LFT recyclate

Combination of LFT with post-consumer and post-industrial recyclates

For long-fibre-reinforced thermoplastics (LFT), established recycling routes that preserve fibre length are not yet available. The IKV project “LFT Recycling” addresses the question of how large-volume LFT components can be recycled at the material level and how high-quality recyclates can be reused. To investigate the material recyclability of long-fibre-reinforced thermoplastics (LFT), a pilot-scale processing chain was implemented, comprising plastification, compression moulding, component production, mechanical shredding, and reprocessing. Substantial fibre damage and shortening already occur during both shredding and plastification. Screw speed proved to be a key parameter. Furthermore, it can be inferred that during shredding, suitable classification enables removal of fine, heavily damaged fractions from the cycle to enhance material quality.

© IKV

In addition to the material aspects, a life cycle assessment (LCA) evaluated the ecological potential of various process routes. The comparison between conventional processes and novel material cycles incorporating 25 % recyclate content reveals substantial savings potential (Fig. 1). In the case of recycling, the elimination of energy recovery at end-of-life contributes particularly to marked improvements. Overall, the research demonstrates that LFT recyclates represent a sustainable alternative to virgin material. Challenges remain, however, in ensuring consistent material quality, process stability at high recyclate contents, and processing of contaminated post-consumer streams. The findings offer specific approaches for systematically addressing these challenges in future projects. The use of fibre-length-preserving processing technologies and the combination of recyclates with recycled UD tapes offer promising development directions.

Project data and funding

We would like to thank the BMWE for funding the IGF project (funding code 22995 N) and the project partners for their cooperation.

Project duration: 01.11.2023 – 31.10.2025