PR 04 – Closed loop recycling of PP strapping reduces waste and cuts material costs – February 2008

An innovative ‘closed loop’ custom processing service to recycle post industrial scrap packaging strapping into reusable polymer is reducing landfill and saving raw material costs.

Developed by Luxus compounding division for Plastic Extruders Ltd, part of the Plastex group of companies and the UK’s leading manufacturer of polypropylene strapping for the packaging industry, the process uses the latest technology melt reclamation technology and technical laboratory services to underwrite quality.

The strapping is extruded from polypropylene homopolymer with an advanced process stabilisation package. Developed especially for extrusion, blow moulding and injection moulding, the material also includes additives that reduce water absorption.

Luxus receive baled strapping waste from Plastic Extruders’ Wickford, Essex plant and undertake a series of tests and processes that convert the material into a polymer to an agreed specification. Protection of the stabilisation and water carrying properties of the material is critical for this product.

Central to the success of converting the waste polypropylene into reusable material is the Luxus technical centre where the feedstock is evaluated and a suitable compound is developed. If required FTIR (Fourier Transform Infrared Spectroscopy) tests can be undertaken to confirm polymer type and identify the presence and composition of any additives. The technical center also monitors the quality of every product and material processed on site.

The strapping material is checked for contamination and then processed on a state-of-the-art Erema melt reclamation plant. At this stage any volatiles or water are driven off and if required any masterbatch or additives can be dosed into the melt to produce the necessary physical characteristics required to meet specifications. During processing the plant’s temperature, pressure and screen changes are monitored closely. Pellet quality is also checked and moulded test samples, produced in Luxus’ technical centre, undergo melt flow and tensile tests.

On completion of compounding each batch of the self coloured material is uniformly blended to ensure colour consistency for the customer.  Recycled material is delivered back to Plastic Extruders in 1000kg bulk bags and reused either with prime polymer, recyclate or at 100% addition rate to produce various grades of strapping.

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