As the chemical industry moves toward sustainability, the mass balance approach is gaining traction as a practical solution for integrating renewable and recycled feedstocks into existing production streams. However, for many manufacturers, questions remain about its credibility, benefits, and implementation. Here’s what you need to know.
In our industry, renewable or recycled feedstocks are introduced at the start of production and allocated to the final product using a mass balance approach. It means manufacturers can lower emissions and reduce reliance on fossil-based inputs, while maintaining the same quality, properties and performance as conventional materials. To ensure credibility, third-party audits certify that sustainable feedstock volumes are accurately tracked and assigned.
As a result, these materials can be used as drop-in solutions in existing formulations and production processes with no modifications required. This significantly lowers the investment costs compared to physically segregating materials in a separate facility.
Why mass balance?
Mass balance is a method of tracking materials through a production process. In essence, it’s an accounting system to ensure the amount of sustainable input that goes in matches the amount of product that comes out.
It considers both conventional materials and sustainable ones, so manufacturers can certify the percentage of sustainable materials used — even when those materials are mixed with conventional ones during production. This is particularly useful if producing with 100% sustainable materials is not yet feasible.
How does mass balance work?
To understand mass balance, let’s compare it to something many of us are familiar with these days: buying green energy.
There’s simply no way to isolate energy from different sources. When you pay for green energy, the actual electricity supplied to you comes from a mixture of sources, which likely includes coal, natural gas, nuclear, and renewables. But your energy supplier guarantees that the amount of renewable energy you paid for has legitimately been generated and fed into the grid. This is tracked and verified through systems like Renewable Energy Certificates.
The same thinking applies to the mass balance approach in manufacturing. Sustainable materials (e.g. recycled or bio-based plastics) and conventional materials (e.g. fossil-based plastics) are blended together, the same way green energy is mixed with brown energy in the grid. Through mass balance certification, manufacturers can guarantee the amount of sustainable material used in each production run and make verifiable claims about individual products with confidence.
Click image to enlarge.
Seamless integration into existing processes
The benefit of mass balance is that it doesn’t require a complete overhaul of current infrastructure. With green energy, you don’t need separate power lines to your house. Similarly, mass balance doesn’t require special production lines. It allows businesses to transition gradually toward more sustainable practices by blending inputs.
Both systems enable industries to take steps toward sustainability without needing to immediately become 100% circular. It’s a practical solution to phase in sustainable inputs over time as they become more readily available and cost effective.
The role of certification
Mass balance certification has become a widely accepted standard in many industries today. Like green energy, some consumers might feel misled if they don’t fully understand how it works. Certification plays an indispensable role here. Transparent tracking makes sustainability claims verifiable. For consumers, this is absolutely critical. It’s how they know that their choices are making a real difference.
ISCC PLUS is a widely accepted certification schemes to verify the sustainable origin of chemicals and plastics. It relies on the mass balance approach, tracking the flow of sustainable materials throughout the supply chain.
By certifying materials, ISCC PLUS accelerates the transition to a circular economy. Digital tracking ensures transparency and integrity. As more companies adopt the standard, economies of scale can reduce the cost of sustainable materials, making them a competitive alternative to virgin and fossil-based inputs.
However, the complexity of the certification process can hinder adoption. Streamlining procedures will help accelerate the transition and boost availability of sustainable materials. By addressing these challenges and continuing to promote ISCC PLUS, the industry can move closer to a more sustainable future.
IMCD has obtained ISCC PLUS certification for multiple entities, reinforcing our commitment to sustainable and traceable sourcing practices.
Supporting sustainable solutions
At IMCD Advanced Materials, we help customers advance sustainability without compromising performance. These industry examples showcase the opportunities a mass balance approach creates in driving responsible innovation.
• Lowering CO₂ footprint without compromise
From concept to final production, IMCD supported the development of an eco-friendlier mattress foam. With a renewable TDI, our customer reduced emissions while retaining a high-quality foam. It’s a drop-in solution that seamlessly integrates into existing production lines without technical modifications.
• Durability and strength with recycled content
To meet market demands and sustainability goals, we guided customers toward a BPA-free copolyester glass. Made with recycled content, Tritan Renew enhances durability and clarity for drink bottles and kitchen appliances.
The path forward for manufacturers
The mass balance approach provides a practical, drop-in solution for industries to increase their use of sustainable materials without switching to 100% sustainable production overnight. It allows producers to scale up their sustainability at a rate that works for them, spread their investment over time, and maintain the flexibility to operate efficiently along the way.
In the end, mass balance is a highly useful method in the transition to a circular economy. But it must be implemented with transparency and accountability to maximise effectiveness and instil consumer confidence.
Feel free to reach out to your local representative for more information. We can help you explain mass balance to your customers and assist them with the certification process.