The project is also intended to align recycling processes with the requirements of the forthcoming European Packaging and Packaging Waste Regulation (PPWR).
Input materials for the trials include packaging from the German PAMIRA system for plant protection and liquid fertiliser containers as well as packaging collected through the GVÖ system for lubricant containers. Both schemes provide controlled collection and pre-treatment processes designed to ensure traceability and consistent material quality at the recycling stage.
Controlled Collection and Pre-treatment
RIGK operates several collective Extended Producer Responsibility systems in Germany under the Packaging Act. In cooperation with companies in the chemical industry, the organisation manages take-back and recycling schemes for industrial, commercial and agricultural packaging. The PAMIRA system records high collection rates and includes defined pre-washing procedures before recycling. GVÖ operates a sector-specific system for lubricant packaging with comparable traceability requirements.
For the recycling trial, materials from PAMIRA and GVÖ were collected and prepared under controlled conditions. The approach ensures a consistent input stream for further processing and allows the origin of the material to be traced through the recycling chain.
Mechanical Recycling and Analytical Validation
The recycling trials were conducted at a mechanical recycling facility operated by GCR Plastic Solutions. The site forms part of a broader investment programme aimed at expanding recycling capacity and preparing for regulatory requirements associated with the PPWR.
The processing stages included hot washing, advanced sorting technologies and extrusion. Additional process elements such as reinforcement boosters and deodorisation units were used to reduce residues and improve material quality. The aim was to enable the recycled material to be used in technical applications without interaction between residual substances from the original packaging and the new product.
In order to meet the anticipated regulatory requirements, the trials incorporated extensive analytical monitoring and process control. These measures are intended to ensure consistent material quality and compliance with technical specifications for circular applications.
Laboratory Infrastructure and Material Testing
The project was supported by the innovation division of GCR Plastic Solutions. The unit combines laboratory analysis with pilot-scale testing facilities that allow recycled materials to be evaluated under conditions comparable to industrial production processes.
The laboratories are equipped with gas and liquid phase chromatography systems that enable detailed analysis of volatile compounds and potential contaminants in recycled pellets. In addition to chemical analysis, the division conducts mechanical testing and rheological assessments to determine whether recycled materials meet the requirements of specific applications.
The analytical approach allows recyclates to be validated not only for purity and compliance but also for performance in downstream manufacturing processes.
Industry Interest and Further Trials
Following initial validation of the recycling process and material quality, several European manufacturers of industrial packaging have expressed interest in integrating the recycled materials into production once technical requirements and supply consistency are confirmed.
The pilot project aims to demonstrate that industrial packaging recycling can be carried out with defined process control, traceability and analytical verification. According to the project partners, these factors are necessary to establish reliable circular material flows for technical packaging applications.
Initial Results and Next Steps
The first trials were conducted at the GCR facility at the end of February. Over a two-day test phase, washing, separation and laboratory analysis were performed to evaluate the recycled material.
Initial results indicate that volatile compounds in the processed material were significantly reduced during the treatment stages. Further trials with industry partners are planned in the coming months to verify the results and assess the recyclates in industrial processing conditions.
