ReSol Project: getting high quality recycled PVC for coating
ReSol project, started in the context of recycling coated PVC textile composites. Polyloop is already specialised in the recycling of PVC-based composite materials, but its recycling process still faces a problem: the r-PVC obtained does not have the right physical and chemical characteristics. Indeed, due to its granulometry, Polyloop’s dry-blend r-PVC cannot be used directly in a plastisol coating manufacturing process. However, this r-PVC compound is very suitable for extrusion, injection and calendering processes.
The purpose of the project is to find a solution to get a r-PVC that can be reused in plastisol coating processes following the recycling process. To this end, the aid allocated by the R&D Booster will make it possible to build a demonstrator in the form of an intermediate pilot capable of processing 5 kg of waste and making it possible to verify the technical viability of incorporating r-PVC into the plastisol process for the fields of protective clothing and construction.
A collaborative project involving two laboratories and a coating manufacturer
To successfully adapt the process to obtain a recycled PVC that meets the technical criteria for coating, Polyloop works with :
Chomarat: company specialised in the manufacture of coated textiles for the automotive, construction and luxury sectors. Chomarat will supply the products to be tested and will host the tests carried out on laboratory scale and on the intermediate pilot.
Laboratories of the Claude Bernard Lyon 1 University (UCBL): the Institute of Analytical Sciences (ISA) and the Laboratory of Automation, Process Engineering and Pharmaceutical Engineering (LAGEPP). These two laboratories will use their knowledge of pharmaceutical technologies and processes to control the final properties of the product. UCBL’s know-how in the physical and physico-chemical characterisation of dispersed systems in terms of size, size distribution and thermal properties, among others, will make it possible to work on the barriers and adapt the recycling process developed by Polyloop.
The project has also been supported by the Axelera (chemistry and environment) and Techtera (French textile industry) competitiveness clusters, which have approved the project.
Why focus on the use of recycled raw materials in coating?
Today Polyloop has solved the challenge for extrusion, calendering etc. Globally, succeeding in obtaining an r-PVC that can be reused by coaters while being compatible with the plastisol process would allow our coating customers:
use this recycled product in a wider range of products.
to operate in a closed loop circular economy: they will be able to recycle and integrate their r-PVC in their production.
reassure on the issue of traceability of the recycled material: recycle its waste and reintegrate it into its production. A known PVC formulation.
For Polyloop, the opening up to coating will make it possible to increase the market of potential customers by 50% thanks to the lifting of this technological lock that the coaters are suffering from.
The recycling of plastics and their composites is a major environmental issue today. Industrialists are looking for new solutions to process larger volumes of waste and thus make savings on materials and reduce environmental impacts (reduced energy and water consumption, CO2 emissions).
The ReSol project was set up in a context where the issue of recycling and the use of recycled material is more than ever at the heart of the problems faced by industry, for example
the quotas for landfill sites are decreasing, leading to an increase in landfill costs.
Extended Producer Responsibility (EPR) means that more and more sectors are taking into account the integration of recycled materials in their products.
stronger demand from customers involved in an environmental approach who also want or need to meet precise specifications regarding the recovery of their materials.
the volatility of the market concerning the purchase of raw materials.
540,000€ of public aid released
Granted by the Auvergne-Rhône-Alpes region, UCBL and Polyloop will receive a €390,000 subsidy and a €150,000 interest-free loan.
The projects selected in the framework of the R&D Booster 2021 represent a total credit of 7 150 704,56 €.
About the R&D Booster
The R&D Booster programme aims to promote collaborative R&D projects (at least two regional companies and a regional research and knowledge dissemination organisation) in response to a challenge of developing new products, processes or services.