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Due to insufficient sorting and recycling, macroscopic contaminations remain in post-consumer polyolefin recyclates. It is known that these contaminations affect the mechanical properties of the recyclates, as they constitute defects and thus crack initiators. However, the influences of different types and amounts of macroscopic contaminants have not yet been analyzed systematically. In this study, to close this knowledge gap, virgin polypropylene (PP) was systematically contaminated with paper, aluminum, sand, wood, in-mold labels, jute fibers and long glass-fibers. Additionally, three commercially available post-consumer PP recyclates were investigated. In a two-stage process, all materials were injection-molded into plates and subsequently milled to specimens. The specimens underwent (i) tensile tests at 50 mm/min, (ii) intermediate-rate tensile tests at 2000 mm/min, and (iii) tensile impact tests. Further, optical microscopy was used to measure the dimensions of the defects on the fracture surfaces. First, the influences of various types and quantities of contamination were evaluated. No significant effects were detected, as the matrix material was very brittle. Compared to the virgin reference grade, most samples showed lower strain-at-break values, except for those with labels and long glass-fibers, for which strain values increased. All PP post-consumer recyclates exhibited a more pronounced ductile behavior, although the contaminations incorporated gave rise to relatively high standard deviations. Second, in a comparison of various testing speeds, a greater influence of contaminants was detected in test (iii). Samples taken from a position close to the sprue had better mechanical properties than samples taken from the opposite side of the plate, as contaminants tend to flow to the end of the produced part. Finally, a non-linear relationship between the energy needed for fracture in testing methods (ii) and (iii) and the dimensions of the contamination on the fracture surface was found.

The use of fossil resources and their negative environmental impacts has awakened the awareness of the petrochemical industry. Hereby, we are presenting some upstream industrial scalable and commercial solutions to process sustainable feedstocks, either biogenic or recycled, to produce drop-in hydrocarbons that can be converted into light olefins using the same assets and infrastructure currently established in the petrochemical industry (e.g. steam crackers), reducing the environmental impact of large-volume chemicals such as ethylene, propylene and benzene, which are the most demanded building blocks in the petrochemical value chain. Mass balanced certified co-processing of biogenic and recycled waste plastics as raw materials, are the key for the de-fossilisation of the petrochemical industry. Production of polypropylene (PP) using renewable feedstock can reduce the GHG above 80% or 3.8 kg CO2eq/kg in comparison with the fossil-based. For making a higher impact in the plastic industry, a full integration of the value chain is needed to guarantee allocation of the sustainable credits to targeted products. As a showcase, a collaboration project between partners in different parts of the value chain to produce biobased PP thermoformed plastic cups, is presented. As a result from this collaboration, PP cups with final properties identical in range to the traditional fossil were obtained and the renewable hydrocarbons could be identified in the product using C14. Drop-in solutions using renewable or recycled feedstock is paving the way in the petrochemical industry to obtaining sustainable products with low impact in the current downstream infrastructure.

The currently achievable flow path lengths in injection moulding often represent a limitation for thin-walled packaging applications as well as for technical components with long flow paths respectively high aspect ratios. Previous investigations have shown qualitatively that a micro-structured mould surface can positively influence the flow and cooling behaviour of the plastic melt in the cavity. This can be attributed to micro air cushions between the plastic melt and the mould, which influence the heat transfer from the plastic melt to the cavity. A lower required injection pressure or the realisation of longer flow paths are the result. In addition, faster filling times at constant injection pressures can reduce the cycle time of the injection moulding process. In order to investigate the influence of the surface structure in more detail, comprehensive practical and simulative investigations are carried out on the resulting flow path length, the surface replication and the melt temperature. Initially, different mould surface structures were produced using sink electrical discharge machining (SEDM) and then analysed with regard to the surface properties such as the surface roughness Ra and the material properties in the surface layer. The influence of the process parameters injection pressure, melt and mould temperature as well as two different polypropylene moulding compounds on the achievable flow path length for the different mould surfaces was then investigated and compared with an unstructured mould cavity. For this purpose, a flow meander tool with an aspect ratio of 460.5 was used and the parameters were varied in a full factorial test design. In addition, the influence of the mentioned parameters as well as the influence of the flow path on the structure replication is examined using laser-scanning microscopy and the melt temperature and cavity pressure along the flow path are determined by means of pressure and infrared sensors. So far, up to 4 % higher flow paths could be achieved due to the SEDM generated mould surface. At the same time, a significant dependence of the surface impression on the flow path length and thus also on the local melt properties such as the pressure or the temperature is shown. In addition to the practical test series, simulative investigations are carried out. By adjusting the heat transfer coefficient as a function of the structure replication in the simulation of the injection moulding process, the influence of the mould structuring on the cooling of the plastic melt can be taken into account. Using the pressure and temperature data of the mould sensor system as input and calibration data as well as the findings from a macroscopic simulation of the modified surface, a micro-model of the surface will also be developed and simulated. The boundary layer of the injection mould, which is influenced by the SEDM process, with e.g. a changed thermal conductivity, can also be taken into account. Finally, the results on the influence of the surface structure on the heat transfer will be transferred into commercial simulation software in order to improve the design of injection moulds. 2b1af7f3a8