At BASF, we calculate PCFs  according to internationally recognized standards to capture emissions from both our own production processes and from the raw materials and energy we purchase.

This transparency enables our customers to better understand the climate impact of materials and make more informed, environmentally conscious decisions along their value chains.

Driving transformation forward together

There is no single path to reducing the climate impact of plastics. Progress comes from combining technologies, energy sources, and circular raw materials—tailored to specific applications and regional conditions.

By making the implications of these decisions transparent through Product Carbon Footprints, BASF helps customers and partners shape their own transformation—and together drive more sustainable and resilient plastics solutions.