The MultiCycle project has produced five case studies into the use of recyclates arising from the project’s novel selective dissolution process to recover pure single polymers suitable for multilayer flexible packaging and fibre reinforced thermoplastic composites from challenging mixed and multimaterial wastes which present a challenge to current recycling systems.

The first three studies cover evaluations within the scope of multilayer film production for flexible packaging designs for personal and health products, and the last two involve evaluation of MultiCycle materials in the design and value chain for fibre reinforced composites-based parts and formed nonwoven textiles used in modern automotive applications.

Download each case studies as a pdf by clicking on its image below.

Getting flexible to drive circularity from mixed polyolefin post-consumer waste

Designing to maximize the scope of use for r-PE in flexible packaging

This case study looks at the evaluation of MultiCycle post-consumer waste derived polyethylene recyclates (r-pc-PE) in commonly encountered packaging formats for home and personal care applications, specifically flow wraps for wet wipes. It features a first time demonstrated use of recyclates sourced from co-mingled, printed flexibles from household municipal waste without special pre-sorting.

Flexible packaging products from high post-consumer recycled PP content film structures

Circular plastics in personal care applications

This case study looks at an evaluation of MultiCycle post-consumer waste derived polypropylene recyclates (r-pc-PP) in lotion sachet and stand-up pouches, both commercially relevant packaging formats for home and personal care applications. r-PP has been used at high concentrations to produce cast and biaxially oriented films, a notable first time demonstration.

Circularity in flexible packaging: polyamide recycled from post-industrial scrap

Oriented film evaluated in a multilayer packaging demonstrator

In this case study, polyamide recovered from mixed post-industrially sourced scrap packaging film, r-pi-PA, has been evaluated as part of a demonstration design for a liquid fill stand-up pouch typically used in home and personal care applications. r-PA has for the first time been successfully extruded into cast film and biaxially oriented at 30% inclusion rate.

New life for old composites: a circular materials loop for car battery trays

Retaining the value of PP and PA in automotive scrap

This case study looks at the use of circular plastics in the production of a car battery carrier (tray) for internal combustion engine driven vehicles, a functional part housed within the confines of the vehicle engine compartment, where adherence to dimensional tolerances and stability are of prime importance. The study featured straightforward substitution of recyclate based formulations into sheet laminate and hybrid composite injection molding processes without sacrificing processability or properties.

Pocketing the benefits: recyclate-based staple fibres in an aesthetic nonwoven form

New possibilities for high value recycling of PET from mixed sources

The door panel pocket is an example of an aesthetically important vehicle interior part where thermoplastic-based nonwovens provide an alternative to natural fibre inserts. In this case study r-PET staple fibres were introduced into near-normal processes for the manufacture of pre-consolidated composite nonwoven sheet and forming.