BASF addresses recycled plastic quality issues with new additives for mechanical recycling

16 Sep 2021 --- BASF is introducing new additive solutions branded IrgaCycle for mechanically recycling plastics, addressing what it calls “the imminent needs in plastics recycling.” 

IrgaCycle is tailored to enhance the quality of post-consumer and post-industrial polyolefin material for reuse in rigid, flexible and molding applications across various target industries.

The launch represents BASF’s latest addition to its Valeras plastic additives portfolio, enabling recyclers, compounders and converters to reach their environmental sustainability targets.

BASF highlights the plastics industry is seeking ways to incorporate higher levels of recycled polymeric material in all major applications while facing growing consumer concerns and stricter regulatory requirements to reduce plastic waste.

Recyclate quality issues
A major challenge is mitigating polymers’ quality deficiencies from thermal and mechanical stress during the recycling process. Recycled plastics often contain impurities and polymer contaminants that accelerate polymer degradation, which change the material properties.IrgaCycle additive solutions are tailored to improve the properties of mechanically recycled plastics for different industries.

Consequently, recyclers and plastic converters are facing quality and performance issues while processing recycled polymeric material. Formulated additive packages improving the properties of these recycled plastics can be a solution for this challenge. 

“The production of plastics from mechanical recycling is expected to almost triple by 2030, driven by improved technologies and regulation. This corresponds to a growth of around 10% per year,” says Dr. Thomas Kloster, president of BASF’s Performance Chemicals division.

“With IrgaCycle, we are expanding our existing portfolio step by step by specific solutions for recycling to support the circular economy goals for plastics.”

The new IrgaCycle range includes additive solutions that can help increase the percentage of recycled content in several end-use applications, including packaging.

These solutions address specific quality issues associated with recycled resins, such as limited processability, poor long-term thermal stability and insufficient protection from outdoor weathering.

Various additive formulations
The IrgaCycle line includes a range of different additive formulations, with more to follow in the future:

• IrgaCycle PS 030 G enhances long-term thermal stability in rigid applications, mainly for recycled HDPE, polyolefins and mixed polymers.
• IrgaCycle PS 031 G improves processing and long-term thermal stability of recycled LDPE and LLDPE for incorporation into films and related flexible packaging applications.
• IrgaCycle PS 032 G provides processing stability and long-term thermal protection for recycled PP and polyolefin blends containing impurities.
• IrgaCycle UV 033 DD combines weathering stability with enhanced thermal and processing stability for reclaimed HDPE and PP blends for reuse in outdoor goods.
• IrgaCycle XT 034 DD rejuvenates processing, long-term heat stability and helps neutralize impurities of the “first life” of the plastic, improving mechanical properties of polyolefin recyclates.

Easy application benefits
A specific advantage of these blends lies in their ready-to-use product forms, which are easy to apply in the recycling process. The granulated non-dusting product form ensures safe and easy dosage during converting or compounding of reclaimed material.

“We have formulated these solutions based on our extensive experience in the plastics industry, combining the high-quality of our antioxidants and light stabilizer systems with our application expertise,” explains Dr. Volker Bach, global lead innovation at BASF Plastic Additives.Dr. Kloster, president of BASF’s Performance Chemicals division, says the production of plastics from mechanical recycling is expected to almost triple by 2030.

“With our global setup, we can engage across the entire value chain of the recycling industry, be it with brand owners or converters alike and in all regions.”

In addition to enabling plastic circularity with IrgaCycle, Valeras solutions bring value to plastic applications by improving durability, reducing waste, saving energy, reducing emissions, and promoting biodiversity, adds BASF.

PackagingInsights recently explored the latest additives innovation with plant-based pioneer Palsgaard, antimicrobial specialist BioCote, and chemical giants BASF, Clariant and Lanxess.

Recycled plastics in high demand
As Kloster points out, the production of plastics from mechanical recycling is expected to almost triple by 2030, driven by improved technologies and regulations, corresponding to growth of around 10% per year.

European Plastics Converters (EuPC) recently warned Plastics Europe that its call for a mandatory EU recycled content target of 30% by 2030 is “legitimate and achievable,” but only if the whole value chain shares the responsibility.

EuPC urges policymakers to avoid placing risks of structural change unilaterally on plastic converters without closely looking into alternative possibilities to increase recycled content in packaging.

Meanwhile, Natural Mineral Waters Europe, the European Fruit Juice Association and UNESDA Soft Drinks Europe urged the European Commission to provide the non-alcoholic beverage industry with “priority access” to recycled PET in the upcoming revision of the Packaging and Packaging Waste Directive amid downcycling concerns.

By Joshua Poole