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COEXPAN has successfully tested mechanically recycled polystyrene in its FFS (Form Fill Seal) facilities at Innotech, (Innovation and Technology Centre of COEXPAN and EMSUR, the rigid and flexible packaging divisions of Grupo Lantero).
This project is an integral part of one of the strategic aims of the value chain initiative SCS, of which Coexpan is a member. SCS innovates together with various partners across the value chain to advance the circularity of styrenic polymers. The ‘r-PS (r-PET alike’) project involves validating post-consumer PS mechanical recycling as well as using processes and technologies similar to those currently used on PET recycling lines: sorting, washing, flake sorting, super cleaning and melt-filtration.
During the trials conducted on the pilot extrusion line, two types of FFS sheets were produced: First an ABA structure in which the middle (B) layer contained encapsulated 50% recycled polystyrene/r-PS between the outer (A) layers of virgin polystyrene. The second trial was conducted on a monolayer structure with 100% post-consumer r-PS.
These materials were then tested on FFS yogurt packaging lines and analysed at the development centre laboratory where all the tests relating to quality analyses, optics, mechanical and functional properties were performed.
The results with both r-PS materials/FFS sheets show the high purity levels of the recycled material (approx. 99.9%), as well as allow very positive conclusions relating to their processability in extrusion and thermoforming.
This step is viewed as an important milestone to deliver on the unique circularity of polystyrene, reaffirming its waste-to-value potential and subsequent industrial applications.
