Implementation of an abrasion-resistant twin-screw extrusion system for producing high-performance hybrid plastics made from a 100% recycled polyolefin matrix reinforced with abrasive fibrous materials

PROJECT COST:

1 001 000 $

PRIMA CONTRIBUTION:

500 000$

PROJECT DETAILS:

This project aims to implement a twin-screw extrusion system specifically optimized for the processing of recycled polymers, with the objective of developing and commercializing high-performance hybrid resins derived entirely from 100% recycled plastic feedstock. The primary technical challenges lie in acquiring a detailed understanding of the rheological and thermal behavior of recycled materials, and in adapting extrusion technologies traditionally designed for virgin polymers to accommodate the variability and complexity of post-consumer plastic streams.

The project is structured into three main phases:

Formulation Development and Configuration Trials — Conducted in collaboration with the Université de Sherbrooke, this phase focuses on the selection and optimization of polymer blends and process parameters.
Technology Adaptation — Modification of the extrusion platform to enable efficient integration of recycled materials while maintaining process stability and product quality.
Prototype Fabrication and Validation — Production of resin prototypes for industrial testing, followed by equipment transfer for commercial-scale deployment.

The overarching objectives are to reduce greenhouse gas (GHG) emissions, divert plastic waste from landfills, and enhance the value proposition of recycled plastics within a circular economy framework. Ultimately, the project seeks to redefine the perception of recycled plastics by demonstrating their potential to meet high-quality performance standards traditionally associated with virgin materials.