NAME OF THE PROJECT
Research works on no-waste technology for production of 100% recycled polyester foamed foil (PET) used in thermal resistant packaging for food industry
PURPOSE OF THE PROJECT
Research on a formula of foamed polyester foil, implementation of its production technology based on 100% recyclate and manufacturing of CPET thermal resistant packaging for direct food contact
BENEFICIARY
Marcato Sp. z o.o.
VALUE OF THE PROJECT
12 504 802,30 PLN
CO-FINANCING
5 597 291,57 PLN
PROJECT DESCRIPTION
The project considers industrial research and development works aimed at preparation of a polyester foamed foil formula made of 100% recyclate and post-production waste, including its production technology. The foil is to be used for manufacturing of barrier packaging used in food industry for direct food contact.
The packaging characteristics include thermal resistance up to 200°C and 100% recyclability.
Improved processing and performance properties of recycled materials are to be achieved by increasing viscosity and obtaining required cleanness as a result of solid-state polycondensation and decontamination.
Increased crystallinity in the thermoforming process gives the CPET packaging higher thermal resistance compared to the present one of amorphous PET foil from 60 to 70°C.
This formula is then foamed which requires also a related know-how. Therefore, the project implementation provides for new knowledge regarding recipes and technologies for production of foamed polyester foil and respective thermal resistant packaging.
The project is to be completed within 27 months in 3 stages. The 1st stage considers gaining new knowledge on increasing viscosity, crystallinity and PET foaming process. This is to be conducted together with research units both in their and Marcato laboratories. The research effects are to be implemented at a later stage in order to work on the foil model recipes for food contact thermal resistant packaging made of 100% recyclate. This stage includes testing of the worked out solutions in order to verify previous parameters. The third stage refers to preparing prototypes of foamed and un-foamed polyester foil of recycled material, to finalize with a prototype packaging, presenting series of CPET packaging and final technology method. A dedicated team has been appointed, consisting in the company employees and selected content-related subcontractors.
This solution is to be implemented in production under Marcato business operations, and then launched on the market as high market potential.
The foamed foil packaging is to be mainly purchased by the „fresh food” sector companies
and producers of read-made dishes, due to the high mono-foil barrier capacity and thermal resistance up to 200°C.
The project outcome is innovative and provides for a resolution of key environmental problem related to the plastic waste management by its recycling and re-usage. The planned design carries all the zero-waste production characteristics and reduces material consumption.
Consequently, the project in whole refers to 11 National Smart Specializations [KIS] regarding: MINIMALIZATION OF WASTE PRODUCTION (INCLUDING E.G. NO-WASTE OR LOW-WASTE PRODUCTION).