Manufacturing of high quality rPET-based formulations

AOC is manufacturing a full range of high quality rPET-based formulations at its Ústí nad Labem site (Czech Republic). The rPET used for making these products is mostly coming from post-consumer waste. Plant Manager Petr Vanek explains the extra steps AOC takes for converting this raw material into products with great performance and low eco-footprint.

AOC has developed a full range of rPET-based formulations based on post-consumer waste. This allows customers to make parts in the right shape, with great strength and durability, and make these more sustainable at the same time.

Conversion of rPET into quality resin

At the Ústí nad Labem site (Czech Republic), AOC is receiving large quantities of rPET waste ground into small chunks and pallets. These are processed into liquid intermediates, which are subsequently converted into various formulations in line with customer specifications.

“As a large portion of the rPET raw material is originating from post-consumer sources, contamination with PP bottle caps, paper and metal can be significant”, explains Petr Vanek, Ústí nad Labem Plant Manager. “Obviously, these contaminants have to be removed for obtaining the desired product property profile, and for ensuring quality consistency.”

In recent years, AOC has made significant investments in the Ústí plant, and put in place a sophisticated filtration systems which separate the liquid intermediate from non-dissolvable materials. This allows manufacturing of high quality intermediates, which are the basis for products used in a broad range of markets and applications.

Great outlook

The Ústí plant is located 70 km Southeast of Dresden (Germany), allowing AOC to provide a great service to its customers in Central/ Eastern Europe as well as in Germany. Besides state-of-the-art production equipment, the plant has unique capabilities for manufacturing green formulations based on recycled PET. With the recent plant modifications and continuous process development, the Ústí team is set for long-term growth.

“We anticipate that the rPET-based formulations are going to be one of the larger product families made in our plant”, comments Petr Vanek. “For our customers, using rPET-based products makes a lot of sense, as these bring a great end-use performance and a simultaneous reduction of eco-footprint.”

“AOC is highly committed to building a sustainable product portfolio, which allows customers making strong and durable composite parts”, adds Stefan Osterwind, Managing Director, AOC EMEA. “I am very happy AOC can convert a valuable resource as rPET-waste into products that feature both high performance and sustainability.”

Broad rPET-based product range

The Synolite™ 4600 series have received Lloyd’s certification for use in Marine, and are available both in RTM/ infusion and hand lay-up versions. The MgO-thickenable Palapreg P 40-01 formulation is ideally suited for SMC and BMC, with great compatibility for fillers and low shrinkage additives.

The Synolite™ 1112-G series can be easily combined with CaCO₃ fillers, yielding parts with predictable dimensions in sanitary and casting applications. For continuous panels, filament winding and pultrusion, multiple products are available from the Palatal® P 42 series that feature great glass fiber compatibility and allow manufacturing of parts with high strength and stiffness.