Innovative Material Recovery Process based on Advanced bio-dissolution for the Re-Cycling of ThermOplastic Helmets

Introduction

Performance is the main concern in the design of motorcycle helmets, and for this reason, there is a continuous search for new materials (especially polymer-based) that can increase their performance. However, while the plastic materials used in the production of motorcycle helmet components are crucial in ensuring the required characteristics of the finished product, they pose a problem when the helmet reaches the end of its life and must be disposed of.

Current Disposal Methods

To date, there are no valid industrial-scale solutions available to recycle these products, which consequently are disposed of primarily through landfill and incineration. The reason for this end-of-life scenario is due to the very complex composition of helmets, especially motorcycle ones.

Challenges in Recycling

Indeed, although the plastics of which they are made are individually recyclable, they are bonded into the finished product by processes that make mechanical separation and recycling very difficult and not industrially and economically feasible. The enormous production of polymeric materials required for helmet manufacturing thus results in a disproportionate accumulation of plastic waste.

Project Goals

LIFE IMPACTO wants to act as a frontrunner in proposing an effective solution to reverse the linear life cycle of this product category. The project aims at the creation of a circular process based on dissolution recycling, targeting directly post-consumer motorcycle helmets, collected by means of a take-back campaign.

Innovative Solutions

The project will develop an innovative industrial-scale plant which will allow the separation of the different plastic materials of which the helmet is composed through the action of bio-based solvents (limonene and ethyl acetate) obtained from food-industry waste.

Expected Outcomes

In this way, it is possible to recover the main plastic materials (ABS, EPS, and PC) to be reused within the same value chain for the production of new helmet components having the same mechanical and safety features of actual standard products.