Highly rigid recycled panels made from mixed plastic waste

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We produce building boards from mixed plastic waste according to a self-developed and patented process. Thereby we reduce the mixed plastic waste, the consumption of new plastic and the CO2 emission by incineration. DescriptionIn Switzerland, mixed plastic waste that is difficult to recycle is usually incinerated. As an alternative to incineration, UpBoards presents an innovative and recyclable solution based on an energetically and economically efficient manufacturing process that achieves significant CO2 savings compared to the single use of plastics. The product is a recycled panel that can be used for various construction applications and for advertising technology. The material formulation of the recycled panels consists of 100% recycled plastic fractions. For the top layer, recycled plastic and fibre waste is used, which is embedded in a thermoplastic matrix. For the core material, low-grade, mixed plastic by-products from CH recycling companies or from companies with high plastic waste (e.g. SBB, Coop, etc.) are to be used in a foam pressing process. This in turn creates a closed-loop recyclable thermoplastic sandwich structure. The ProblemIn Switzerland, the total consumption of plastics is about 1 million tonnes per year. Approx. 220,000 tonnes remain in long-term use (e.g. window frames). Of the 780,000 tonnes that are disposed of, only about 10% can be recycled. 6% are energetically recovered, i.e. the calorific value is used to produce other goods (e.g. cement). The remaining 84% (approx. 655,000 tonnes) are used thermally (waste incineration, district heating). For every kilogram of plastic burnt, 3 kg of CO2 are produced. Based on the total amount burned, this amounts to CO2 emissions of about 2 million tonnes per year. This is about 5% of the total Swiss CO2 impact. In order to reduce CO2 emissions in Switzerland, valuable plastics should therefore no longer be incinerated but returned to the cycle. The SolutionThe reused plastic waste saves resources and reduces the CO2 emissions that would result from their incineration. Since old recycling sheets can also be reused, a closed cycle is created. We have also set ourselves the goal of offering a solution to all companies that want to become more sustainable. By having their plastic waste analysed by us and developing a customised recycling sheet together with us, we create a win-win situation. With every square metre of UpBoards board produced, we reduce plastic waste by 10 kg and 30 kg of CO2. Our goal this year is to recycle approx. 150 tonnes of mixed plastic waste and manufacture new products from it. The ProjectWith the money from the "Zero Emission" Booster, we are financing the development of a new board that will compete with so-called wood composites (MDF) in order to use local plastic waste, conserve wood as a resource and reduce imports from abroad.The TechnologyWe have developed and patented our own process for producing sheets from mixed plastic waste.

Project Idea Metadata

Project Idea Name: Highly rigid recycled panels made from mixed plastic waste
Date: 3/30/2022 9:37:13 PM
Administrators:

Project Idea Description

Description

In Switzerland, mixed plastic waste that is difficult to recycle is usually incinerated. As an alternative to incineration, UpBoards presents an innovative and recyclable solution based on an energetically and economically efficient manufacturing process that achieves significant CO2 savings compared to the single use of plastics. The product is a recycled panel that can be used for various construction applications and for advertising technology. The material formulation of the recycled panels consists of 100% recycled plastic fractions. For the top layer, recycled plastic and fibre waste is used, which is embedded in a thermoplastic matrix. For the core material, low-grade, mixed plastic by-products from CH recycling companies or from companies with high plastic waste (e.g. SBB, Coop, etc.) are to be used in a foam pressing process. This in turn creates a closed-loop recyclable thermoplastic sandwich structure.

The Problem

In Switzerland, the total consumption of plastics is about 1 million tonnes per year. Approx. 220,000 tonnes remain in long-term use (e.g. window frames). Of the 780,000 tonnes that are disposed of, only about 10% can be recycled. 6% are energetically recovered, i.e. the calorific value is used to produce other goods (e.g. cement). The remaining 84% (approx. 655,000 tonnes) are used thermally (waste incineration, district heating). For every kilogram of plastic burnt, 3 kg of CO2 are produced. Based on the total amount burned, this amounts to CO2 emissions of about 2 million tonnes per year. This is about 5% of the total Swiss CO2 impact. In order to reduce CO2 emissions in Switzerland, valuable plastics should therefore no longer be incinerated but returned to the cycle.

The Solution

The reused plastic waste saves resources and reduces the CO2 emissions that would result from their incineration. Since old recycling sheets can also be reused, a closed cycle is created. We have also set ourselves the goal of offering a solution to all companies that want to become more sustainable. By having their plastic waste analysed by us and developing a customised recycling sheet together with us, we create a win-win situation. With every square metre of UpBoards board produced, we reduce plastic waste by 10 kg and 30 kg of CO2. Our goal this year is to recycle approx. 150 tonnes of mixed plastic waste and manufacture new products from it.

The Project

With the money from the "Zero Emission" Booster, we are financing the development of a new board that will compete with so-called wood composites (MDF) in order to use local plastic waste, conserve wood as a resource and reduce imports from abroad.

The Technology

We have developed and patented our own process for producing sheets from mixed plastic waste.