FlexPO4films

The FlexPO4films project focuses on the recovery of polypropylene (PP) recyclates from flexible packaging suitable to produce new packaging. In Europe, around 11 million tons of plastics are used for flexible packaging every year, with only 8.5% of this being recycled material. In view of the new EU targets, which prescribe a recyclate share of at least 35% by 2030 and as much as 65% by 2040 for packaging, there is an urgent need for innovative recycling technologies. Flexible packaging, which often consists of multilayer materials, presents a particular challenge because its complex composition hampers recycling considerably.
In this project, solvent-based recycling is considered a key technology for the recovery of polypropylene (PP) from flexible packaging. Through targeted adaptations of the existing process, which is already successfully used to recover LDPE recyclates, the PP-containing residues generated in the recycling process are to be utilized as valuable raw materials. These residues, which consist of a mixture of plastics and other materials, contain a significant proportion of PP, which can be selectively extracted by the process and recovered in a highly pure form.
The PP recyclates obtained in the project are then tested for their processability in film extrusion. The films produced are characterized in terms of their mechanical and optical properties. These comprehensive tests and analyses enable the creation of a detailed application profile for the recyclates. In addition, the possibility of deriving optimization potential in the recycling process is being investigated to further increase the efficiency and quality of the recyclates. The results of the project are designed to increase the marketability of PP recyclates and to contribute to the fulfillment of the EU requirements for the use of recyclates in packaging.