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A Process to Engineer and Manufacture High Value Products using Mixed Polymer Waste

Develop a cost-effective technology to recycle mixed plastic waste into high-value products with strength and good surface quality, offering an alternative to raw materials and landfill disposal. The project aims to manufacture flood barriers, railway cable channels, and other complex products.

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A Process to Engineer and Manufacture High Value Products using Mixed Polymer Waste

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  1. A Process to Engineer and Manufacture High Value Products using Mixed Polymer Waste

  2. Need • Our modern life would be impossible without the availability of versatile plastics – bottles, packaging, electrical items, cars, construction – the list is almost endless • However, increasing prices of raw material, environmental concerns and cost implications of disposal are growing every year!

  3. Opportunity • One of the biggest challenges facing the recycling industry is what to do with mixed plastic waste – whilst there have been many advances in recycling technology, this type of waste remains an area for development • In order to develop sustainable pathways to recycle mixed plastic waste, innovative technologies that can use it as a raw material and put into something productive and beneficial are vital • PRIME seeks to create a ‘cradle to cradle’ approach for this waste to eliminate it from landfills mixed plastic waste and turn it into a valuable resource Example of Mixed Plastic

  4. Objectives • To develop a cost-effective flexible moulding technology using a combination of established and innovative techniques • Using mixed polymer waste to manufacture high value products with strength and good surface quality that have similar properties to timber or aluminium • Materials will have with a mixed recyclate core and a reinforced skin, balancing stiffness, surface quality and strength • The process is designed to be suitable for a wide range of complex products such as flood barriers, marine and construction products! Flood Defence Barriers

  5. Aims The consortium has defined these technical aims: • Capability to manufacture complex 3D components from a combination of virgin polymer, mixed recycled polymer and reinforcing materials • To achieve mechanical strength/stiffness adequate to replace aluminium alloys for some applications without excessive increases in cross section (strength to weight ratio, etc) • The option of being able to incorporate either discrete reinforcing materials or composite skins without compromising recyclability • Capability to produce components that are resistant to UV, Ozone, water, fire and other environmental degradation mechanisms Railway Cable Channel

  6. Who? • Pan European consortium working together in partnership with the EC, 10 partners uniting the diverse PRIME consortium - 3 in Belgium, 5 in UK, 1 in France and 1 in Hungary • Partners have very diverse backgrounds – SME’s, universities and research centres • ARMINES, MaTRI, and Brunel University have strong capabilities in mould design, process optimisation and material science • Acorn are a proven innovator in manufacturing using mixed polymers • Caro will be developing a flood defence system and Mikrolin cable channel that to be used in, for example, railway construction

  7. Current Status • Experts in material science and innovations in manufacturing using mixed polymers are currently researching and developing pressure forming methods for: • Innovative composite formulations – to meet the vigorous properties required of the materials • High efficiency heat transfer – resulting in manufacturing energy savings • Project runs from July 2010 to June 2013 • Developments will be communicated as the project progresses Impact Tester

  8. And Finally … • Website – www.fp7prime.eu • The research leading to these results has received funding from the European Community's Seventh Framework Programme managed by REA-Research Executive Agency http://ec.europa.eu/research/rea ([FP7/2007-2013] [FP7/2007-2011]) under grant agreement n° [243756-2] • Any questions, please contact Steve Morgan (steve.morgan@recoup.org or +44 1733 375679)

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