PROJECT DESCRIPTION
BACKGROUND
Plastics are key materials in the global economy, but they are associated with significant environmental, health, social and economic impacts. In 2014 Europe generated about 25 million tonnes of post-consumer plastic waste, only 39.5% of which was recovered and 29.7% recycled, while 30.8% went to landfill. More than 8 million tonnes of plastic ends up in the world's seas and oceans, with harmful effects on the marine environment.
To create an effective after-use economy, recycled plastics must satisfy market needs, particularly for added value applications, and there must be sufficient flows of high-quality recyclates.
OBJECTIVES
The LIFE CEPLAFIB project aimed to produce a new material called CEPLAFIB for the packaging, automotive and construction industries. This was aimed to be made from deinked pulp (from recycled newspapers), recycled polypropylene and high-density polyethylene. The goal of LIFE CEPLAFIB was to demonstrate that the new material can be produced at a competitive price and that it is suitable for extended manufacturing techniques such as thermoforming and injection moulding. The project would involve partners from four countries (Slovenia, Finland, Poland and Spain), representing plastics and paper recyclers, manufacturers, technology suppliers and researchers. LIFE CEPLAFIB aimed to support EU policies on recycling and zero waste, including the Waste Framework Directive, the Landfill Directive and the Directive on Packaging and Packaging Waste. By improving product durability and recyclability it would also be in line with the goals of the Ecodesign Directive. Closing the loop for the plastic and paper value chains was expected to contribute to the implementation of the circular economy action plan.
RESULTS
The LIFE CEPLAFIB project team developed an innovative composite material, called ‘CEPLAFIB’, made from recycled post-consumer plastic waste and recycled newspaper fibres. Its uses was explored in the packaging, automotive, and construction industries.
The project partners developed new software and hardware (nozzle and sensors) to adapt current manufacturing processes to produce the new material for various applications.
The new composite material was tested in the production of several products, in particular multi-purpose thermoformed packaging trays; and a thermoformed protective automotive panel, hot-pressed pipe covers, and an injection-moulded load-bearing distance holder for raising the flooring of recreational vehicles or mobile homes. In these applications, the material showed very good mechanical and chemical properties, and had a lower environmental impact than virgin plastic. The manufacturing price of the new material is also competitive, and the prospect for commercialisation is very good.
Slovenian motor-home manufacturer Adria has already approved internal elements made from the material in their vehicles, and up to 200 000 pieces are foreseen to be needed per year.
Several other products were also made in smaller demonstrative quantities, for example, acoustic panels and casings for an electronic gadget, showing that the innovative material could be successfully utilised in a wide range of applications, especially in the packaging and construction sectors.
It was estimated that at least 25 000 citizens in the EU were made aware of the LIFE CEPLAFIB project through various dissemination and cooperation actions.
Further information on the project can be found in the project's layman report (see "Read more" section).
