Industrial Research Project to Advance Mechanical Recycling of Flexible Polyethylene

The Institute for Plastic Processing for Industry and Craft (IKV) at RWTH Aachen University in Germany will coordinate a project aimed at improving mechanical recycling of flexibly PE. The industrial research project “Loopcycling” will seek to achieve the best possible recyclate qualities by consistently combining the best industrial recycling technologies. Based on existing industrial process technologies, the processes will initially be optimized using common polyolefin sorting fractions from the household collection of packaging waste. A transfer to well-designed monomaterials including upscaling is conducted in parallel. The results will be used to derive future design-for-recycling standards.

The EU Packaging and Packaging Waste Regulation (PPWR) adopted by the EU Parliament in April 2024 sets, among other things, ambitious minimum targets for the percentage of recyclate in new plastic packaging, raising new challenges for industrial recycling technologies. In order to meet the requirements, a significant increase of the percentage of recyclate in contact-sensitive applications like food and cosmetics packaging is mandatory. Chemical recycling processes provide recyclates that meet the quality requirements of such applications. However, the available capacities are far from sufficient to meet the demand. Mechanical recycling, as the most energy- and material-efficient plastics recycling process, can provide corresponding quantities, but not in the required recyclate quality. Intensive research into both recycling routes will therefore be crucial for the industry.

Loopcycling considers the entire process chain of mechanical recycling: sorting, shredding, washing, de-inking, compounding with stabilizers, decontamination and odor removal as well as the characterization of recyclate, reprocessing and reuse. Industrial technology providers within the consortium representing each process step ensure that the systems and technologies involved are operational on an industrial scale today. IKV is coordinating the project, carrying out compounding trials and reprocessing tests in its pilot plants and laboratories, and contributing its expertise in recyclate characterization.

Loopcycling is scheduled to run for two years and will start in January 2025. The consortium currently includes technology suppliers such as manufacturers of sorting systems, providers of de-inking technologies, manufacturers of recycling systems, materials and additives, and providers of decontamination technologies. Interested recyclers, recyclate processors, packaging manufacturers, brand owners and retailers are invited to a separate kickoff event on Sept. 10, 2024, at IKV in Aachen.