Presentation of the recycling process developed in CarE-Service Project during the First Exploitation Webinar of the project held on 9th December 2020 by Radici Group

1. EXPLOITATION WEBINAR
Engineering Polymer Recycling
Solutions
9th December 2020
Riccardo Galeazzi
Susanna Caprotti
Claudio Ghilardi

2. Agenda
1. RadiciGroup High Performance Polymers. Brief introduction
2. Development of engineering polymer recycling solutions
3. Environmental impact assessment
4. Recycled material usage: from characterization to real application

3. RadiciGroup High Performance Polymers
Brief introduction
V I S I O N
Growth through Innovation,
with a focus on speciality products,
mainly based on polyamide grades.
Sustainability commitment
along our entire
production chain.
FA C T S
Main Brands:
Vertically integrated production of
PA 6 Radilon® S, PA 6.6 Radilon® A,
PA 6.10 Radilon® D, PA 6.12
Radilon® DT and copolymers.
Worldwide production and sales
network. Manufacturing footprint in
Europe, Americas and Asia.
Complete range of materials
available in all countries, including
high performance products and
special custom grades.
Our people's expertise and support for the development of new applications
and solutions on a global level. We consider our approach to innovation as a
competitive advantage – from CAE design to product development.
Our commitment to sustainability
We support the circular economy. Our
15-year-old commitment to sustainability
is embedded in the RadiciGroup Mission
set down back in 2000.

4. Is it possible ?

5. Solution development stages
Preliminary
study
Component
selection and
pre-treatment
evaluation
Formulation
tuning
Scale-up
Environmental
impact
assessment
(LCA)
and
demonstration
phase
70%

6. Product definition by material source
Intermediates,
polymers
Finished product:
Prime material
Polymerization,
textile and
manufacturing
scraps
Finished product:
Post-industrial recycled material
Preliminary
treatments
Recompounding
End-of-life cars
or other EOL sources
Finished product:
Post-consumer
recycled (PCR)
material
Engineering
polymer
components
VIRGIN MATERIAL POST-INDUSTRIAL POST-CONSUMER

7. Development of engineering polymer recycling solutions
FINAL GOALS
The expected results are:
• First, controlling (limiting) the property variability of the post-consumer recycled material.
• Second, preserving material performance or trying to increase it (even better).
Formulation Tuning of
Post-Consumer Material
Reduce
Variability
Preserve/Increase
Performance
Material
Property
Prime
Material
Post-Industrial
Material
Post-Consumer
Material
Mean
Lower Limit
Upper Limit
Legend
Post-Industrial
Applications
Prime
Applications
Post-Consumer
Applications
• Third, assessing the economic sustainability of the post-consumer recycling process.

8. Developmentof engineeringpolymer recycling solutions 1/4
METHODOLOGY  Dismantling, Cleaning and Selection
3 - Cleaning
2 - Polymer selection, and metal separation.
Visual
technique
1- Dismantling*
*Many other polyamide components were dismantled from cars, while measuring the effort required in
terms of “Time Spent“. The selected components had a better ratio between weight or polymer quality
and time spent (refer to Deliverable 1.2 – Deliverable 3.2 – Deliverable 5.3).
Components* Quantity
External door handle ≈ 30kg
Cooling fan 5 units
Rear wiper ≈ 30kg
Wheel covers ≈ 30kg
Engine cover 5 units
Radiator tank 5 units
Airbags ≈ 30kg

9. Development of engineering polymer recycling solutions 2/4
METHODOLOGY  Formulation tuning
6 - Oven drying
9 - Production (extrusion)
8 - Formulation tuning  Post-
consumer materials produced are:
- 18 scouting materials
- 6 reference materials
7 - Lab analysis of raw materials:
- FTIR (Fourier-transform infrared spectroscopy)
- DSC (Differential scanning calorimetry)
- Ashes
- Viscosity
5 - Metal
separation*
*These activities were conducted in collaboration with STIIMA-CNR.
4 - One-step 6 mm grinder*
24 different
materials
Finished product
appearance

10. Development of engineering polymer recycling solutions 3/4
METHODOLOGY Pilot results and validation
Here you can see the best results obtained
using airbags and wheel covers as source
materials (PA 6.6 base polymer)
Wheel cover source
Airbag source Rear wiper source
Validated by rear wiper source
(PBT-PET base polymer)

11. Development of engineering polymer recycling solutions 4/4
METHODOLOGY Scale-up
1,240 kg of airbags and 1,200 kg of wheel covers were processed by industrial
methods to assess the effects of the process on final properties.
Material production
PA6.6 (GF+MD) 30
Glass Fibre Mineral Filler
Wheel covers
Post-Industrial
PA 6.6
AIRBAG SOURCE WHEEL COVER SOURCE
Dilution
Material production
Airbags +
Silicon Polymerization
Scrap
Yarn Scrap
PA 6.6
Base
PA6.6 MP1/K
Glass Fibre Additives
PA6.6 GF030/1K
PA6.6 GF050
PA6.6 GF25 HF

12. Development of engineering polymer recycling solutions 4/4
METHODOLOGY Results
This material, still in the scouting phase, is PA 6.6, with 30% glass fibre, thermal
stabilizer and black colour, produced using airbag source.
5 repetitions performed for each case at
23°C – RH 0%
The cotton stitching obstructed
the extruder filter.
The procedure to replace the filter took
into account the material loss. The
extruder had to be stopped and opened.

13. Development of engineering polymer recycling solutions 4/4
METHODOLOGY Results
This material, still in the scouting phase, is PA 6.6, with glass fibre, mineral filler
and black colour, produced using wheel cover source.
5 repetitions performed for each
case at 23°C – RH 0%
Inclusion of extraneous material from
chromium plating can be seen. This
could be a problem for processing and
structural applications. Applications
should be selected carefully.

14. Demonstration phase - Ongoing
Can the recycled materials designed in this project be used to produce real
components?
INJECTION MOULDING TRIALS 3D PRINTING TRIALS

15. Agenda
1. RadiciGroup High Performance Polymers. Partner introduction
2. Development of engineering polymer recycling solutions
3. Environmental impact assessment
4. Recycled material usage: from characterization to real application

16. The Eco-design strategy wheel. (Source: Brezet and van Hemel 1997: 81)
assessment of policies (models for
recycling, etc.)
substance and material flow analysis; hazard
and risk assessment of chemicals
risk analysis and risk management of
facilities and plants;
product stewardship, supply chain management
inclusion of environmental aspects in product
standards, life cycle management
quantification, monitoring and reporting of entity
and project emissions and removals, and
validation,
verification and certification of greenhouse gas
emissions
environmental management accounting, life
cycle costing
LCA (ISO 14040) - A.1 integration of environmental aspects into product design and development (design for environment)
(ISO/TR 14062)
Environmental impact assessment – LCA
Solution development stages
Preliminary
study
Component
selection and
pre-treatment
evaluation
Formulation
Tuning
Scale-up
Environmental
impact
assessment
(LCA)
and demonstration
phase
70%

17. The Eco-design strategy wheel. (Source: Brezet and van Hemel 1997: 81)
Environmental impact assessment – LCA

18. The Eco-design strategy wheel. (Source: Brezet and van Hemel 1997: 81)
assessment of policies (models for
recycling, etc.)
substance and material flow analysis; hazard
and risk assessment of chemicals
risk analysis and risk management of
facilities and plants;
product stewardship, supply chain management
inclusion of environmental aspects in product
standards, life cycle management
quantification, monitoring and reporting of entity
and project emissions and removals, and
validation,
verification and certification of greenhouse gas
emissions
environmental management accounting, life
cycle costing
LCA (ISO 14040) - A.1 integration of environmental aspects into product design and development (design for environment)
(ISO/TR 14062)
Environmental impact assessment – LCA

19. Product assessment by material source
Data used to assess each unit processed
(product/process) within the systems boundary
(starting from the extraction of raw materials) can be
classified under major headings, as follows:
• Energy inputs, raw material inputs, ancillary
inputs and other physical inputs
• Products, co-products and waste
• Emissions to air, discharges into water and soil,
and other environmental impacts
In environmental law, the polluter pays principle
(PP Principle) has been enacted to make the party
responsible for producing pollution responsible for
paying for the damage done to the natural
environment.
.
Waste is an environmental burden generated by the production of a product.
The impact assessment of a product always includes the environmental “damage” caused by the waste generated
during its whole life cycle, according to the PP Principle.
That’s why products made from “waste” have no environmental burden for raw materials.

20. Assessing engineering polymer reuse and
recycling solutions
The products made from “waste” are
environmental burden-free ONLY with
respect to raw materials, NOT the
processes needed to make them suitable
for a new life cycle (RECYCLING).
As the new life cycle begins, a new environmental
accounting of:
• Energy inputs, raw material inputs, ancillary inputs
and other physical inputs
• Products, co-products and waste
• Emissions to air, discharges into water and soil, and
other environmental impacts.
begins as well.
The more difficult the waste is to recycle,
the more the environmental impact of the
recycling process increases.

21. Assessing engineering polymer reuse and
recycling solutions
The higher the expected technical performance of the
recycled product, the higher the complexity of
formulation and process steps to achieve it.
In the Wheel Cover case, after the cleaning and sorting
phase, polymerization scrap or off-spec granule was
added to enhance the properties of the recycled
material.
In the Airbag case, an additional step had to be
performed (dilution), because of the presence of a
conflicting substance, to make the recycled material
suitable for compounding.
Each additional process step performed
and each virgin raw material added is
accounted for in the Life Cycle
Assessment of the recycled product.

22. Assessing engineering polymer reuse and recycling
solutions – impact assessment  Results
This material, still in the scouting phase (not yet available), is PA 6.6 with 20%
glass fibre, 7% mineral filler and black colour, produced using wheel cover source.

23. Assessing engineering polymer reuse and recycling
solutions – Impact assessment  Results
This material, still in the scouting phase (not yet available), is PA 6.6, with 30%
glass fibre, thermal stabilizer and black colour, produced using airbag source.

24. Key outcomes
› The materials presented here are more sustainable (up to 70-90% CO2
reduction) compared to the corresponding prime grades.
› Does all this compensate for the inevitable material property loss? The right
application must be selected.
› To foster recyclability, ecodesign must take place in the earliest stage of the
life cycle of the components.
› Recycling post-consumer waste is a challenge: the determination, knowledge,
expertise and environmental-orientation of everyone involved in the process is
required.

25. Agenda
1. RadiciGroup High Performance Polymers. Partner introduction
2. Development of engineering polymer recycling solutions
3. Environmental impact assessment
4. Recycled material usage: from characterization to real application

26. Performance loss of PCR materials:
Is it an issue?
CAE simulation tools can help design engineers to evaluate and choose the right material for an
application, as well as allow them to redesign the component to compensate for an unavoidable
loss of properties.
Harsh environmental conditions during the working life of components:
Heat ageing, UV rays, chemical action (oil, glycol…), etc.
Do we necessarily need to downgrade the material application?
Property Loss

27. CAE = Computer Aided Engineering
Many software tools are available to support technicians
and engineers in carrying out numerous tasks.
CAE often refers to software solvers using the FEM (Finite
Elements Method) to solve technical problems numerically
in different fields:
• Structural mechanics
• Kinematics
• Acoustics
• Electrodynamics
• Heat transfer
• Fluid dynamics
• (...)
CAE (Computer Aided Engineering)

28. CAE simulation at RadiciGroup
•Injection moulding and derived technologies
(injection-compression, GAIM, micro-foaming,
etc.)
•Flow, packing, cooling and warpage analysis
•Prediction of process-related defects and
parameters
Process
Simulation
•Static non-linear analysis, multi-body contact,
stress and strain field prediction
•Failure prediction, thermo-mechanical effects
and long-term behaviour (creep, fatigue)
•Dynamic analysis, impact, natural frequencies
Structural
Simulation
•Taking into account process-induced
microstructural properties in a structural study
•Anisotropic mechanical behaviour (GF
orientation), welding lines, residual stress and
warpage effects
•Multiscale and multipurpose material modelling
Integrated
approach

29. Fundamental INPUTs for CAE simulation
An accurate material characterization of recycled grades and modelling their
rheological and mechanical behaviour help the designer to select the most
appropriate engineering applications for the green compounds.
Output = F (Material, Geometry + Mesh, Process Parameters)
F is the solver. The analysts (and material suppliers) are responsible for “feeding” it.
FEM
Solver
Material Characterization
3D Geometry
Boundary Conditions
Simulation Results
Geometry Discretization (Mesh)

30. Material characterization: Process
• RADILON A RV300W 333 BK (PA66 GF30 Virgin grade benchmark )
• HERAMID A GF030/1K (PA66 GF30 Post-industrial grade from textile regrind scraps)
• RADILON CARE A GF030 (PA66 GF30 Post-consumer grade from airbags)[*]
• RADILON CARE A GFP3015 (PA66 GF+MD30 Post-consumer grade from wheel covers)[*]
• Rheological Curves
(Viscosity)
• Pressure-Volume-
Temperature (PVT)
• Heat Capacity
• Thermal Conductivity
• Mechanical Properties
EXPERIMENTAL
MEASUREMENTS
MATHEMATICAL
MODEL BUILD-UP
MATERIAL CARD
READY FOR VALIDATION
[*] This material is still in the scouting phase (not yet available).

31. Material characterization: Structural – integrated
• RADILON A RV300W 333 BK (PA66 GF30 Virgin grade benchmark – J2-EP pre-existing)
• HERAMID A GF030/1K (PA66 GF30 Post-industrial grade from textile regrind scraps)
• RADILON CARE A GF030 (PA66 GF30 Post-consumer grade from airbags)[*]
• RADILON CARE A GFP3015 (PA66 GF+MD30 Post-consumer grade from wheel covers)[*]
Tensile experimental data
@ 0°, 30°, 90°
@23°C DAM, 120°C DAM
Microstructure of specimens:
microtomography scan (μCT)
analysis
Micromechanical
material model
J2-EP + Failure Index
TH3D-TI
Reverse engineering
Digimat-MX
calibrating and fitting
the model
to experimental data
Verification
and
Validation
AVAILABLE FOR
ENGINEERING USE!
1st check: ISO527-1A
injected specimen
compliance
2nd check: 4PB “Demonstrator”
beam reproduction
(with Digimat-RP + Marc)
[*] This material is still in
the scouting phase (not
yet available).

32. Material card validation: Experimental test
• Test configuration:
4PB tests performed by
- “Demonstrator” ribbed beam
injected in 1 head gate
configuration
- Test results (force vs. standoff)
to be compared with FEM
predictions obtained with
previously calibrated models

33. Material card validation: Results
- Good repeatability for all grades
- Less distance between HER and CARE
030 compared to specimens
- FEM results slightly overestimate stiffness
especially at high warpage
- Failure deflection captured well (except
CARE 030 a little early)
PCR/Airbag
RAD CARE A
GF030 [*]
PCR/Wheel Cover
RAD CARE A
GFP3015 [*]
PIR - HER A GF030/1K
[*] This material is still in the scouting phase (not yet available).

34. Real application: Gear-motor cover for electric
adjustable desk
Electric Adjustable Desk
Electric Gear-Motor
Cover made of
thermoplastic material
- RADILON A RV300W (PA66 GF30, Virgin Grade)
- RADILON CARE A GF030 [*] (PA66 GF30, PCR Grade)
Simulations and actual injection
moulding process were performed with
the following materials:
Courtesy of
[*] This material is still in the
scouting phase (not yet
available).

35. Process simulation: Melt flow front
RADILON A RV300W (PA66 GF30, Virgin Grade)
RADILON CARE A GF030 [*](PA66 GF30, PCR Grade)
[*] This material is still in the scouting phase (not yet available).

36. Process simulation: Warpage – total displacement
RADILON A RV300W (PA66 GF30, Virgin Grade)
RADILON CARE A GF030 [*] (PA66 GF30, PCR Grade)
The PCR material has slightly higher warpage compared to the virgin material, but the
coupling between the two parts is guaranteed.
[*] This material is still in
the scouting phase (not
yet available).

37. Structural integrated simulation: Set-up
Ft
Fr
Fa
A
Cover
FEM Structural Model Boundary Conditions
GF Orientation (Process
Simulation)
Mapping GF Orientation on
Structural Mesh

38. Structural integrated simulation: Failure index
RADILON A RV300W (Virgin Grade) RADILON CARE A GF030 [*] (PCR Grade)
Failure expected at 10.8 Nm of torque. Failure expected at 10.2 Nm of torque.
Failure is expected when the Failure Index reaches a value of 1.
Section View [1,0,0] Section View [1,0,0]
[*] This material is still in the scouting phase (not yet available).

39. Injection moulding trials
Moulding Trials @
Mould Mould
Opening
Cover Assembly Product Assembly

40. Yes it is possible!

41. THANKS FOR YOUR ATTENTION!
www.radicigroup.com
www.careserviceproject.eu
Follow us on:

42. Acknowledgements
• All third-party images and multimedia used in this presentation are the
property of their respective owners and, where not specifically mentioned
otherwise, are reported here under assumptions of “fair use”.
• Special thanks for valuable support and effective collaboration to:
– All participating colleagues from RadiciGroup High Performance
Polymers
– Angela Iannuzzo and Sandra Cherubini from E-Xstream engineering
– Giorgio Nava from Moldex3D Italy
– Pollini Lorenzo e figli Srl
– IMA GmbH
– Labormet Due Srl
– Luca Avataneo from Electro-Parts SpA