Recycled Polyethylene Packaging via Ozonation and Segmentation
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Solution Overview
Problem
Current recycling technologies for plastic waste fail to produce materials suitable for primary extrusion-blown packaging, such as bottles and tanks, due to inconsistent performance, odor issues, color uniformity, chemical and mechanical resistance, and microbiological contamination, limiting their use in aggressive and cosmetic-food product containers.
Innovation Solution
A process involving the selection, grinding, odor reduction, microbial treatment, tempering, regranulation, and dehumidification of industrial and post-consumer plastic waste to produce high-density and high-molecular-weight polyethylene materials, which can be used to create packaging with consistent performance and safety standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If recycled plastic waste is used directly for packaging production, then environmental benefits are improved, but material performance consistency deteriorates
Solution Approach 1:
The recycling process is divided into multiple distinct stages: pre-treatment (sorting, cleaning), mechanical processing (grinding, regranulation), and chemical treatment (ozonation). Each stage addresses specific aspects of waste plastic, allowing comprehensive processing while maintaining performance consistency through systematic segmentation of the recycling workflow.
Solution Approach 2:
The invention applies ozonation (chemical parameter change) to transform the molecular structure of waste plastics, removing contaminants and improving material properties. Additionally, the process controls physical parameters such as particle size during grinding and temperature during regranulation to ensure consistent output quality regardless of input variability.
2Device complexity
If waste plastics are processed with minimal treatment, then processing cost is reduced, but odor and microbial contamination increase
Solution Approach 1:
The invention employs ozonation using ozone (O3), a strong oxidant, to eliminate odors and reduce microbial contamination. The ozone treatment oxidizes organic compounds responsible for bad smells and kills microorganisms, effectively addressing harmful factors without requiring excessively complex processing equipment.
3Manufacturing precision
If extensive sorting and treatment is applied to waste plastics, then material quality is improved, but processing time and complexity increase
Solution Approach 1:
The recycling process is divided into multiple distinct stages: pre-treatment (sorting, cleaning), mechanical processing (grinding, regranulation), and chemical treatment (ozonation). Each stage addresses specific aspects of waste plastic, allowing comprehensive processing while maintaining performance consistency through systematic segmentation of the recycling workflow.
Solution Approach 2:
The invention introduces an intermediary regranulation stage that transforms processed plastic into uniform granules before final extrusion. This intermediary step acts as a buffer that standardizes the material properties, ensuring consistent quality in the final product while simplifying downstream processing operations.
4Object-affected harmful factors
If post-consumer waste is used alone, then environmental benefits are maximized, but material suitability for aggressive product containers deteriorates
Solution Approach 1:
The invention merges post-consumer waste with industrial waste plastics in controlled proportions. This combination leverages the complementary properties of different waste streams, where industrial waste often provides structural integrity while post-consumer waste contributes to volume and environmental benefits, achieving both strength and sustainability.
Solution Approach 2:
The invention applies ozonation (chemical parameter change) to transform the molecular structure of waste plastics, removing contaminants and improving material properties. Additionally, the process controls physical parameters such as particle size during grinding and temperature during regranulation to ensure consistent output quality regardless of input variability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process transforms waste plastics into materials with defined color, odor-free, and enhanced mechanical properties, suitable for packaging containers, reducing environmental impact and meeting the performance standards of virgin plastics.
Implementation Method 1
Step 5), instead, comprises the reduction of the smell generated by the waste through an ozonation. Step 6) comprises the reduction of the microbial load developed by the waste through an ozonation.
Data Source
AI summary
The present invention relates to a process for preparing plastic materials from recycled plastic materials, and to the use of such materials for the production of packaging.