Purpose: Mixtures of organic chemicals are a part of virtually all life cycles, but LCI data exist for only relatively few chemicals. Thus, estimation methods are required. However, these are often either very time-consuming or deliver results of low quality. This article compares existing and new methods in two scenarios and recommends a tiered approach of different methods for an efficient estimation of the production impacts of chemical mixtures. Methods: Four approaches to estimate impacts of a large number of chemicals are compared in this article: extrapolation from existing data, substitution with generic datasets on chemicals, molecular structure-based models (MSMs, in this case the Finechem tool), and using process-based estimation methods. Two scenarios were analyzed as case studies: soft PVC plastic and a tobacco flavor, a mixture of 20 chemicals. Results: Process models have the potential to deliver the best estimations, as existing information on production processes can be integrated. However, their estimation quality suffers when such data are not available and they are time-consuming to apply, which is problematic when estimating large numbers of chemicals. Extrapolation from known to unknown components and use of generic datasets are generally not recommended. In both case studies, these two approaches significantly underestimated the impacts of the chemicals compared to the process models. MSMs were generally able to estimate impacts on the same level as the more complex process models. A tiered approach using MSMs to determine the relevance of individual components in mixtures and applying process models to the most relevant components offered a simpler and faster estimation process while delivering results on the level of most process models. Conclusions: The application of the tiered combination of MSMs and process models allows LCA practitioners a relatively fast and simple estimation of the LCIA results of chemicals, even for mixtures with a large number of components. Such mixtures previously presented a problem, as the application of process models for all components was very time-consuming, while the existing, simple approaches were shown to be inadequate in this study. We recommend the tiered approach as a significant improvement over previous approaches for estimating LCA results of chemical mixture
