Circular economy for bio-based mountaineering rope

AI Quick Summary

Thematic focusThe project idea is to mechanically recycle the existing ropes and compound them into new plastic granules that can be used to manufacture new products again, preferably ropes.There are different approaches possible to achieve a high-quality material that can be used again for ropes:Separately recycle the core (2/3 of the rope, no colouring, potential higher quality of the recycling material possible) and the sheath, which encloses the core, (1/3 of the rope, coloured, more contaminants) material of the ropeUse very fine screens (< 50 µm) to remove as much contaminants as possibleUse additives for chain extension of the PA This project idea fits to the Innovation Booster as the emissions can be reduced significantly by using recycling instead of virgin material for Mammut’s products. Degree of innovationPost-consumer polyester/polyamide textile waste is nowadays often collected and then reused, chemically recycled, or disposed in landfills. Mechanical recycling would be a new approach that creates less emissions than chemical recycling.Mammut has already performed preliminary tests for mechanical recycling of their ropes. They made trials with taking back their ropes, which ensures a defined material stream. The recycling took place at an industrial recycling facility. However, the obtained quality was not sufficient for fibre spinning due to contaminations.With the new approach of sorting the ropes and IWK’s possibility to use very fine screens and additives if needed, it is likely to achieve a higher quality of the material. EffectSustainability and the reduction of CO2 emissions is nowadays an important factor for customers. This project idea allows Mammut to stay competitive with other manufacturers of outdoor gear by using less virgin material and therefore reducing the environmental impact.It is estimated that Mammut can collect >5 tons of ropes per year that could be recycled and used for new ropes. If a successful recycling process for Mammut’s rope are found, this method could also be applied for other mountaineering rope as well as industrial and sailing ropes. Methodological qualityThe methodology in this project is according to the work packages in the section scope and tasks. The IWK has already gathered experience in different recycling projects with PET-materials and textiles. With this know-how, it is possible to tackle this project’s challenges.Also, the modern machine park at IWK (mill, compounder, extruders, etc.) and highly qualified specialists allow to cover the entire process from recycling of the material until production of prototypes. There is also a well-equipped laboratory to analyse and identify materials and perform different tests. This allows to work at one place and integrate the insights directly for the entire process.Additionally, Mammut already has >1t of post-consumer mountaineering ropes available for testing, so there is no need to procure material for this project. Gender and DiversityBoth Mammut and IWK have a strong gender equality commitment and both genders are represented in the project team. Scope and tasksThe following tasks will be executed at IWK if not declared otherwise. WP1: Evaluation 01.01.2023 – 01.05.2023Analysis of the available post-consumer ropes (ropes with core and sheath)Design of experimentsPre-treatment of the material (sorting, washing, etc.) WP2: Testing and Validation 01.05.2023 – 30.09.2023· Tests at the compounder (feeding, compounding, pelletizing)· Analysis of the recycled material (intrinsic viscosity, contaminations, etc.)· Validation of the process-->IWK, Mammut BudgetThe detailed budget including the distributions of the budget between the project partners is attached to this application.Here is a summary of the budget:Total project budget (funding + personnel costs Mammut): CHF 29'462Seed money from the Innovation Booster Plastics for Zero Emission: CHF 25'000Mandatory assessment of CO2 reduction potential (external experts): CHF 1'000

Project Idea Metadata

Project Idea Name: Circular economy for bio-based mountaineering rope
Date: 10/13/2022 9:04:55 AM
Administrators:
- Karin Brändli Hedlund

Project Idea Description

Thematic focus

The project idea is to mechanically recycle the existing ropes and compound them into new plastic granules that can be used to manufacture new products again, preferably ropes.

There are different approaches possible to achieve a high-quality material that can be used again for ropes:

Separately recycle the core (2/3 of the rope, no colouring, potential higher quality of the recycling material possible) and the sheath, which encloses the core, (1/3 of the rope, coloured, more contaminants) material of the rope
Use very fine screens (< 50 µm) to remove as much contaminants as possible
Use additives for chain extension of the PA

This project idea fits to the Innovation Booster as the emissions can be reduced significantly by using recycling instead of virgin material for Mammut’s products.

Degree of innovation

Post-consumer polyester/polyamide textile waste is nowadays often collected and then reused, chemically recycled, or disposed in landfills. Mechanical recycling would be a new approach that creates less emissions than chemical recycling.

Mammut has already performed preliminary tests for mechanical recycling of their ropes. They made trials with taking back their ropes, which ensures a defined material stream. The recycling took place at an industrial recycling facility. However, the obtained quality was not sufficient for fibre spinning due to contaminations.

With the new approach of sorting the ropes and IWK’s possibility to use very fine screens and additives if needed, it is likely to achieve a higher quality of the material.

Effect

Sustainability and the reduction of CO2 emissions is nowadays an important factor for customers. This project idea allows Mammut to stay competitive with other manufacturers of outdoor gear by using less virgin material and therefore reducing the environmental impact.

It is estimated that Mammut can collect >5 tons of ropes per year that could be recycled and used for new ropes. If a successful recycling process for Mammut’s rope are found, this method could also be applied for other mountaineering rope as well as industrial and sailing ropes.

Methodological quality

The methodology in this project is according to the work packages in the section scope and tasks.

The IWK has already gathered experience in different recycling projects with PET-materials and textiles. With this know-how, it is possible to tackle this project’s challenges.

Also, the modern machine park at IWK (mill, compounder, extruders, etc.) and highly qualified specialists allow to cover the entire process from recycling of the material until production of prototypes. There is also a well-equipped laboratory to analyse and identify materials and perform different tests. This allows to work at one place and integrate the insights directly for the entire process.

Additionally, Mammut already has >1t of post-consumer mountaineering ropes available for testing, so there is no need to procure material for this project.

Gender and Diversity

Both Mammut and IWK have a strong gender equality commitment and both genders are represented in the project team.

Scope and tasks

The following tasks will be executed at IWK if not declared otherwise.

WP1: Evaluation 01.01.2023 – 01.05.2023

Analysis of the available post-consumer ropes (ropes with core and sheath)
Design of experiments
Pre-treatment of the material (sorting, washing, etc.)

WP2: Testing and Validation 01.05.2023 – 30.09.2023

· Tests at the compounder (feeding, compounding, pelletizing)

· Analysis of the recycled material (intrinsic viscosity, contaminations, etc.)

· Validation of the process

-->IWK, Mammut

Budget

The detailed budget including the distributions of the budget between the project partners is attached to this application.

Here is a summary of the budget:

Total project budget (funding + personnel costs Mammut): CHF 29'462
Seed money from the Innovation Booster Plastics for Zero Emission: CHF 25'000
Mandatory assessment of CO2 reduction potential (external experts): CHF 1'000