According to World of Petroleum and Bitumen (WPB), a German cleantech startup is introducing a transformative solution in road building by replacing traditional polymer additives in asphalt with high-performance recycled plastics — a move poised to reduce both carbon emissions and plastic waste.
The company, ecopals, emerged from a student initiative rooted in firsthand exposure to unmanaged plastic pollution across regions in Asia. Witnessing the widespread burning of plastic and the lack of infrastructure, the founders began to explore practical applications for this waste. Their research led to the idea of utilizing discarded plastic as a replacement for the virgin polymers commonly used in European road construction — materials that account for nearly a third of asphalt formulations in the region.
In Germany, where over half of plastic waste is incinerated under the term “thermal recovery,” ecopals identified a striking contradiction: while resources are burned locally, costly, CO₂-intensive polymers are imported for construction use. The team recognized an opportunity for intervention.
To address the technical challenges of integrating recycled plastics with bitumen — an oil-derived binder that doesn’t naturally combine with polymers — ecopals collaborated with a research institute in Itzehoe. This partnership led to the development of EcoFlakes: clean, engineered polymer pellets specifically tailored for asphalt mixing. These additives not only improve road performance and elasticity but also cut down environmental impact.
Despite its innovation, ecopals had to navigate a complex and highly decentralized market. Unlike some other European countries with consolidated infrastructure sectors, Germany’s road construction industry comprises hundreds of independent companies. To gain ground, ecopals adopted a hands-on approach — conducting pilot projects, on-site tests, and extensive outreach to prove the reliability of its product. From emissions and durability assessments to compliance with specific elasticity standards, the company invested heavily in data-driven validation to build confidence among contractors and regulators.
Support from MHI, a strategic investor with deep ties in Germany’s infrastructure sector, further accelerated ecopals’ integration into the market. The financial and logistical backing helped the company navigate industry resistance and regulatory hurdles, where long-standing practices and skepticism toward recycled materials often slow innovation.
Now poised for international growth, ecopals is eyeing global markets — each with distinct regulatory frameworks and industry mindsets. According to the company’s co-CEO, gaining acceptance abroad hinges not just on product quality, but on relationship-building and contextual understanding. Motivations vary across countries; while some prioritize cost-efficiency, others focus on environmental benefits. Fortunately, ecopals’ solution addresses both.
Nonetheless, significant challenges remain. The road construction industry is still largely risk-averse, and adoption of new materials typically requires cooperation across multiple stakeholders — from mixers to contractors to regulatory bodies. The startup advocates for greater openness and flexibility in testing and implementing innovations, emphasizing that performance must remain at the core of all sustainable alternatives.
As climate and waste crises intensify, ecopals believes the pressure to decarbonize infrastructure will eventually drive systemic change. Until then, the company continues its mission: to offer a practical, cost-effective, and sustainable material that redefines what roads can be made of — one project at a time.
By WPB
Asphalt, Bitumen, Pavement
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