Specifically, the focus is on improving industrially available LDPE recyclate qualities from household PCR (Post-Consumer Recycled) materials.
The project involves the entire value chain of plastic recycling to expand the limits of mechanical recycling and achieve the best possible recyclate qualities using established industrial processes.
© IKVThe EU Packaging and Packaging Waste Regulation (PPWR) adopted by the EU Parliament in April 2024 sets ambitious minimum targets for the proportion of recyclate in plastic packaging, among other things, and thus poses new challenges for industrial recycling technologies. In order to meet the requirements, the proportion of recyclate in contact-sensitive applications in the food and cosmetics sectors in particular must be significantly increased. The available capacities are not yet sufficient for chemical recycling, which can supply the corresponding recyclate qualities. As the most energy and material-efficient plastics recycling process, mechanical recycling can provide corresponding quantities, but not in the required recyclate quality. Intensive research into both recycling routes will therefore be of existential importance for the industry.
The Institute for Plastics Processing (IKV) in Industry and Trade at RWTH Aachen University has therefore initiated the industrial research project “LOOPCYCLING – Advanced Mechanical Recycling of Flexible Polyethylenes”. The aim is to significantly push the boundaries of mechanical recycling and to achieve the best possible recyclate qualities by consistently combining the best industrial processes. Based on existing industrial processes, the processes will initially be optimized with common polyolefin sorting fractions (DSD310) from the household collection of packaging waste. At the same time, the transfer to well-designed mono materials including upscaling is being worked on. The results will also be used to derive future design-for-recycling standards.
LOOPCYCLING considers the entire process chain of mechanical recycling: sorting, shredding, washing, de-inking, compounding with stabilizers, decontamination and odour removal as well as the characterisation of the recyclates and reprocessing and reuse. Each process step is represented by industrial technology providers in this area, ensuring that the systems and technologies included are already available and usable in industry today. IKV is responsible for project coordination, carries out compounding and reprocessing tests in its pilot plants and laboratories and contributes its expertise in recycling characterisation.
LOOPCYCLING is conceived as a purely industrial project without public funding, thus allowing the project to start soon. However, it builds on IKV’s findings from previous projects, some of which were publicly funded. The project is scheduled to run for two years and will start in January 2025.
The consortium currently includes technology suppliers such as sorting plant manufacturers, providers of de-inking technologies, recycling plant manufacturers, raw material and additive manufacturers and providers of decontamination technologies. Interested recyclers, users of recyclates, packaging manufacturers, brand owners and retailers are invited to a separate kick-off event on September 10, 2024 at IKV in Aachen.