AKP achieves industrial-scale decolorized recyclate using Newcycle tech

12 Jan 2022 --- German recycling technology company APK has successfully proven it can mass-produce decolorized post-consumer plastic recyclate from mixed waste, marking what it calls a “milestone” for the business.

The recyclate is produced using APK’s flagship technology, Newcycling – a form of advanced material and physical recycling.

APK’s director business development, Florian Riedl, tells PackagingInsights the Newcycling process works by adding a solvent-based step after mechanical pre-treatment.

“During this step, we are able to separate several different polymers from each other (for example, multilayer), and we purify the target polymer from contaminants, such as remaining inks, additives or organic residue.”

“But we do not break the polymer chain, and therefore we can reduce the carbon footprint of our recyclates compared to virgin plastics of the same type or compare to other novel technologies of the chemical variety that perform de/repolymerization.”

“Crowning achievement”
APK says obtaining pure plastic recyclates from mixed consumer waste is the “crowning achievement” for any recycling company since the demand for recycled material is so high.

“Pure secondary raw materials are in high demand as they provide an opportunity to achieve close loops for material used in manufacturing, and use less (new material), safe emissions, ensure quality and safety,” explains Riedl. Transparent recycled film made from APK’s Newcycling tech (left) and film made of virgin plastics (right) (Image credit: APK).

A study by Wageningen University in the Netherlands last year found demand for recycled plastics is massively outstripping supply, with legal, business and quality barriers preventing many companies from obtaining needed recyclate to boost their environmental sustainability credentials.

One of the main quality barriers for packagers is obtaining colorless material, explains APK. However, the company also claims the Newcycle process goes beyond this hurdle.

“It is not only about decolorization. It is about sound mechanical, physical and optical properties. But of course, decolorization is the ‘obvious’ one,” says Riedl.

Challenges overcome
Riedl explains AKP went through various difficulties in achieving the current quality of recycled material.

“You have to decide on an input stream (in our case, flexible packaging) and then optimize your process to get the optimal result. This [optimization] starts with choosing a solvent, potentially changing your choice and seeing which parameters are fitting best together along with all the equipment you use,” he says.

“It took a few years to achieve this [optimal result] at industrial scale, and we are very proud of our successful campaign with mixed flexible packaging waste in autumn 2021.”

Riedl says the company is already producing recycled material from industrial sources en masse, and will soon use consumer waste sources for production.

“Our recyclate is made from post-industrial multilayer low-density polyethylene and polyamide film production waste,” he adds.

“These products are fully commercialized. Now we have achieved proof of concept for post-consumer waste from the household collection. We plan to build a plant in the coming few years. Engineering for said plant is already finalized.”

By Louis Gore-Langton

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