SmartReUSE – AI-controlled optimisation of the use of recyclates in plastics processing / plastics production
The aim of the technology transfer project is to enable a more efficient use of recyclates in order to improve the circular economy of polymers. By reducing CO₂ emissions, the project contributes to European environmental protection and climate objectives. To achieve this, various recyclate streams and qualities are being investigated and analysed using methods that are as practical and economical as possible. Based on the data generated and collected in collaboration with industrial partners, pattern recognition software is being developed and trained. Using a small number of meaningful parameters, the software will be able to provide recommendations for the processing and additive modification of recyclates.
News
Launch of the First Sub-Project
In May, the first sub-project, “RecyBrewHolder” was launched together with the SMEs ComRec-ReCond and BKW Kunststoff GmbH.
The project focuses on recycling post-consumer HDPE. The materials are blended with virgin material and subsequently given a second life as beer keg holders.
Post-Consumer-HDPE
Blends with virgin Material
Pattern recognition of HDPE in structural components
Project Workflow
From recycled material to optimized production
Recyclate
Collection of different recyclate streams and qualities.
1
Laboratory Analysis
Practical, economically viable testing of materials.
2
Material Data
Structured collection of all measured values.
3
AI
Trained pattern recognition software identifies correlations
4
Optimisation
Recommendations for processing and additive modification.
5
Production
More efficient, resource-conserving utilisation.
6
Project Focus Areas
Four solution approaches form the backbone of the project
1.
Local Recycling
Increasing the local recycling of materials leads to shorter transport routes and greater regional value creation.
2.
Material Processing
Processing contaminated material to achieve a significantly higher usable recyclate quality.
3.
Artificial Intelligence
Trained pattern recognition provides recommendations based on a small number of meaningful parameters.
4.
Process Optimisation
Implementation of AI-optimised processes for the processing and additive modification of recyclates.
Benefits for Companies
Concrete economic and environmental benefits of the SmartReUSE approach
Material Costs
Lower material costs through a higher proportion of economically usable recyclates.
CO₂-Emissions
Reduced carbon footprint throughout the entire processing chain.
Recyclate Content
Higher recyclate content in products while maintaining consistent quality.
Production waste
Reduced production waste through optimised additive modification.
Product Quality
More stable and better reproducible product quality in serial production.
Efficiency
More efficient processes through data-driven AI recommendations.
Project in Numbers
24
Months
Project Duration
Multi-year technology transfer project
8+
Companies
Project Partner
Regional companies
1,2 Mio.
Euro
Funding
The technology transfer project is co-funded by the Free State of Bavaria and the European Union.
4
Cross-Functional Areas
Technologies
Recycling · Analytics · AI · Optimisation
Project Partners & Funding
Institutional Sponsorship, Network Partners and Public Funding
Public Funding
The technology transfer project is co-funded by the Free State of Bavaria and the European Union.
NETWORK & INDUSTRY PARTNERS
-
Small and medium-sized plastics processing companies in the region
-
Recycling and material processing companies
-
Additional industrial and research partners under coordination
Sub-Projects in Detail
Latest News
TP1
Sub-Project 1 “RecyBrewHolder”
Post-consumer HDPE from different material streams and molecular weights
Investigation of grinding degree and blending intensity with virgin material
Pattern recognition for the use of PCR-HDPE in structural components (here: beer keg holder)
The first sub-project focuses on HDPE recyclates from various applications, including waste containers, transport packaging (trays), telecommunications cable sheathing and pipes. These differ in terms of their processing history, ageing, additive modification and rheological properties.
Through systematic material characterisation and defined blending with virgin material, the project investigates how these differences affect processing and component properties.
A load-bearing beer keg holder manufactured by industrial injection moulding serves as the demonstrator. This component places high demands on stiffness, impact strength and process stability, making it ideally suited for evaluating the potential of different recyclate blends under practical conditions.
Project Partner
TP2
Sub-Project 2 “PET2Cycle”
Virgin and PIR/PCR materials: PP, PET, HDPE, LDPE, LLDPE
Blending of polyolefins with PET
Pattern recognition of contaminants in real recyclate streams
Project Partner
TP3
Sub-Project 3 “IonCycle”
Virgin and post-industrial ionomers based on zinc and sodium
Recycling of post-industrial material in co-extruded ionomer films
Pattern recognition of potential recyclate contents and blends for film production
Project Partner
Direct Contact with the Project Team
Interested in collaborating within the SmartReUSE project?
We look forward to receiving your enquiry regarding recyclate analysis, data cooperation or joint process optimisation.
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Interested in collaborating within the SmartReUSE project?
We look forward to receiving your enquiry regarding recyclate analysis, data cooperation or joint process optimisation.Interested in
collaborating within
the SmartReUSE
project?