Periodic Reporting for period 2 - Ecoplastomer (Breakthrough Technology for Plastic and Rubber Waste Circular TPE)
Reporting period: 2023-09-01 to 2024-08-31
The project aims to address two major environmental challenges: disposal of waste rubber and two types of polyolefins (HDPE & PP) and reduction of virgin resources consumption. Rubber is commonly found in discarded tires, industrial products, and consumer goods, while polyolefins are widely used plastics in packaging, automotive parts and various consumer products. These durable and lasting materials are difficult to decompose in landfills, leading to environmental pollution and resource wastage. Therefore, recycling them has become a priority to promote sustainability and reduce environmental burden.
The overall objectives of the project are strictly connected with planned Work Packages:
- Scale up of the existing production line technology to the size of the pilot industrial scale and ensuring that it performs as expected with regard to product quality, output quantity and durability, and is thus ready for full commercialization.
- Testing the number of recycling cycles that Ecoplastomers can undergo while keeping their original quality and mechanical properties.
- Research and development of modifications of existing Ecoplastomers that meet the needs of the market and customers.
1.Research and Development: The project aims to confrm applicability of commercially processing Ecoplastomers with commonly known methods, i.e. extruding, injection moulding, and pressing (even into thin foils) (see fig.1).
2.Technology Development: Based on the research findings, the project team designs and develops new materials employing available equipment.
3.Pilot Testing: The newly developed Ecoplastomers are tested with potential customers to assess feasibility, efficiency, and quality of the produced items (see fig.2).
4.Scaling Up: Successful pilot tests pave the way for commercializing the processes. This involves optimizing technology for larger volumes of Ecoplastomers and establishing partnerships with suppliers, manufacturers and other stakeholders.
5.Quality Assurance: To ensure that Ecoplastomers meet quality standards, rigorous testing and quality assurance protocols are implemented. Our team has implemented the ISO 9001 standard. Moreover, the company has contracted modern equipment for control tests to ensure high quality of produced materials. This step is essential to encourage the adoption of obtained materials by industries (especially automotive and construction).
6.Advocacy and Education: Raise awareness about environmental benefits of reusing recyclable materials and promote circularity and responsible waste disposal practices among consumers, industries, and governments.
7.Monitoring and Improvement: Continuously monitor the technological processes' environmental impact, economic feasibility and technical performance. Make iterative improvements based on data and feedback.
8.Long-term Sustainability: Establish a self-sustaining recycling ecosystem by fostering collaborations, investing in research and development and adapting to changing market demands and technological advancements. External LCA analysis confirmed that each kg of Ecoplastomer will save over 65% of CO2 compared with production of virgin elastomers.
Through these steps, the project aims to significantly impact the environment, economy, and society by reducing waste, conserving resources and promoting a circular economy.
The overall objectives of the project are strictly connected with planned Work Packages:
- Scale up of the existing production line technology to the size of the pilot industrial scale and ensuring that it performs as expected with regard to product quality, output quantity and durability, and is thus ready for full commercialization.
- Testing the number of recycling cycles that Ecoplastomers can undergo while keeping their original quality and mechanical properties.
- Research and development of modifications of existing Ecoplastomers that meet the needs of the market and customers.
1.Research and Development: The project aims to confrm applicability of commercially processing Ecoplastomers with commonly known methods, i.e. extruding, injection moulding, and pressing (even into thin foils) (see fig.1).
2.Technology Development: Based on the research findings, the project team designs and develops new materials employing available equipment.
3.Pilot Testing: The newly developed Ecoplastomers are tested with potential customers to assess feasibility, efficiency, and quality of the produced items (see fig.2).
4.Scaling Up: Successful pilot tests pave the way for commercializing the processes. This involves optimizing technology for larger volumes of Ecoplastomers and establishing partnerships with suppliers, manufacturers and other stakeholders.
5.Quality Assurance: To ensure that Ecoplastomers meet quality standards, rigorous testing and quality assurance protocols are implemented. Our team has implemented the ISO 9001 standard. Moreover, the company has contracted modern equipment for control tests to ensure high quality of produced materials. This step is essential to encourage the adoption of obtained materials by industries (especially automotive and construction).
6.Advocacy and Education: Raise awareness about environmental benefits of reusing recyclable materials and promote circularity and responsible waste disposal practices among consumers, industries, and governments.
7.Monitoring and Improvement: Continuously monitor the technological processes' environmental impact, economic feasibility and technical performance. Make iterative improvements based on data and feedback.
8.Long-term Sustainability: Establish a self-sustaining recycling ecosystem by fostering collaborations, investing in research and development and adapting to changing market demands and technological advancements. External LCA analysis confirmed that each kg of Ecoplastomer will save over 65% of CO2 compared with production of virgin elastomers.
Through these steps, the project aims to significantly impact the environment, economy, and society by reducing waste, conserving resources and promoting a circular economy.
As part of development work, research was carried out to modify Ecoplastomer and properties of obtained materials were examined. The results of these works were presented at two scientific conferences. These works enjoyed great interest in the scientific community and industry Special attention commands research on surface of products made of Ecoplastomers, which confirm large application possibilities for painted/varnished elements, especially in the automotive industry. Profile of surface irregularities confirms that this can positively affect the adhesion of varnish/paint to the surface of products. Moreover, it was analysed how we can further improve functional properties of Ecoplastomers, in order to expand it applicative possibilities. Therefore, two series of polymer blends based on Ecoplastomer PP70 containing 10, 20, and 30 wt.% of flame retardants, have been prepared.
Additionally, using Fused Deposition Modelling (FDM), 3D printing technique, we have determined the effect of production parameters on key properties of Ecoplastomers.
Additionally, using Fused Deposition Modelling (FDM), 3D printing technique, we have determined the effect of production parameters on key properties of Ecoplastomers.
R&D team conducted continuous research on circularity of Ecoplastomer and this material's utilitarian properties. Among others, experimental research has been performed, including determining impact of production parameters on key properties of products made of recyclates. Ecoplastomers have been processed into a filament from which specific products will be printed. The impact of 3D printing conditions on properties of the final products have been assessed.