Periodic Reporting for period 2 - PRecycling (Plastics Recycling from and for home appliances, toys and textile)
Reporting period: 2023-10-01 to 2025-03-31
PRecycling aims to develop an easy-to-use methodology for sampling and analysis procedures of recyclates. The outcome will be the establishment of a methodology for recyclate definition, promoting the circularity and safety of plastic materials throughout polymer recycling based on the degradation degree, production and verification of recyclate's quality, smart traceability solutions and digital information management. The aim is to show that ‘waste to product’ transformation is scalable, replicable, traceable, potentially and commercially viable and, most importantly, safe to use. The production of new safe products from recycled materials for home appliances, toys for children and textiles, will form part of a community awareness and a pilot demonstration initiative, showing that high quality, unique materials made from recyclates can find new use, both within the same and new supply chains. These outputs will have practical use and therefore commercial and industrial interest, apart from the significant societal impact. The challenge of changing the ‘waste problem=cost’ for the end-of-life disposer to a ‘re-born product=value’, which is fully recycled and safe, preserving the embedded value as it moves through the whole process, will be faced by the proposed methodology. The anticipated impact can be categorized into three distinct dimensions: scientific, economic and technological, and societal and environmental. The route to achieving a scientific impact involves advancing innovative approaches and techniques for polymer and recyclate recycling, upcycling, track-and-trace systems, and the sampling and analysis of recyclates, the creation of effective verification methods for recycled content in products, extending to the establishment of a widely accepted EU definition of recyclate. The economic and technological impact is expected to materialize through the advancement of improved recycling and reuse processes, the utilization of secondary raw materials, expanded services to the polymer processing industry, sustainable-by-design technologies, digital tracing tools, the implementation of product Digital Twins, the development of the "PRecycling Plastic Recyclates Handbook," and the contribution to the EU plastic industry by recording recyclate volumes on the MORE platform. Anticipated societal and environmental impact includes a decrease in the consumption of natural resources, a reduction in CO2 emissions, enhanced knowledge regarding safety and environmental assessments of PWS, safeguarding human health and the environment from harmful and toxic chemicals, the generation of new employment opportunities, strong environmental awareness, the establishment of living labs involving parents and children, and fostering societal engagement through regional collaborations.
During the 2nd reporting period, the inventory and initial characterization of plastic waste streams (PWS) for different applications were completed, including material and product requirements. Selected PWS were extensively characterized, including polymer classification using LIBS and Raman spectroscopy, and processing via scalable dissolution-based recycling methods. Polymer restabilization using additives and solid-state polymerization, and assessments of recyclate in form of pellets and filament by injection molding and printability testing supported high-performance recovery and processing of recycled materials. Analytical methods and sampling strategies for recyclates were defined, ensuring consistent quality assessment. Degradation behaviour was investigated through mechanical, thermal, and spectroscopic analysis, while lifetime prediction models and accelerated aging protocols were validated and adapted for recycled polymers. Material and substance flow analyses were developed to trace specific additives in plastic waste. Tracing compounds were identified, and their detectability confirmed using LIBS and LIF techniques. Proof-of-concept demonstrations for traceability were conducted using waste from toys and appliances, while digital tools were integrated to support data exchange and future implementation of Digital Product Passports. Furthermore, material specifications for demonstrators were established, and concept designs for 3D-printed components completed. Various compounding and processing methods were optimized for recycled and virgin materials, and successful trials demonstrated the suitability of upcycled polymers in real applications. Enhancements in fiber spinning using solid-state processing and chain extenders improved recycled polyester performance. Safe-by-design practices, risk and exposure assessments were performed, while LCA and LCC processes were initiated to support the integration of circular and sustainable design principles.
PRecycling develops innovative reclamation and repurposing routes for end-of-life plastics, to produce recyclates of high and verified quality, and to demonstrate their safe use in several applications in domestic appliances, toys, and textiles. All aspects and stages of high-quality thermoplastic materials development from recycled resources, starting with the selection of suitable waste streams, strategies for material repair, compatibilization, and upgrade towards injection molding (IM)/ Additive manufacturing (AM) processing, and closed-loop recycling material optimization in terms of processability and performance are being addressed. Key results include advanced polymers sorting and characterization using LIBS and Raman, scalable dissolution-based and mechanical recycling processes, solid-state polymer repair, and additive-based stabilization. Degradation and lifetime modelling, alongside material flow analysis and molecular tracing, support recyclate quality and traceability. Digital tools enable data exchange and integration with emerging systems like Digital Product Passports. The project demonstrates the feasibility of a distributed recycling model that can be implemented locally with industry and waste operators. To ensure further uptake and impact, there is a need for large-scale demonstrators, access to funding for scale-up, supportive regulatory frameworks, harmonised standards, and IPR protection to accelerate commercialisation and drive adoption in EU markets.