CLIPP

Study of recyclability of printed or laminated plastic packaging films using supercritical C02 technologies

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 Obiettivo del progetto (Objective)

'This project aims to promote the “valuable recycling resource” concept for industrial painted and laminated packages (injected parts and extruded films), nowadays considered as a problem, promoting their recycling in the original application (closed loop cycle) and minimizing the environmental risks and impacts. The CLIPP Recycling System for printed and laminated plastic fraction, will contribute to the post-industrial waste management goal of this new century: the development of intelligent solutions that are technically and environmentally innovative, and economically viable. The project proposal is based on the elimination (90% w/w) and compatibilisation of the paint contaminants in packaging by the synergetic combination of CO2 in super-critical-conditions (sc-CO2) with innovative high performance filters (micro-filters) and suitable coupling agents as a dispersion-aid. The sc-CO2 is a promising technology in the plastic processing industry due to its special properties such as polymer viscosity reduction and dispersion and removal of low molecular weight substances. The advantageous physic-chemical properties of CO2 compared to conventional organic solvents are capacity of mass transfer and more environmentally friendly operation. Three machine configurations will be studied and scale-up using one-step process by combining different types of extruders and devices in order to improve the quality of the pellet, increase remain contaminants dispersion and matrix-filler compatibilization and reduce CO2 foaming problems: 1) A two consecutive single screw extruder (Tandem extrusion process), 2) MRS (Multi Rotation System) and 3) Tandem extruder system with a MACD (Multiple Annular Channel Device). CLIPP process must be suitable for decontaminating the most thermoplastics materials used in the packaging sector (PE, PP , PS and PET).'

Introduzione (Teaser)

Industrial painted and laminated plastics currently present a recycling problem. An EU project has produced improved-quality recycled plastics from printed plastic packaging.

Descrizione progetto (Article)

Some plastics can be recycled, but transparent film plastics are presently not considered worth reclaiming from landfill. An EU project aimed to change that, promoting flexible painted and laminated plastic film (commonly used for food, toys, cosmetics, and industrial parts) as a valuable recycling resource. The project planned to make a similarly transparent plastic recyclate of equal quality and safety to the non-recycled version. Since the new plastic would be "infinitely" recyclable, that kind of waste could be virtually eliminated, helping EU industry to achieve the packaging-reduction directives set by the EU parliament.

The 'Study of recyclability of printed or laminated plastic packaging films using supercritical CO2 technologies' (CLIPP) project consisted of nine European companies and research organisations. It aimed to develop an innovative process to make a continuous film of high-quality transparent plastic.

The process relies on stripping ink, adhesives, and contaminants using supercritical carbon dioxide (CO2) as an industrial solvent. Supercritical is an intermediate physical state combining the flow properties of liquid with the expansion properties of gas; supercritical CO2 is an effective and environmentally safe industrial solvent. In conjunction with the CO2 system, the CLIPP process uses systems for micro-particle filtering, which remove impurities, plus a series of innovative extruders. The resulting system allows smooth production of a translucent film.

Full transparency has not yet been achieved with the method tried. However, CLIPP modified its interim goals, aiming instead to make a plastic as transparent as possible, also having low-odour properties.

These efforts successfully produced a translucent material of suitable quality, including low-odour, appropriate for various non-food packaging purposes. An additional translucent recycled material, in conjunction with a barrier layer, proved suitable for sunflower seed packets. Economic analysis indicates that these developed products can be profitably used in value-added manufacturing, and work has begun on full commercial implementation.

Project results have further increased the expertise of EU plastic recycling industries. That may lead to further steps towards the original manufacturing goals. Overall, the outcome will include reduced plastic waste, healthier environments and lower greenhouse gas emissions.