Technology Spotlight: Episode 7
Learn how to unleash the true potential of rPET upcycling for your next project.
You may have read that the LEGO Group recently abandoned its plans to replace Acrylonitrile Butadiene Styrene (ABS) in its toy bricks with recycled Polyethylene terephthalate (rPET), as part of a comprehensive 2032 sustainability program. Not only could LEGO not duplicate the color, gloss and satisfying sound of clicking together its beloved bricks, the substitution would have led to higher carbon emissions from its production units.
Seems like a major setback to a circular economy for rPET, but that’s hardly the case. rPET is the most recyclable plastic worldwide, and its use is fairly ubiquitous, from carpet fiber to clothing to food packaging, and more.
But what’s stopping rPET from becoming an even more valuable feedstock, and increasing its content in new consumer and industrial applications? Many challenges persist, including:
Quality - Damage from environmental exposure in service e.g. thermo-oxidative aging; further degradation via the mechanical recycling process, affecting molecular weight, acid value, color, clarity
Contamination - Moisture, metals, paper, other plastics, and odors from prior use
Processing inefficiency - Slower throughput and reliance upon Solid State Polymerization (SSP) to rebuild molecular weight of inconsistent feedstocks with low intrinsic viscosity
Energy demands - Increased fixed costs from higher energy consumption
Let’s talk about overcoming these challenges with Reactive Recycling technology from Nexam Chemical AB. The ideal complement to mechanical recycling, Reactive Recycling can both repair and upcycle waste plastics using existing processing equipment. Reactive extrusion of rPET with thermally active masterbatches transforms the melt by chain extension, long-chain branching, or crosslinking. Processing is readily improved, as measured by enhanced intrinsic viscosity, improving the manufacturing efficiency of blown films, bottles, tanks, sheets, foams, fibers, etc.
Reactive Recycling adds value and expands opportunities for rPET usage. If you’re involved with staple fibers for carpet manufacture, or food packaging applications, here are some specifics to gain a competitive advantage:
Staple fibers - Enjoy cost savings by upcycling lower quality, less expensive, non-bottle grade feedstocks. Avoid equipment modifications via direct charging to hoppers or side feeders. Achieve higher melt strength and greater process efficiency.
Food packaging - Realize higher recyclate content of finished parts via compatibilization of recycled/prime feedstocks. Ensure food contact compliance with relevant FDA/EFSA regulations. Save energy with reduced SPP operation.
And lastly, for recyclers looking to gain your own competitive edge with rPET - Widen your choice of feedstocks by dialing in IV for greater consistency. Add Reactive Recycling to complement your mechanical recycling process, for higher quality, higher value pellets your customers will appreciate.
Want to learn more about unlocking the potential of rPET upcycling? Reach out for a free initial consultation today.