Periodic Reporting for period 3 - EGREMPLARE (Enabling greasy mixed plastics recycling)
Periodo di rendicontazione: 2022-10-01 al 2024-03-31
Due to the combination of unrivalled properties and low cost, plastics are the workhorse material of the modern economy. While delivering many benefits, the current plastics economy has drawbacks that are becoming more apparent by the day. The primary problem is the high material waste rate and poor closed-loop recycling in plastics manufacturing. In Europe, only 32,5% of all the generated plastic waste
is recycled, the other 67,5% is incinerated or landfilled. This entails an enormous environmental burden; it is estimated that the life-cycle emission of plastics was 1.8 billion tonnes, which is around 3,3% of the total global emissions. A part of this emission could be avoided in the future by improving and increasing recycling efforts.
Almost half of the plastics that are collected end up in the mixed plastics fraction. One of the main challenges for recycling of this fraction is the high content of oils and greasy residues. Current recycling technology cannot clean this waste stream without using excessive energy or corrosive and unhealthy chemicals. As a result of these high processing costs, greasy mixed plastics are currently sent to incinerators or to landfills which is very undesirable.
TUSTI has developed a breakthrough process for the recycling of greasy mixed plastics: EGREMPLARE.
EGREMPLARE makes it possible to obtain high grade resins, applicable for packaging manufacturing and civil
& construction engineering, from the currently disposed (mainly to landfills) greasy mixed plastics fraction.
The core of this process is an innovative and patented washing process based on bio-based cleaning liquids,
which offer several advantages over the industrial standard for plastic washing (using steam and/or hot water and corrosive cleaning agents), uniquely positioning TUSTI for the recycling of greasy mixed plastics.
Thanks to EGREMPLARE, TUSTI will increase the percentage of plastics recycled, using an eco-efficient technology with an exceptionally low energy consumption and without generating new waste streams.
During the Horizon 2020 project, the aim was to build a demonstrating factory for the recycling of post-consumer household packaging in the Netherlands using the EGREMPLARE technology. This first industrial plant will allow us to secure know-how on the process and build a brand name. The obtained knowledge and results serve as input to develop a growth strategy and eventually spread the technology all over Europe.
is recycled, the other 67,5% is incinerated or landfilled. This entails an enormous environmental burden; it is estimated that the life-cycle emission of plastics was 1.8 billion tonnes, which is around 3,3% of the total global emissions. A part of this emission could be avoided in the future by improving and increasing recycling efforts.
Almost half of the plastics that are collected end up in the mixed plastics fraction. One of the main challenges for recycling of this fraction is the high content of oils and greasy residues. Current recycling technology cannot clean this waste stream without using excessive energy or corrosive and unhealthy chemicals. As a result of these high processing costs, greasy mixed plastics are currently sent to incinerators or to landfills which is very undesirable.
TUSTI has developed a breakthrough process for the recycling of greasy mixed plastics: EGREMPLARE.
EGREMPLARE makes it possible to obtain high grade resins, applicable for packaging manufacturing and civil
& construction engineering, from the currently disposed (mainly to landfills) greasy mixed plastics fraction.
The core of this process is an innovative and patented washing process based on bio-based cleaning liquids,
which offer several advantages over the industrial standard for plastic washing (using steam and/or hot water and corrosive cleaning agents), uniquely positioning TUSTI for the recycling of greasy mixed plastics.
Thanks to EGREMPLARE, TUSTI will increase the percentage of plastics recycled, using an eco-efficient technology with an exceptionally low energy consumption and without generating new waste streams.
During the Horizon 2020 project, the aim was to build a demonstrating factory for the recycling of post-consumer household packaging in the Netherlands using the EGREMPLARE technology. This first industrial plant will allow us to secure know-how on the process and build a brand name. The obtained knowledge and results serve as input to develop a growth strategy and eventually spread the technology all over Europe.
During the EGREMPLARE project the mail goal for TUSTI was building a demonstrator plastic recycling factory. In this patented process, all major types of plastic that are present in European plastic waste can be separated and cleaned. This project consists of three consecutive phases. First, pilot testing (WP2), followed by building and installing the machines accordingly (WP3). In the next phase, the plastic that is produced is tested externally by our customers (WP4). During these three phases, project management is executed (WP1) and a strategy is designed to spread the TUSTI technology over Europe (WP5).
During the first part of the project pilot tests were performed. TUSTI has analysed industrial samples from five different suppliers from three different European countries (The Netherlands, Germany and France). These samples were processed using the TUSTI patented EGREMPLARE technology and have been analysed afterwards. The results are very promising: sellable, high quality circular resources have been produced from plastic waste. Using the results, design for the industrial scale plastic recycling factory was created.
To establish this demonstrating recycling factory a very good location was found. The construction of the building was finished in June 2022, and the setup of the processing line could start.
It became clear that there are shortages in raw materials (such as steel and copper) and the electronics required to operate the necessary machines. Therefore, it was decided that the demonstration facility would be built in two phases. During phase 1, only the machines that are necessary to process polyolefinic plastic packaging were ordered and installed. Due to the density of polyolefins being lower than 1 kg/m3, they float in water. After treatment in the TUSTI recycling line, the plastic waste is reduced in size, clean and dry and hence can be used directly in high-quality applications. In the second phase, which was started in 2023, the processing line was extended with equipment suitable for the processing of the materials that sink in water such as metals, stones, but also plastic types such as PET and PS. To minimize costs and be independent of external delivery times, existing machines have been adapted by the inhouse technical team to make them suitable for the processing of heavy materials.
Ultimately a processing line for the recycling of post-consumer household packaging was set up which is able to process 15.000 tons per year. This recycle line is able to process dirty mixed plastics into clean flakes which can be used to produce new products, without requiring high temperatures or harmful chemicals. Samples of the products were shared with potential customers for validation. They were able to process the material into various high-quality products like tubes, bottles or bottoms and tops of key kegs.
Communication activities resulted in a robust network with partners all over Europe. Sales conversations have taken place with a large number of customers, and long-term collaborations have been established. To create additional awareness and build a brand name for the EGREMPLARE technology and the produced end products, a new website was launched. Next to communication via the website there have been several publications on LinkedIn and in different media sources.
To facilitate upscaling of the EGREMPLARE process across Europe, the TUSTI technology has been patented and optimized. Together with LyondellBasell as a partner, the expansion of the EGREMPLARE technology to other recyclers in the network is discussed.
During the first part of the project pilot tests were performed. TUSTI has analysed industrial samples from five different suppliers from three different European countries (The Netherlands, Germany and France). These samples were processed using the TUSTI patented EGREMPLARE technology and have been analysed afterwards. The results are very promising: sellable, high quality circular resources have been produced from plastic waste. Using the results, design for the industrial scale plastic recycling factory was created.
To establish this demonstrating recycling factory a very good location was found. The construction of the building was finished in June 2022, and the setup of the processing line could start.
It became clear that there are shortages in raw materials (such as steel and copper) and the electronics required to operate the necessary machines. Therefore, it was decided that the demonstration facility would be built in two phases. During phase 1, only the machines that are necessary to process polyolefinic plastic packaging were ordered and installed. Due to the density of polyolefins being lower than 1 kg/m3, they float in water. After treatment in the TUSTI recycling line, the plastic waste is reduced in size, clean and dry and hence can be used directly in high-quality applications. In the second phase, which was started in 2023, the processing line was extended with equipment suitable for the processing of the materials that sink in water such as metals, stones, but also plastic types such as PET and PS. To minimize costs and be independent of external delivery times, existing machines have been adapted by the inhouse technical team to make them suitable for the processing of heavy materials.
Ultimately a processing line for the recycling of post-consumer household packaging was set up which is able to process 15.000 tons per year. This recycle line is able to process dirty mixed plastics into clean flakes which can be used to produce new products, without requiring high temperatures or harmful chemicals. Samples of the products were shared with potential customers for validation. They were able to process the material into various high-quality products like tubes, bottles or bottoms and tops of key kegs.
Communication activities resulted in a robust network with partners all over Europe. Sales conversations have taken place with a large number of customers, and long-term collaborations have been established. To create additional awareness and build a brand name for the EGREMPLARE technology and the produced end products, a new website was launched. Next to communication via the website there have been several publications on LinkedIn and in different media sources.
To facilitate upscaling of the EGREMPLARE process across Europe, the TUSTI technology has been patented and optimized. Together with LyondellBasell as a partner, the expansion of the EGREMPLARE technology to other recyclers in the network is discussed.
Using the EGREMPLARE technology, greasy mixed plastic waste has been processed to high quality circular resources with a material efficiency of 60-85%. Contrary to the state of the art, that uses only part of these materials in low value applications.
To operate this process on industrial scale, a factory has been built and the required machines were installed and commissioned. The processing parameters were optimized to obtain material which can be reused in high-quality recycled products. The recycling plant setup by TUSTI during the project directly contributes to the European Green Deal objective of ‘Mobilising the industry for a clean and circular economy’. The European Commission has recognized plastics as one of the resource-intensive sectors that need focus on the new Circular Economy action plan.
TUSTI has a positive impact on society as the EGREMPLARE plant is able to process 2,5 tons of plastic waste per hour (15.000 tons per year). By recycling, emissions from incineration/landfilling are prevented. Additionally, emissions for the production of new plastics are avoided.
To operate this process on industrial scale, a factory has been built and the required machines were installed and commissioned. The processing parameters were optimized to obtain material which can be reused in high-quality recycled products. The recycling plant setup by TUSTI during the project directly contributes to the European Green Deal objective of ‘Mobilising the industry for a clean and circular economy’. The European Commission has recognized plastics as one of the resource-intensive sectors that need focus on the new Circular Economy action plan.
TUSTI has a positive impact on society as the EGREMPLARE plant is able to process 2,5 tons of plastic waste per hour (15.000 tons per year). By recycling, emissions from incineration/landfilling are prevented. Additionally, emissions for the production of new plastics are avoided.