A cross-company collaboration at K 2025 in Düsseldorf demonstrates how used plastic packaging from the yellow bag is turned into a stable, foamed building block for the construction industry. ENGEL, EREMA, PreZero, Moxietec, ExxonMobil and Movacolor are pooling their expertise to demonstrate a comprehensive solution for processing post-consumer recyclate (PCR) – efficiently, sustainably and economically. Both EREMA and ENGEL will be presenting the specific processing steps involved in this joint project in live demonstrations at their exhibition stands.
At the heart of the application is a component made from 100% post-consumer material – collected by PreZero, high-quality recycled by EREMA and processed on an ENGEL injection moulding machine. The material base comes directly from the yellow bag and comprises washed PP regrind that has not been wind-sorted and also contains the light fraction – in other words, a slightly processed material stream from sorting. Thanks to excellent regranulate processing and perfectly coordinated processing technology, this challenging material stream is transformed into a high-quality, resilient component – proof of the innovative strength of the partners involved.
Recyclate processing as the key
EREMA plays a key role in recyclate processing. At the heart of the process is the INTAREMA® TVEplus® DuaFil® Compact machine, which sets new standards in efficiency thanks to its compact design and double filtration. The combination of proven TVEplus® technology and the patented DuaFil® Compact architecture enables particularly gentle processing.
Thanks to the shortened extruder length, reduced melt temperature and efficient pressure build-up through a melt pump tailored to the application, energy consumption and dwell time are significantly reduced. At the same time, the powerful degassing and fine final filtration ensure high-quality regranulate – even with minimally processed input material such as washed, non-wind-sorted PP regrind including light fractions. The machine is therefore ideal for applications that require the highest recyclate quality with maximum energy efficiency.
"The fact that such a low-grade post-consumer stream can be turned into a high-quality technical component impressively demonstrates what is possible with state-of-the-art technology and close cooperation. This project is a real best practice example – and that is exactly what the K trade fair is for: to showcase such solutions and inspire others."
Clemens Kitzberger, Business Development Manager Post-Consumer EREMA Group
EREMA and ENGEL demonstrate the application live
At K 2025, both EREMA and ENGEL will be presenting the respective processing steps at their exhibition stands. EREMA uses an INTAREMA® 1108 TVEplus® DuaFil® Compact for regranulate production, while ENGEL processes this with the fully electric e-mac 220 injection moulding machine. The compact production cell converts the PCR fully automatically into a foamed injection-moulded part – efficiently, space-savingly and with integrated automation. Digital assistance systems ensure stable processes and high component quality.
Efficient foaming – developed jointly
A specially developed additive and blowing agent mixture from Moxietec is used to foam the component, supplemented by the Vistamaxx additive from ExxonMobil. Gravimetric dosing is carried out using a system from Movacolor. This combination ensures a particularly homogeneous foam structure – ideal for thick-walled components where classic physical foaming processes reach their limits.
The result:
The recycled product is ideal for replacing concrete, for example in shafts, as well as for a wide range of applications such as garden sheds and garden fences.
A strong sign for the future of plastics processing
This application at K 2025 shows how partnerships across company boundaries are becoming the driving force behind sustainable innovation. Each partner contributes its expertise – from collection and processing to additives and automated processing. The result is a genuine building block for the circular economy – lightweight, stable and resource-efficient.
Experience it live at K 2025
1) Live recycling at EREMA in the Edvanced Recycling Centre (Outdoor Area FG CE03):
Washed post-consumer PP regrind (including light fraction, not wind-sorted)
Washed post-consumer PP regrind (including light fraction, not wind-sorted)
2) Live processing of the regranulate at ENGEL:
The regranulate is processed directly into a foamed injection-moulded part.
