JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 37

New trends in composites and plastics recycling

Fig. 4: Porcher PPS/GF Thermosaïc®

Fig. 2: Thermosaïc® recycled composite

Fig. 3: ThermoPRIME® recycled composite

generates very high waste volumes every year.
A material recycling channel does exist, but
for the moment it only manages to capture a
small part of the waste stream (around 10%).
Another part of this stream is captured for
energy recovery (about 20%). Thus, on a
global scale, nearly 70% of waste is dispersed
in nature or buried. As before, this situation is
no longer acceptable at present. The plastics
industry must increase the recycling rate of
its resins through the use of applications with
a higher added value, by approaching the
composites industry in particular.

Thermoplastic composite waste:
Thermosaïc® technology
Starting from a deposit of production waste
(and then end-of-life products), this technology consists in shredding the material in
order to maximize its economic potential
for recovery. The Thermosaïc® technology
(Figure 2) retains the intrinsic value of the
initial composite material, continuously
moulding these shreds by thermocompression into panels. Compared to recycling into
short fibre compounds, Thermosaïc® panels
have significantly better mechanical properties and a high formability potential.

This mutual understanding between two
formerly compartmentalised industries offers
new waste recovery prospects. In this respect,
Cetim Grand Est developed two eco-technologies that meet the upcycling expectations for
these materials.

Industrial applications
Thermoplastic composite waste recycling has
already been the subject of various studies, in
particular with Porcher Industries, the aim
being to find ways of recovering materials
such as PPS/glass with a high added value
(Figure 4).
Generally speaking, the aeronautical industry
shows interest in any technology capable
of recycling various production waste (up
to 40% waste) resulting from stamping or
thermocompression operations.
With the same logic of economic optimization and reducing the environmental
footprint of materials, an eco-designed
laptop case demonstrator (Figure 5) made
of recycled and/or bio-sourced materials is

currently being developed for the fashion
and luxury sector (CARATS) of the Carnot
institutes.
Through the LCFC (Low Carbon Footprint
Composite) collaborative project, associating
Cetim Grand Est and IS2M (Institut des
Sciences et Surfaces de Mulhouse) within
Carnot MICA, a proof of concept was developed based on the manufacture of a material
combining a recycled matrix (polypropylene) with a bio-sourced fibre reinforcement
(nettle).
These examples show the interest of manufacturers and academics in major subjects that
meet strong societal expectations. This flexible and agile technology makes it possible to
recycle all types of thermoplastics (from PP
to PEEK) and reinforcements (glass, carbon,
flax, etc.). It is mature enough to support
industrial needs through feasibility studies,
proofs of concept, specific formulations, pilot
production, etc.

N°136 September - October 2020

More information:

https://www.
cetimgrandest.fr/
industrie-durable/

https://youtu.be/GaPm9KJ6ms

/ jec composites magazine

Feature Sustainability

Two technologies with
the same production line
Using a step-by-step thermomechanical process, this innovative process (Figure 1) allows
the continuous production - from waste - of
recycled semi-finished products in the form of
large-scale thermoplastic composite panels.
The pre-industrial production line installed in
Mulhouse's workshop, designed in a flexible,
cost-effective and versatile way, and with an
"upcycling" approach, allows the recovery
of various thermoplastic waste into ranges of
recycled composite semi-finished products
with high added value and an optimised and
competitive cost/performance ratio.
Starting from the same production line,
but with two different feed systems, the
Thermosaïc® and ThermoPRIME® (Thermo
Plastic Recycling for Innovative Material and
Ecodesign) eco-technologies were developed
to fully exploit the recycling potential of composite and plastics materials.

Plastic or fiber waste:
ThermoPRIME® technology
Starting from a recycled plastic material with
low added value, formulated to the specific
needs of the application (controlled quality),
ThermoPRIME® (Figure 3) consists in associating this polymer with continuous or long
fibre reinforcements to produce continuous
laminates with high durability and economic
recovery potential.

Fig. 5: Example of a product thermostamped with
ThermoPRIME®/Thermosaïc® technologies

37


https://www.cetimgrandest.fr/industrie-durable/ https://youtu.be/Ga-Pm9KJ6ms

JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020

Cover
Edito
“We can change the way we envision global shipping overall”
Contents
NEWS
In brief
Agenda
BUSINESS
Reinforcement - Natural-fibre composites: an overview
Startup - When 3D printing meets sustainability
China - Xinzhou bets on the bamboo-based composites industry
MANUFACTURING
Wind - lnnovation in wind power through multi-process-capable systems
Automation - Higher production capacity thanks to automated manufacturing
FEATURE Sustainability - The path has been plotted
Recycling ecosystem - Composites recycling: in search of the circular economy
Mobility - A new generation of recycled composite materials for sustainable mobility
Preimpregnated textile - Healable composites to improve circularity
Process - New trends in composites and plastics recycling
Raw materials - Innovative composites made from up to 92% reclaimed materials
Construction - Biocomposites and automation: a sustainable future for the building industry
Ressources - Waste-free composite wheel production
Wind energy - From bottle to blade
Durable composites - Upcycling plastic bottles into value-added composite applications
Matrix - Novel thermoset composites for more competitive and sustainable industries
SOLUTIONS
Aerospace - Slinging rockets into space
Aerospace - Composites push back the final frontier
Railway - Composite overhead line catenary system for light rail
TECHNOLOGY
Repair - Developing an eddy current-based sensor system for quality assurance of carbon fibres
Inside the lab - Advanced Composite Materials Facility University of Southampton
Resin - Development of new type of plastics: Polypropylene 2.0
Index
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JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Cover
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 2
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Edito
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - “We can change the way we envision global shipping overall”
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 5
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Contents
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 7
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - In brief
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 9
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 10
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Agenda
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Reinforcement - Natural-fibre composites: an overview
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 13
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Startup - When 3D printing meets sustainability
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 15
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - China - Xinzhou bets on the bamboo-based composites industry
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 17
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Wind - lnnovation in wind power through multi-process-capable systems
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 19
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 20
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 21
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Automation - Higher production capacity thanks to automated manufacturing
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 23
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 24
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 25
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Recycling ecosystem - Composites recycling: in search of the circular economy
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 27
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 28
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 29
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 30
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Mobility - A new generation of recycled composite materials for sustainable mobility
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 32
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Preimpregnated textile - Healable composites to improve circularity
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 34
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 35
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Process - New trends in composites and plastics recycling
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 37
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Raw materials - Innovative composites made from up to 92% reclaimed materials
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 39
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Construction - Biocomposites and automation: a sustainable future for the building industry
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 41
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Ressources - Waste-free composite wheel production
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 43
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Wind energy - From bottle to blade
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 45
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Durable composites - Upcycling plastic bottles into value-added composite applications
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 47
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Matrix - Novel thermoset composites for more competitive and sustainable industries
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 49
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 50
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Aerospace - Slinging rockets into space
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 52
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 53
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Aerospace - Composites push back the final frontier
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 55
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Railway - Composite overhead line catenary system for light rail
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 57
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 58
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Repair - Developing an eddy current-based sensor system for quality assurance of carbon fibres
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 60
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 61
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Inside the lab - Advanced Composite Materials Facility University of Southampton
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 63
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Resin - Development of new type of plastics: Polypropylene 2.0
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 65
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 67
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 68
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