GePart

Development of efficient process technologies within the closed particle foam material cycle

As part of the collaborative research project GePart, it was demonstrated that the recycled content in the processing of expanded polypropylene (EPP) particle foam into molded parts can be significantly increased by selecting appropriate recycling and manufacturing processes while simultaneously reducing energy consumption. Within the project, recycled content exceeding 70% was achieved.

Furthermore, it was proven that EPP particle foam can fundamentally be processed into molded parts using RF technology and that specific machine and tool functions are required for this purpose. However, due to the selection of an unsuitable tool material, a functional RF demonstrator tool could not be approved by the project’s conclusion. Nevertheless, the material cycle was successfully closed and quantified using life cycle assessment (LCA). Ultimately, the recycled content in EPP molding was significantly increased while adopting manufacturing processes that substantially enhance resource efficiency.

Notably, at the Institute of Lightweight Engineering and Polymer Technology (ILK) at TU Dresden, a simulation methodology was developed to predict the foam properties under compressive and tensile loads at the particle foam level based on the characterization of the initial PP materials.

The collaborative project was completed in 2024.

Closed Particle Foam Material Cycle for EPP.

Period

01.12.2020–31.05.2024

Project partners

Consortium Leadership

RUCH NOVAPLAST GmbH

Project Partners

Associated partner

Kaneka Belgium NV

Funding

Federal Ministry for Economic Affairs and ClimateAction (BMWK): Technology Transfer Programme Lightweight Construction (TTP LB)
Funding code: 03LB2000G