Viridor DKY Holding Limited

/

England

,

United Kingdom

High Yielding, De-Inking "Film to Film" Recycling Process

A proprietary process and additive, which washes and de-inks post-consumer flexibles, maximising the yield of high value clear and white films.  Cleaned, sorted and de-odourised material is extruded to pure LDPE and PP pellet, providing a circular solution to replace virgin polymer in new blown film applications.

The majority of post-consumer film is printed with ink. Although c. 65% of a typical post-consumer film bale is natural, clear or white, only c. 12% is unprinted material.

Clear LDPE trades at a significant premium to coloured LDPE. Under conventional film recycling processes, the majority of the clear LDPE is downcycled into coloured LDPE, because the ink remains and the recycled product would not be suitable for use in clear applications.

Our process increases the addressable material and enhances the yield of high value clear LDPE through removal of the ink - c. 5x as much high value material.

It also improves the quality of the coloured LDPE. Residual ink impurities in pellets lead to gasification issues creating bubbles and char in blown film, making the product unsuitable for consumer packaging. Removal of the ink ensures the recycled coloured LDPE is filmable to a high quality, attracting a further value premium.

Conventional low yields and predominantly low quality coloured output dis-incentivise polymer recyclers. With minimal additional capital cost and use of our proprietary de-inking additive our process delivers a commercially and economically viable solution, which is scalable to address all post-consumer film in the UK.

UK supermarkets are trialling Front of Store (FOS) film collection, but there is currently no viable offtake for recycling with material unfortunately diverted to use as an alternative fuel source, deterring the supermarkets from supporting collection. Our solution will unlock a true circular solution to recycle film to grades suitable for new blown film application, and additionally offer traceability. This has attracted significant interest from UK supermarkets.

We believe our process has the potential to be optimised to address FOS film, but also film derived from MRF separated kerbside collected material, and in future potentially film recovered from waste sent to ERFs.

Lead organization region / continent
Europe
Location of future work
Europe
North America
North Asia
South & Southeast Asia
Solution type
Sorting and Preparation
Physical Recycling