Upcycle project to transform nonrecyclable plastics into circular packaging solutions

Aimplas, the Plastics Technology Centre located in Spain, has unveiled the Upcycle project, which unites 19 partners from 12 countries with the goal of converting nonrecyclable plastic waste into recyclable and nonpersistent packaging materials.

Source: RecyclingToday

Project Overview

This initiative is funded by Horizon Europe through the European Health and Digital Executive Agency (HADEA) and is coordinated by Aalborg University in Denmark. The research embraces Safe and Sustainable by Design principles, leveraging artificial intelligence (AI) for process intensification, smart polymerization strategies, and eco-design methodologies.

Target Applications

The project focuses on various applications, including:

• Flexible packaging for fresh food
• Short-lifetime deli packaging
• Beverage bottles
• Personal care packaging

Addressing Plastic Waste Challenges

According to Aimplas, over 460 million metric tons of plastic are produced globally each year, with a mere nine percent being effectively recycled. Plastic packaging constitutes 40 percent of the demand and 60 percent of plastic waste in Europe. Most packaging is single-use, with two-thirds discarded within a year, often stemming from complex or contaminated plastic streams that linger in the environment for centuries.

The Upcycle project is designed to tackle these issues by creating innovative circular value chains that convert nonrecyclable plastic waste into recyclable packaging materials. Aimplas aims to lessen dependence on incineration and landfills, support the European Union’s (EU) circular economy objectives, and pave the way for nonpersistent, safe, and sustainable plastics.

Aimplas’ Contribution

Aimplas is tasked with bridging the gap between polymer research and practical packaging applications. The center is developing new polyesters and copolyesters through formulations and pilot-scale production using cutting-edge technologies like:

• Reactive extrusion
• Compounding
• Injection molding
• Blow molding

Additionally, Aimplas assesses the behavior of these materials at the end-of-life stage by conducting:

• Biodegradation modeling
• Compost testing (both industrial and home)
• Environmental assessments in soil, freshwater, and marine environments
• Multicycle mechanical recycling trials

Aimplas also plays a role in defining end-user requirements, conducting market analysis, and ensuring regulatory compliance, all to guarantee that Upcycle’s materials are safe, scalable, and ready for market entry.

Future Goals

By 2029, Upcycle aims to produce packaging materials that are highly recyclable, nonpersistent, and biodegradable when appropriate, with a target of reducing greenhouse gas emissions by 30 percent compared to current bioplastics. These advancements will align with EU strategies regarding plastics, the Single-Use Plastics Directive, and the Circular Economy Action Plan.