Results

Results

1. For Designers and Manufactures

Design for and From Recycling: Practical Guidelines for Designers

A world without plastic is unthinkable nowadays, and for most of us plastics have become part of everyday life. In the space of about seventy years, the production of plastic has increased from 1.5 million tonnes in 1950 to 368 million tonnes in 2019.

Today, in Europe the plastics industry has a yearly turnover of more than 360 billion EUR and the sector employs more than 1.6 million people. Download the guidelines to learn more about circular design and how to close the loop with design FOR and FROM plastics recycling.

This is a PDF (30KB)

Value Chain Map of Circularity in the EEE Sector

A Visual Guide to the Value Chain Map of Circularity in the EEE Sector

This is a PDF (30KB)

D1.4 Matrix of industrial symbiosis opportunities

The report evaluates the possibility to open the loop for electronic applications on the ‘intake’ side and to consider the use of PCR plastics from a different origin than WEEE, laying the foundations for possible symbiosis between EEE and the other relevant sectors. To fully understand the potential of a symbiosis between these different sectors, the opposite scenario was considered, with examples of application for EEE wastes in different sectors.

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D8.6 Guidelines on improvement of the entire value chain of plastics

The report provides a comprehensive set of recommendations (technical and organisational) that aim to improve each stage of the complex EEE/WEEE plastics value chain. The recommendations leverage on the project's research findings and on the support of the Expert Network members (representing for example OEMs, take back schemes, consumers, designers, researchers, collection and logistic operators, WEEE pre-processors, plastic recyclers).

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D8.3 Dematerialisation study business case and benefits

The report assesses the benefits for dematerialisation and circular economy business models for EEE compared to traditional linear economy business models. Recommendations for changes in product design, and other operational issues, based on the dematerialisation trials, are compiled.

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D8.2 Resource efficiency studies and Life Cycle assessments

The report evaluates whether and to which degree the production of PCR plastics is environmentally beneficial compared to the production of primary plastics (LCA of PCR and primary plastics production) and which environmental and resource savings can be expected in a scenario where all PCR plastics that can be produced from WEEE are used in new EEE (mass implementation of PCR plastics use).

This is a PDF (30KB)

D6.1 Map of market situation, derived barriers, drivers and information needs

The report analyses the barriers, drivers and information needs for an enhanced secondary market for PCR plastics. It provides an interactive geographic map of the recycling market as well as price developments for recycled plastics.

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D5.8 Summary of expansion of matrix from 5.1 with data sheets for the relevant material properties of the included materials

The report provides a matrix of the plastic types and additives developed during the project considering their potential use in EEE, expanding the list of materials shown in the Deliverable 5.1, and supporting the technical strategy development for re-use of WEEE materials. Both polymeric compounds and additives developed are listed and their main characteristics are presented. This report can be used as a reference for the selection of materials aiming for the circularity of WEEE materials.

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D5.6 Application guide of PCR compounds & data sheets

The report provides an application guide of PCR compounds & data sheets for PC, PC-ABS and ABS.

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D5.1 Material matrix with the predominant polymers and their additives in PCR polymers from WEEE

The report summarizes the possible additives that can be found in WEEE plastics and how these polymers can be stabilized for further use, including thermo-oxidative and photo-oxidative stabilizers, compatibilizers and chain extenders. Fire retardants are elaborated with their mechanism and problematics as there is a prominent shift nowadays to non-halogenated flame retardants. Finally, possible fillers are discussed in order to enhance certain properties of the WEEE plastics and in so, compensate or improve the difference in properties compared to their virgin counterparts.

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D2.4/2.5 Possibilities and limitations in the value chain and conditions for change

The report assess the needs, financial and technical possibilities and limitations of actors in the value chain such as producers of plastics, EEE manufacturers including the purchasing departments and product designers, collectors and treatment operators of WEEE, and recyclers of plastics. It describes the current framework situation in the plastic value chain by summarising the main economic and technical challenges that are preventing the various actors in the WEEE plastic value chain to transition from a linear to a circular economy, and by highlighting the existing opportunities for each actor to favour such transition. Furthermore, it illustrates the conditions for addressing the “missing link” between the recycling sector and the designers/manufacturers part of the circular value chain. The deliverable showcases an accumulated set of recommendations targeting governments and businesses on actions needed to close the e-plastics loop and to make the circular plastics value chain and the current business environment more appealing for all stakeholders involved. It exemplify in tangible terms a scenario for addressing e-plastic waste generation looking into the following four key conditions for adopting circularity: (1) technical, (2) environmental, (3) economic and (4) legal.

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D1.3 Value chain map of current level of circularity in EEE plastics

The report presents a cumulative value chain map of current level of circularity in the plastics value chain, with a specific focus on the electrical and electronic equipment (EEE) sector. It is a source of insight into the current level of adoption of the Circular Economy among businesses and consumers and a guidance towards strengthening, supporting and incentivising sustainable trends in our European economy and society. It includes a “Sales Pitch” promotional infographic that showcases the benefits for adopting post-consumer recycled (PCR) plastics into business operations, which entails persuasive arguments to sell the concept of using more recycled plastics in new applications for internal communication purposes.

This is a PDF (30KB)

D1.2 Report on drivers, risks and limitations to assess business model in the electronics sector

The report investigates the implementation of circular business models and the factors that influence their uptake and success. A stakeholder survey, together with in-depth interviews, goes beyond the theoretical implications from the literature review to gain greater detail, through direct communication with those involved. The results explore the impacts, drivers and limitations of circular business models in the electronics sector.

This is a PDF (30KB)

D8.1 Guidelines on Life cycle thinking integration and use of PCR plastics in new electronic products

This report is organised in three main parts. First, the current policy and legal background is presented and supplemented by information about recent standardisation and labelling activities at the global and European level. Several existing initiatives and guidelines are presented and accompanied by fact sheets in the Annex. Second, two complementary design strategies aiming to enhance the circular flow of products and materials are presented. The “design for recycling” strategy shows best practices during the product development process, following the sequential design phases of material selection, part, and product design. The “design from recycling” strategy looks to what extent new products can be manufactured using recycled plastics. The new Drop-In Approach™ provides a practical tool for product developers to start designing with recycled plastics. A complexity flowchart helps designers to focus on priority parts and a six step material approval approach allows them to gradually reduce the risk that is linked to using recycled plastics.

This is a PDF (30KB)

D1.1 Identification of circular business models and shortlist of applicable dematerialisation options

The report investigates different types of business models that generate revenues through the adoption of an alternative approach for value creation, delivery and capture. Based on several case studies from the electronics sector, the report provides metrics criteria in order to classify the business models. The final aim is to contrive a matrix facilitating the classification and characterization of business models deemed as circular.

This is a PDF (30KB)

2. For Recyclers

D4.5 Uniform grade system that can be used for trading PCR and will serve as a basis for the integration of an online platform in WP6

The report provides information about the developed grading systems for recycled plastics, one for mixed plastic flakes that serves as an input in a plastics recycling facility and one for the final plastic granulates that are ready to be used for the production of plastic components. The uniform grading system for recycled plastics is designed to facilitate and stimulate the international trade with post-consumer recycled plastics from WEEE. Two different phases of the supply chain are identified where the grading system can be applied: the phase between pre-processor and plastic recycler, where plastics are exchanged in the form of mixed plastic flakes and the phase between plastic recycler and product manufacturer, where recycled plastics are present in the form of granulates.

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D4.3 Description of standard and systematic testing procedures for the different types of PCR

The report provides an industrially applicable method for the determination of the quality of a mixed plastic waste stream including relevant impurities. The method has been applied to improve the production of the PolyCE product demonstrators. A reference analytical method has been developed to determine the size distribution, the colour composition and the plastic composition with FTIR that can also analyse black plastics.

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D4.2 Design from Recycling strategy for PCR polymers from WEEE

The report investigates a Design from Recycling strategy for PCR plastics from WEEE aiming to support the design of EEE parts and products using recycled materials. To further facilitate the effective implementation of Design from Re-cycling, sector-specific tools have been developed in intensive academic-industrial collaboration. The report presents the dEEEterminator - an injection moulding product, which serves as a tactile tool for the product developer to evaluate the material hands-on and first-hand.

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D4.1 Report on minimum material requirements for the trials

The report gives an overview of the minimum requirements for distinct plastic grades of the different post-consumer recyclate (PCR) types targeted in the PolyCE project for different stages in the value chain. The requirements are defined for the following two stages of the value chain: (1) mixed plastic flakes from WEEE, which are the plastics separated from WEEE by pre-processors, (2) post-consumer recyclates compounds, which are the compounds supplied to the original equipment manufacturers that are produced from sorted and cleaned mixed plastic flakes. The work identified that many of the minimum requirements from the OEMs side are very application specific and are defined specifically for a material in a certain application. Therefore, a more general definition of minimum requirements can be achieved by identifying key properties that allow a first pre-screening process. For this purpose it will be necessary to further translate application specific requirements into properties that are listed in a shortlist, which sufficiently covers main quality aspects for recycled plastics.

Christian Rath

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D3.5 Re-design value and supply chain for maximum effect

The report provides recommendations on how to improve the after use management of WEEE post-consumer plastics, including of recommendations for improved collection, logistics, WEEE pre-treatment and WEEE plastics recycling. Furthermore, the report contains the feedback on the adoption of the recommendations received from relevant stakholders.

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D3.4 Identification of WEEE recycling improvement for high quality plastic

The report evaluates modifiable parameters in the WEEE plastics pre-treatment processes and provides recommendations aiming to improve the volumes and quality of the plastics materials delivered to post-consumer plastics recycling facilities. For this purpose, the report investigates and analyses different shredding technologies applied by WEEE pre-treatment operators and their output particle size as well as the sorting technologies used by recycling facilities and their required input particle size.

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D3.3 Reverse logistics requirements for environmentally sustainable collection, recycling and reuse of PCR plastics

The report establishes methodologies to find best-practice network configurations in the domain of Reverse Logistics. Reverse Logistics is concerned with any process arising at the end-of-life of a product, and the way(s) in which that product is handled. The focus of this investigation is the identification and rectification of these inefficiencies within the product end-of-life handling process.

Christian Rath

This is a PDF (30KB)

D3.2 Collection requirements for clustering products

The report provides an analysis on how to improve the quality of recycled plastics through clustering strategies and optimization methods for material sorting. Feature engineering techniques (based on basic concepts from the field of graph theory) are derived to quantify how efficiently distinct product components can undergo joint treatment. The methods are illustrated by means of case studies for the cooling and freezing equipment, large household appliances and small household appliances waste streams. Recommendations are formed on clustering policies for these WEEE categories.

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D3.1 Quantification of material flows along the entire chain

The report investigates the current EEE/WEEE plastic value chain with attention to material flows and mass balances. It provides an overview and identifies the crucial nodes of the EEE/WEEE plastic chain. The adopted methodology includes the evaluation of the quantity of plastic put on the market, closely linking it with the amount of EEE put on the market; the amount of WEEE PCR plastic is put in relationship with WEEE collected and treated. Furthermore, a qualitative assessment has been performed developing a matrix showing the plastic content of the actual EEE and WEEE flows at polymer level.

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3. PolyCE Case Studies

D7.8 Assessment of non-WEEE PCR plastics for EE applications

The report explores other waste streams for their suitability in new EE applications and so opening to look at the intake. It explores three challenging waste materials from non WEEE-sources and materials with a high difficulty for implementation. Issues that can occur within recycling are tackled and results are used as input to improve material quality, enable use in higher-end applications, serve as verification of new recycling technologies and showcasing the potential of currently untapped sources. To showcase the possibilities of non-WEEE materials, examples of the use of these materials in the other demonstrator cases are briefly discussed.

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D7.7 3D printing demonstrator for PCR from WEEE

Deliverable 7.7 has the scope to serve as a practical guide to evaluate polymer feedstock materials, mainly post-consumer recycled (PCR) and post-industrial recycled (PIR) plastics as candidates for additive manufacturing (3D printing) applications. It investigates the most effective and efficient processing strategies and conditions for recycled polymers processing in 3D Printing (in both single and multi-material applications), and the most promising strategies to improve the strength and quality of 3D-printed parts. The conditions examined refer to fused filament fabrication, a commonly used 3D printing technology and 3D printed parts obtained by a new micro-extruder printing head which is a pellet-based printing technology.

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D7.6 Whirlpool Large domestic Appliances demonstrator

The Whirlpool demonstrator elaborates on the work performed within the clustering demonstrator (Task 7.1) and verified the quality improvements and opportunities by using the material into large-scale demonstrator cases. This resulted in individual parts produced with these materials at the required level of quality and performances. Whirlpool focussed on components for washing machines made of PCR-PP (CaCO3 filled), and explored refrigerators components made of PCR-PS. It was shown that obtaining fridge parts with the right technical and esthetical quality lies within the possibilities of todays technologies, however obtaining food contact approval remains a big hurdle. Next to this it was proven that materials obtained from the right recycling clusters could be implemented in washing machine parts without compromising on quality nor having to adapt processing parameters.

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D7.5 Philips PCR plastics demonstrator

Within the PolyCE project Philips has developed new insights and tangible demonstrator prototypes to test the limits and possibilities of recycled plastics. Applying the Design from Recycling approach and looking at the three key pillars for development led to several amazing demonstrator cases. The Philips demonstrators helped to explore the implementation possibilities and generate insights on how to solve the challenges in material validation, aesthetic standards, long term production stability and material availability. Several demonstrator cases showcase the possibilities and are now in the loop for market release. One of the cases has been successfully introduced on the market within the timeframe of the project.

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D7.4 Demonstrator SME EE product

Pezy developed a new demonstrator product with one of its SME customers based on WEEE sourced PCR plastics. Together with Wireless Value, a company producing wireless sensors, a new product housing line was developed. During the development process of these products, Design for/from Recycling guidelines were closely followed without compromising on quality and functionality. The product was successfully launched to the market and received positive feedback from industry.

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D7.3 Demonstrator LED lighting

ONA developed a high end LED light fixture taking into account the Design from Recycling strategy developed within the PolyCE project. The PCR plastics used in this case were compounded by the project partners and were especially developed and sourced to show the quality that can be obtained by recycling. Special attention was put on Design for Disassembly and Design for Recycling to ensure that the different lighting components can be separated from each other when the product reaches its end-of life, thus allowing to close the loop for all PCR polymers in a sustainable manner.

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D7.2 Demonstrator IOT connected sensor device

The Imagination Factory developed an IoT sensor for an SME called FundWaste. The plastic housing of the sensor was designed and moulded using recycled materials developed by one of the PolyCE consortium partners. These moulded housings were tested to verify their performance in real world conditions and fulfilled the product requirements while demonstrating the quality of these recycled materials.

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D7.1 Demonstrator for the WEEE supply chain

The report provides an overview of the improvements achieved by redesigning the end-of-life (EOL) value chain of post-consumer plastics from WEEE and following in practice the recommendations from WP3 and WP4, iincluding optimized collection, clustering, pre-treatment, sorting and re-processing of WEEE. The results give new insights on material quality improvements by clustering. The report includes also the description of the activities performed to evaluate the possibility of obtaining food grade approval from PCR WEEE plastics and the anlaysis performed by KUL to assess the potential upscaling of the solutions proposed in the PolyCE project increasing the amount of e-waste plastics properly collected.

This is a PDF (30KB)

4. Polyce Makers

Design for and From Recycling: Practical Guidelines for Designers

A world without plastic is unthinkable nowadays, and for most of us plastics have become part of everyday life. In the space of about seventy years, the production of plastic has increased from 1.5 million tonnes in 1950 to 368 million tonnes in 2019.

Today, in Europe the plastics industry has a yearly turnover of more than 360 billion EUR and the sector employs more than 1.6 million people. Download the guidelines to learn more about circular design and how to close the loop with design FOR and FROM plastics recycling.

This is a PDF (30KB)

Value Chain Map of Circularity in the EEE Sector

A Visual Guide to the Value Chain Map of Circularity in the EEE Sector

This is a PDF (30KB)

D8.2 Resource efficiency studies and Life Cycle assessments

The report evaluates whether and to which degree the production of PCR plastics is environmentally beneficial compared to the production of primary plastics (LCA of PCR and primary plastics production) and which environmental and resource savings can be expected in a scenario where all PCR plastics that can be produced from WEEE are used in new EEE (mass implementation of PCR plastics use).

This is a PDF (30KB)

D8.1 Guidelines on Life cycle thinking integration and use of PCR plastics in new electronic products

This report is organised in three main parts. First, the current policy and legal background is presented and supplemented by information about recent standardisation and labelling activities at the global and European level. Several existing initiatives and guidelines are presented and accompanied by fact sheets in the Annex. Second, two complementary design strategies aiming to enhance the circular flow of products and materials are presented. The “design for recycling” strategy shows best practices during the product development process, following the sequential design phases of material selection, part, and product design. The “design from recycling” strategy looks to what extent new products can be manufactured using recycled plastics. The new Drop-In Approach™ provides a practical tool for product developers to start designing with recycled plastics. A complexity flowchart helps designers to focus on priority parts and a six step material approval approach allows them to gradually reduce the risk that is linked to using recycled plastics.

This is a PDF (30KB)

D9.5 Policy measures, Environmental labelling and standardization input: Summary of policy recommendations

Deliverable 9.5 provides an overview of current product and waste-related policy framework that has a direct impact on the circularity of high-tech plastics from WEEE. Based on the evidence generated throughout the PolyCE project, the report makes recommendations with the overall aim to bring the value chain a step forward to a coherent and comprehensive legislative framework towards reusing and recycling technical plastics from WEEE.

This is a PDF (30KB)

5. Consumers

Value Chain Map of Circularity in the EEE Sector

A Visual Guide to the Value Chain Map of Circularity in the EEE Sector

This is a PDF (30KB)

PolyCE Project: A Social Experiment

Consumer awareness and information campaigns on circular consumption models.

Watch the Video on youtube

PolyCE Project: A Social Experiment

Consumer awareness and information campaign on the benefits of recycled plastics.

Watch the Video on youtube

PolyCE Project: Circular Future

Consumer awareness and information campaigns on circular consumption models.

Watch the Video

D1.4 Matrix of industrial symbiosis opportunities

The report evaluates the possibility to open the loop for electronic applications on the ‘intake’ side and to consider the use of PCR plastics from a different origin than WEEE, laying the foundations for possible symbiosis between EEE and the other relevant sectors. To fully understand the potential of a symbiosis between these different sectors, the opposite scenario was considered, with examples of application for EEE wastes in different sectors.

This is a PDF (30KB)

D1.3 Value chain map of current level of circularity in EEE plastics

The report presents a cumulative value chain map of current level of circularity in the plastics value chain, with a specific focus on the electrical and electronic equipment (EEE) sector. It is a source of insight into the current level of adoption of the Circular Economy among businesses and consumers and a guidance towards strengthening, supporting and incentivising sustainable trends in our European economy and society. It includes a “Sales Pitch” promotional infographic that showcases the benefits for adopting post-consumer recycled (PCR) plastics into business operations, which entails persuasive arguments to sell the concept of using more recycled plastics in new applications for internal communication purposes.

This is a PDF (30KB)

D1.2 Report on drivers, risks and limitations to assess business model in the electronics sector

The report investigates the implementation of circular business models and the factors that influence their uptake and success. A stakeholder survey, together with in-depth interviews, goes beyond the theoretical implications from the literature review to gain greater detail, through direct communication with those involved. The results explore the impacts, drivers and limitations of circular business models in the electronics sector.

This is a PDF (30KB)

D1.1 Identification of circular business models and shortlist of applicable dematerialisation options

The report investigates different types of business models that generate revenues through the adoption of an alternative approach for value creation, delivery and capture. Based on several case studies from the electronics sector, the report provides metrics criteria in order to classify the business models. The final aim is to contrive a matrix facilitating the classification and characterization of business models deemed as circular.

This is a PDF (30KB)