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Problem statement
Manufacturing companies face increasing pressure to reduce CO₂ emissions, limit the use of virgin plastics, and meet circular economy requirements while maintaining high product quality, process efficiency, and cost competitiveness. Traditional thermoplastics and many sustainable alternatives fail to meet these demands simultaneously, often requiring compromises in performance, recyclability, or production costs. Therefore, there is a clear need for a fully circular, high-performance thermoplastic made from 100% recycled content that can be processed using standard manufacturing technologies without sacrificing quality or efficiency.
1. Ecoplastomers are a Highly Tested and Precise Injection Moulding Materials – Ideal for Replacing Existing Virgin Thermoplastics. In recent injection process trials, automotive parts made from Ecoplastomer® demonstrated equal or superior quality to their traditional counterparts. Remarkably, we achieved almost 13% reduction in injection time for one component. 2. Ecoplastomer® has Undergone Rigorous Coating Adhesion Tests, Demonstrating its Exceptional Compatibility with Various Coatings.
Test results conducted in Wrocław laboratories confirm that our product's unique structure eliminates the need for any specific pre-coating preparation, making it a highly efficient choice for coating applications. Additionally, Ecoplastomer® successful performance in these tests underscores its reliability and suitability for diverse coating needs.
3. Ecoplastomers have Undergone Successful Testing in Spray Coating to Protect Metal Step from External Factors.
The experiment on Ecoplastomer® PP 70 revealed that our 100% recycled content thermoplastic material sprays very well, and a lower consumption of materials (about 8%) was demonstrated compared to traditional polyolefin.
4. Ecoplastomer® Offers Optimal Balance of Durability and Elasticity: Paint Boxes Manufactured from Ecoplastomer® PP 70. The use of our circular thermoplastic material significantly enhances the durability of paint containers. Ecoplastomer® contains recycled rubber, allowing for flexibility that prevents the lid hinge from cracking. Ecoplastomer® eliminates the need to seal the lid immediately after injection, while the product is still hot. This flexibility simplifies the production process, allowing for more efficient manufacturing without compromising the integrity of the product.
5. Successful Use of Ecoplastomers in Thermoforming. The sample was made by thermoforming the Ecoplastomer® PP 70 from a 2 mm plate produced by a press. These parts are suitable for creating closed, hollow products using laser welding. 6. Successful Usage of Ecoplastomers for 3D Printing.
To start the process, we needed to produce the filament using Ecoplastomer®. This was achieved using a single-screw extruder. The final stage of the extrusion process involved winding the filament onto a spool with a winder. Afterward, we utilized a Prusa MK3S 3D printer to print two samples, ISO 178 and ISO 527, with a solid structure at 100% infill. The printer was equipped with a Volcano (E3D) nozzle with a 0.8mm diameter, and we designed an additional thermal shield for it.
Main outcome
100% Recycled Content: Ecoplastomer® is made solely from recycled content, eliminating the need for virgin plastomers and even majority of plastics made from crude oil.
Quality on Par with Traditional Thermoplastic Materials: Density and hardness are similar to traditional (virgin) thermoplastics, making it easy to incorporate Ecoplastomer®.
Up to 30% Reduction in Production Costs: Reduction in injection cycle time of between 10%-30% provides considerable cost savings, not achievable with virgin thermoplastics.
Up to 69% CO₂ Reduction: Production process of Ecoplastomers emits up to 69% less CO₂ than traditional plastomers, according to the LCA analysis.
Digital Product Passports: We provide digital product passports, allowing our clients to trace and calculate their CO₂ emissions.
Fully Circular, Easily Recyclable: Any product made from Ecoplastomer® can be recycled repeatedly. This way, the recycled content does not go to the landfill and stays in the closed loop.
No Chemical Additives: Ecopolplast patent technology creates strong bonding of recycled rubber and plastic without chemical additives or stabilisers.
Zero-waste Production: Every grain of the purchased material can be returned to the production process.
Scent-neutralised, Suitable for Indoor: It reassesses how we approach the use of recycled materials in product manufacturing, e.g. automotive, construction, sports equipment, home and garden or storage solutions.
Performance: Currently, two types of Ecoplastomer® are available: with PP and HDPE. All composites show excellent balance of stiffness, resilience, impact and UV-light resistance as well as dimensional stability.
Easy to Implement in the Mass Production Process: Processing method is the same as for traditional materials, it is equally easy to implement in the manufacturing process."
