MATERIALS | RECYCLED MATERIALS


IMAGE: HEXPOL


content for multi-component applications. TPEs with 35-60% PCR/PIR content that offer adhesion to PP, PA, PC, PC/ABS and other thermoplastics are available. They have been tested according to the VDI 2019 standard. For example, Dryflex PCR 68.01B270 – used for power tools – is a 68 Shore A TPE with 60% recyclate, and has fracture pattern D with 5.0 N/mm in peel strength with PA 6.6 GF30. In automotive, TPEs with 25-50% PCR sourced


Above: Hexpol’s new range of TPEs with recyclate can be used in applications such as


automotive


the core of recycled material in a thin layer of virgin material. As well as many bright colours and pastel shades, the products with masterbatches from the Fibafekt range can be finished with a metallic look, pearlescent or glitter. With its Fibarec series, Finke has developed a


range of recyclate-based masterbatches for common thermoplastics. These are available based on recyclates of common packaging polymers. As they can be processed in the same way as master- batches based on virgin material, they are also ideal as a drop-in solution. As well as masterbatches, liquid colorants are becoming increasingly important for colouring plastics with a high recycled content. The main advantages are independence from the carrier material and high material efficiency. Finke’s Fibsol range of liquid colorants offers a large selection of colours. Temperature- and light-resistant as well as physiologically safe, they can be used in most thermoplastics, even those with a high proportion of recyclate. Properties can be precisely controlled by selecting suitable pigments and additives. Hexpol TPE has further expanded its Dryflex


Right: The Turtle project has an inner core of


mechanically recycled ABS from Elix Polymers


Circular TPE materials containing post-consumer and/or post-industrial recycled content. The new materials have been developed with higher levels of post-consumer recyclate (PCR). TPEs with 20-75% PCR content are available in hardness range 40 to 95 Shore A. Various colour options are available, including natural. Compared to equivalent virgin TPE grades, these PCR grades enable a product carbon footprint (PCF) reduction of up to 35%, says the company. “Our first TPEs with recycled content were sold


in 2005, and we’re constantly evaluating recyclate sources,” said Thomas Köppl, group product manager at Hexpol TPE. “These developments are part of our ongoing work to bring TPEs to the market that deliver on performance, product safety and push possibilities using recycled materials.” Hexpol has also developed TPEs with recycled


42 INJECTION WORLD | September/October 2024 www.injectionworld.com


from within the industry are available for exterior applications such as mud flaps and other soft trims. They comply with new targets proposed by the European Commission as part of the End-of-Life Vehicles (ELV) Directive. These are already used by several European OEMs. They enable a product carbon footprint (PCF) reduction of around 25% compared to equivalent virgin TPE grades. TPEs for interior applications, with PCR/PIR content up to 75%, have been tested to automotive standards for odour and emissions. For example, Dryflex PCR 853405 with 85 Shore A and 25% PCR content achieved 3.0 for odour (VDA 270, B3), 65 µg/g for thermodesorption VOC (VDA 278) and 607 µg/g for thermodesorption FOG (VDA 278).


Sandwich product KraussMaffei will produce an injection moulded ‘sandwich’ product – using different types of recycled material – during Fakuma. The product is a blue turtle, which has an outer


layer of chemically recycled ABS and a black core made of mechanically recycled PC/ABS. It will be made on an all-electric PXZ 121-380-180 Multinject. Many features of the PXZ 121, such as the new sandwich panel, near-contour mould temperature control and APCplus machine function, make the multi-component process more efficient and economical. “The increased use of recyclates has brought sandwich technology back into focus in multi-com- ponent technology,” said Manuel von Varchmin, who is responsible for sales of injection moulding technology and automation at KraussMaffei.


� IMAGE: KRAUSSMAFFEI


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