Periodic Reporting for period 2 - SURPASS (Safe-, sUstainable- and Recyclable-by design Polymeric systems - A guidance towardS next generation of plasticS)
Reporting period: 2023-12-01 to 2024-11-30
Plastic waste outlive us on this planet as they take centuries to break down. The hazard of endocrine disruption by leached substances, fast growing and pollution of land, air and water as well as greenhouse gas emissions are only some of the adverse effects of plastic waste on public and environmental health. Still, 70% of plastic waste collected in Europe is landfilled or incinerated.
The aim of SURPASS project is to lead by example the transition towards more Safe, Sustainable and Recyclable by Design (SSRbD) polymeric materials.
The SURPASS consortium of 13 partners develops SSRbD alternatives with no potentially hazardous additives through industrially relevant case-studies targeting the three sectors representing 70% of the European plastic demand:
- Building: bio-sourced polyurethane resins with enhanced vitrimer properties to replace PVC for window frames
- Transport: lightweight, therefore less energy-consuming epoxy-vitrimer, as alternative to metal for the train structure, anticipating emerging use of non-recyclable composites.
- Packaging: MultiNanoLayered films involving less compatibilizers to replace currently non-recyclable multi-layers films.
Along with the development of innovative materials, the project optimize reprocessing technologies adapted to the new SSRbD systems to support the achievement of ambitious recyclability targets.
The project is also developping a scoring-based assessment to guide material designers, formulators and recyclers to design SSRbD polymeric materials, operating over the plastic’s entire life cycle, including hazard, health, environmental and economic assessment.
All the currently generated data and the associated relevant methodologies will be made accessible on a digital infrastructure.
SURPASS address in particular its results to SMEs and has an outstanding potential to contribute to the transition towards green economy.
The aim of SURPASS project is to lead by example the transition towards more Safe, Sustainable and Recyclable by Design (SSRbD) polymeric materials.
The SURPASS consortium of 13 partners develops SSRbD alternatives with no potentially hazardous additives through industrially relevant case-studies targeting the three sectors representing 70% of the European plastic demand:
- Building: bio-sourced polyurethane resins with enhanced vitrimer properties to replace PVC for window frames
- Transport: lightweight, therefore less energy-consuming epoxy-vitrimer, as alternative to metal for the train structure, anticipating emerging use of non-recyclable composites.
- Packaging: MultiNanoLayered films involving less compatibilizers to replace currently non-recyclable multi-layers films.
Along with the development of innovative materials, the project optimize reprocessing technologies adapted to the new SSRbD systems to support the achievement of ambitious recyclability targets.
The project is also developping a scoring-based assessment to guide material designers, formulators and recyclers to design SSRbD polymeric materials, operating over the plastic’s entire life cycle, including hazard, health, environmental and economic assessment.
All the currently generated data and the associated relevant methodologies will be made accessible on a digital infrastructure.
SURPASS address in particular its results to SMEs and has an outstanding potential to contribute to the transition towards green economy.
In the first 30 months of the SURPASS project, significant progress was made in developing polymeric systems, (re)processing methods, and Safe-Sustainable-and-Recyclable-by-Design (SSRbD) assessments. The project also analyzed EU and national regulatory landscapes and operationalized the SSbD framework for polymeric materials, resulting in the definition of technical content for a digital infrastructure to be implemented in the final phase. An inventory of additives, along with toxicity data, was compiled. The strategy for contributing to current and future standardization efforts was also developed.
In terms of material development (WP2) and reprocessing (WP3), the following activities were undertaken in the project:
Case Study 1 focused on bio-based polyurethane (PU) for window frames, addressing sustainability challenges of PU as a PVC alternative. LEITAT and CEA introduced disulphide bonds and vitrimer technology for end-of-life reprocessing, achieving promising results but requiring further optimization. Case Study 2 developed recyclable epoxy-based vitrimer composites with non-halogenated flame retardants for railway applications, meeting specifications for thermal, mechanical, and fire properties. Both mechanical and chemical recycling methods were explored, recovering key composite components. CIDETEC, with contributions from Fraunhofer ICT, BASF, and CEA, developed innovative composites and optimized mechanical and chemical recycling methods. Case Study 3 CS3 of the SURPASS project investigates material development and recycling strategies for MNL packaging films developed in WP2. These films face contamination challenges from food, material migration, and thermal degradation. The recycling process involves washing, decontamination, and reprocessing into new films, followed by recyclability evaluation using the RecyClass protocol. Decontamination process via extractive extrusion and strategic planning for washing and RecyClass evaluation was undergone in the current period and demonstrated a reduced emission of volatile organic compounds resulting from degradation products.
These achievements collectively contribute to advancing sustainable recycling methods and materials across different sectors, addressing lifecycle challenges and enhancing resource efficiency.
An important aspect of the WP4 and WP5 activities was on the operationalization of the SSbD framework (criteria definition, method development, scoring strategies …). Moreover, data generation on hazard, release, exposure and environmental and economic impacts were generated. The structuration of the content of the knowledge-based digital infrastructure, was a key achievement of the second period of the SURPASS project. D5.1 describes the overall structure of the SSRbD knowledge, the overall sustainability assessment and the main lessons learnt from the three case studies. Based on the conclusions from T5.1 the SURPASS digital infrastructure will be implemented and tested in the final period.
The integrated SURPASS approach supports early-stage eco-design, recyclability, and sustainable innovation across sectors, addressing lifecycle challenges and advancing polymeric materials' resource efficiency.
The strategy for contributing to current and future standardization efforts was developed as part of WP6 activities. The Spanish Association for Standardisation (UNE) plays a key role in supporting these efforts, ensuring alignment with national and international standards.
Case Study 1 focused on bio-based polyurethane (PU) for window frames, addressing sustainability challenges of PU as a PVC alternative. LEITAT and CEA introduced disulphide bonds and vitrimer technology for end-of-life reprocessing, achieving promising results but requiring further optimization. Case Study 2 developed recyclable epoxy-based vitrimer composites with non-halogenated flame retardants for railway applications, meeting specifications for thermal, mechanical, and fire properties. Both mechanical and chemical recycling methods were explored, recovering key composite components. CIDETEC, with contributions from Fraunhofer ICT, BASF, and CEA, developed innovative composites and optimized mechanical and chemical recycling methods. Case Study 3 CS3 of the SURPASS project investigates material development and recycling strategies for MNL packaging films developed in WP2. These films face contamination challenges from food, material migration, and thermal degradation. The recycling process involves washing, decontamination, and reprocessing into new films, followed by recyclability evaluation using the RecyClass protocol. Decontamination process via extractive extrusion and strategic planning for washing and RecyClass evaluation was undergone in the current period and demonstrated a reduced emission of volatile organic compounds resulting from degradation products.
These achievements collectively contribute to advancing sustainable recycling methods and materials across different sectors, addressing lifecycle challenges and enhancing resource efficiency.
An important aspect of the WP4 and WP5 activities was on the operationalization of the SSbD framework (criteria definition, method development, scoring strategies …). Moreover, data generation on hazard, release, exposure and environmental and economic impacts were generated. The structuration of the content of the knowledge-based digital infrastructure, was a key achievement of the second period of the SURPASS project. D5.1 describes the overall structure of the SSRbD knowledge, the overall sustainability assessment and the main lessons learnt from the three case studies. Based on the conclusions from T5.1 the SURPASS digital infrastructure will be implemented and tested in the final period.
The integrated SURPASS approach supports early-stage eco-design, recyclability, and sustainable innovation across sectors, addressing lifecycle challenges and advancing polymeric materials' resource efficiency.
The strategy for contributing to current and future standardization efforts was developed as part of WP6 activities. The Spanish Association for Standardisation (UNE) plays a key role in supporting these efforts, ensuring alignment with national and international standards.