FILM | INNOVATION
pendent packaging and sustainability consultant. In phase one of the project, PP film and packag- ing samples containing more than 50% of PP recyclate were successfully produced. The base material was printed biaxially oriented PP (BOPP) film with nitrocellulose-based ink formulations. However, the recyclate quality was not completely satisfying in regard to material properties such as colour, smell and processability. Based on the initial results, PrintCYC members strived for further improvement by testing alterna- tive ink formulations for printing on BOPP and LDPE films. Switching to a polyurethane-based ink system in flexo printing in phase two resulted in significant improvements in the mechanical recycling process on a production line typically used for reprocessing printed film waste. Due to the high temperature resistance of the inks – great- er than 240°C – no volatile by-products, odours or gels were observed, leading to a new class of premium quality recyclates showing colour-stable properties. A first environmental impact assess- ment showed decreased greenhouse gas emis- sions due to lower energy consumption of me- chanical recycling of LDPE films compared to virgin
material production. The recyclates showed excellent processability for the production of blown, cast and biaxially-oriented films which were 100% comparable to virgin material, say the project partners. Up to 100% recyclate in the inner layer of a three-layered ABA film structure could be implemented successfully. Two interdisciplinary five-year research projects have been completed in Austria by printing com- pany Renner, recycling firm Walter Kunststoffe and consulting company M2 Consulting. The companies say that the resulting Circular-Print process makes it possible to reuse heavily printed PP sheet waste to create pellets in an upcycling process for the production of new, printable sheet. The project uses Corema technology from Erema in the upcycling process that enables recycling and compounding in a single step. The project focussed on PP labels used in horticulture but the process has since been extended to applications throughout the large- format printing sector. A new certification label has been created with the help of the Johannes Kepler University Linz, Austria, in order to distinguish printable plastic sheet products with post-industrial recycling qualities or
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