At Apex Polymer Solutions, we pride ourselves on developing innovative and sustainable solutions. One of our standout achievements is the upcycling of PolyAl, a composite material from Tetra Pak cartons. Let’s explore how PolyAl is upcycled and the significant benefits it offers in promoting sustainability.
Understanding PolyAl
Tetra Pak cartons are composed of:
- 75% cardboard – Recycled into paper products
- 14% plastic – Part of the PolyAl composite
- 5% aluminium – Also part of the PolyAl composite
- 6% bioplastic cap – Biodegradable
The plastic and aluminium components are bound together and cannot be separated, forming what we call “PolyAl.”
The Challenge and Our Solution
A multinational retail and design company approached us to create a fully recyclable material suitable for promotional displays. Traditionally, PolyAl was downcycled into single-use items such as car floor mats, plastic pens, and flooring, all of which eventually end up in landfills. At Apex we set out to develop a more sustainable solution that could handle large volumes of PolyAl waste.
The Upcycling Process
- Collection and Separation: The recycler collects waste cartons from landfills and separates the cardboard from the plastic and aluminium.
- Pelletization: The bound plastic and aluminium are pelletized into PolyAl pellets which are supplied to Apex
- Extrusion: At Apex, we extrude these pellets into workable PolyAl sheets. Apex was the first globally to get this right.
- Design and Manufacturing: These sheets are designed to be flat-packed, reusable, and adjustable for various applications, including point-of-sale (POS) displays.
Key Benefits of PolyAl
- 100% Recyclable: PolyAl sheets can be returned and reprocessed into new sheets.
- Versatile Applications: PolyAl was initially designed for POS displays, but the applications are endless!
- Cost-Effective: It offers up to 20% cost savings and uses up to 90% less corrugated board compared to traditional materials.
- Sustainability: Using PolyAl reduces the carbon footprint by 40% and aligns with global environmental regulations.
Case Study: From Concept to Reality
Our initial brief was to work solely with packaging waste to produce aesthetically pleasing, printable, and formable sheets for POS fabrication. After 18 months of rigorous trial and error, we succeeded in creating PolyAl sheets. This success marked us as the first company globally to achieve this feat, significantly impacting the future of retail POS displays.
Real-World Applications
PolyAl has already made its mark in retail stores with POS units that are:
- Reusable: Up to 24 times with adjustable shelving.
- Flat-Packed and Easy to Assemble: For quick and efficient setup.
- Environmentally Friendly: Showcasing a great sustainability story with an earthy appearance in its raw sheet form.
How You Can Benefit
By understanding your current plastic waste management process, you can identify non-recyclable plastic waste that could be transformed into usable resources. Apex Polymer Solutions can partner with you to develop sustainable solutions tailored to your needs, turning waste into valuable materials.
Conclusion
PolyAl represents a significant leap towards sustainable manufacturing practices. By upcycling plastic waste into reusable and versatile sheets, Apex Polymer Solutions is not only addressing environmental concerns but also offering cost-effective and innovative solutions for various industries. Explore how PolyAl can be implemented in your production processes to contribute to a greener future.
For more information and to explore our comprehensive range of PolyAl products, visit our website or contact our team of experts today.
