Flame retardant polymer from recycled plastic

Edited by the Engineeringtalk editorial team Nov 30, 2007

Material potentially offers manufacturers a variety of new high value applications, particularly where offering a recycled content provides a marketing advantage or reduces production costs.

Axion Polymers is claiming a technical breakthrough in the production of a new flame retardant impact styrene formulation with high recycled content following successful laboratory trials.

With up to 70% recycled content, the company says its new material demonstrates the feasibility of making a highly flame retardant polymer, branded Axpoly PS01 FR, from its Axpoly PS01 halogen-free recycled plastic.

However, having cracked the concept, Axion is quick to point out the next challenge is to make the process commercially viable for large-scale production.

The material potentially offers manufacturers a variety of new high value applications, particularly where offering a recycled content provides a marketing advantage or reduces production costs.

The recycled component of Axion's new formulation generates 10% of the amount of CO2 that is made in the production of virgin polymer.

"We have proved that a V0-performance material can be made in the laboratory and this has been independently tested by a major petrochemical company".

"We believe the future market potential is excellent as flame retardant plastics make a major contribution to safety and saving lives".

"However further research and development is needed to create commercially viable routes to market", comments Axion's Technical Director Keith Freegard.

Axion was engaged to assess the commercial viability of using high quality recycled polymers derived from WEEE (Waste Electrical and Electronic Equipment) in new products, such as TV casings.

Achieving the "yellow card" (UL94 accreditation) for the formulation and scaling up production are the next critical steps, according to Axion's Technical Consultant, Robin Hilder.

"Axpoly PS01 FR is an excellent raw material and in plentiful supply from recycled electrical appliances".

"This breakthrough means suppliers of flame retardant grades could benefit from using a base resin with a high recycled content, rather than virgin polymer; with obvious economic and environmental benefits".

"Using high quality recycled polymers in new electrical and electronic equipment offers benefits to manufacturers in terms of reducing raw material costs, cutting CO2 emissions, as well as boosting their 'green' credentials in the market", he adds.

Axion's new polymer is based on a bromine-free material that can meet the V0 flame-retardant specification using a special flame retardant additive.

It was developed at the firm's state-of-the-art processing facility at Salford, one of the most advanced recycling facilities in Europe for handling the polymer waste stream produced by the primary treatment of WEEE (Waste Electrical and Electronic Equipment).

Axion Polymers offers Axpoly branded polystyrene and HIPS injection- grade materials based on raw materials sourced from primary WEEE treatment plants for fridges, televisions and smaller electrical appliances.

The range of available grades is growing as the production plant takes on a wider variety of input raw materials from mixed household electrical goods and business equipment waste.