Improving mechanical recycling through R&D in plastic processing : LyondellBasell (LYB) is enhancing its high -quality standards for mechanically recycled materials through investments in their R&D capabilities.
One example is at the innovation Center in Frankfurt where LYB is strengthening its efforts in the development of advanced sorting, decontamination and compounding technologies as well as advanced analytics of post-consumer recyclates under near industrial conditions.
Advanced sorting, decontamination and compounding technologies
LYB is developing mechanical recycling technologies using its new innovation facility designed to simulate industrial conditions, focusing on advanced sorting, decontamination and compounding technologies for post-consumer waste feedstocks.
“With the ability to process several hundred kilograms of test material – sorted by plastic type and color – and combining this with options for decontamination, extrusion and degassing, this facility marks a key milestone in developing our technologies under near-industrial conditions. In this way, we continuously improve our processes together with our locations in Geleen, where we already operate mechanical recycling technologies,” says Ulf Schüller, head of Process Technology Development Frankfurt.
Investments include the installation of a new flake sorter, decontamination steps as well as extrusion, downstream degassing and purification units, that will enable us to develop more consistent and higher quality end-products for our customers.
Trace analytics to achieve a cosmetic-grade application
Analytics play a crucial role in enabling the safe use of mechanically recycled materials for future applications. That is why the in-house analytics team at LYB in Frankfurt is advancing trace analysis to assess the suitability of these materials for cosmetic packaging.
CosPaTox – short for Cosmetics, Packaging, and Toxicology – is a European consortium that has developed a voluntary safety guideline for post-consumer recycled plastics (PCRs) in cosmetic and household packaging. The guideline provides a promising framework, as experts across cosmetics, packaging, and toxicology increasingly converge on previously missing safety and quality standards for recyclates, including the development of robust testing methodologies.
Examples of analytical methods used to evaluate recycled materials include:
- Gas Chromatography–Mass Spectrometry (GC-MS) for identifying and quantifying trace organic contaminants
- Inductively Coupled Plasma Mass Spectrometry (ICP-MS) for detecting heavy metals
- High-Performance Liquid Chromatography (HPLC) for analyzing additives and degradation products
These techniques help ensure that recycled materials meet stringent safety requirements, particularly for sensitive applications like leave-on cosmetics. “Smart recycling begins with smart analytics. Through continuous research and cutting-edge technology, we can truly meet our customers’ expectations and drive the future of recycling – ensuring recyclates are free from hazardous substances like heavy metals, plasticizers, and other toxic chemicals,” says Diana Doetsch, R&D Lead Polymer Physics & Characterization.
Matching our recycling technologies to waste types
Each recycling technology developed by LyondellBasell offers distinct strengths, collectively contributing to the reduction of plastic waste and advancement of a circular economy. Understanding that not all plastic waste is the same is essential – processing flexible plastics requires different technologies than processing rigid ones.
An overview of plastic types and our technologies:
- Mechanical recycling especially for rigid plastic waste (PP and HDPE)
- Solvent-based recycling to address flexible plastic waste (LDPE) – Newcycling
- Chemical recycling offers a solution for highly mixed and contaminated pre-sorted post-consumer waste – MoReTec