Advanced PCR recycling approaches: chemical depolymerization and enhanced mechanical recycling

Overview

ZAFA Biorefinery is developing two complementary approaches to address the persistent challenges of recycling post-consumer recycled (PCR) plastics, namely color change and quality degradation. The first approach leverages chemical recycling to fully depolymerize PCR materials back into monomers, which can then be repolymerized into new plastics with properties comparable to virgin material. The second approach refines mechanical recycling through selective washing to remove oligomers, volatile organic compounds (VOCs), and other additives, combined with biobased additives that lower processing temperatures to prevent the formation of degradation products during recycling. Together, these strategies aim to expand the range of PCR materials that can be effectively reused while preserving or restoring material quality.

Technical specifications

Chemical recycling pathway:

• Complete depolymerization of PCR plastics into their constituent monomers
• Repolymerization of recovered monomers into new plastic materials with virgin-like properties
• Represents a transformative, near-complete recycling solution

Enhanced mechanical recycling pathway:

• Selective washing step designed to remove oligomers, VOCs, and residual additives prior to processing
• Incorporation of biobased additives that enable lower processing temperatures
• Reduced thermal stress during recycling minimizes degradation product formation
• Prevents color change and preserves material quality across recycling cycles

Key benefits:

• Addresses two of the most common barriers to PCR adoption: discoloration and mechanical property loss
• Offers flexibility to choose between a transformative chemical route and a refined mechanical route
• Supports circular plastics economy goals by enabling higher-value reuse of recycled content

Technology readiness level

The chemical recycling approach has been partially validated through laboratory-scale depolymerization of selected polymers, with results indicating feasibility for broader PCR application. Further validation is planned, including detailed chemical recycling studies and aided mechanical recycling trials. The technology is currently at an early-to-mid stage of development, with additional research and scaling required before commercial deployment. Detailed validation protocols and collaboration opportunities are available upon request.