Diblock copolymer compatibiliser for maximizing PCR content in polyolefin resins

Overview

Interface Polymers is advancing its diblock copolymer technology to help plastics manufacturers incorporate higher levels of post-consumer recycled (PCR) content without sacrificing product quality. The core hypothesis is that a purpose-designed diblock copolymer acts as a dispersion aid at the interface between a base polyolefin resin and contamination phases, reducing contamination particle size and embedding contaminants within the matrix. This compatibilisation approach has already been validated over a five-year programme for recycling PE/PA and PP/PA flexible packaging streams. The current initiative focuses on extending and optimising the technology so that processors can maximise PCR loading (targeting 10–50% levels) in injection molding applications while still meeting end-product requirements.

Technical specifications

Key features:

• Diblock copolymer compatibiliser designed to sit at the interface between base resin and contamination phases
• Dispersion aid functionality that reduces contamination particle size and improves embedding within the host resin
• Applicable to polyolefin systems including PE and PP combined with PA contamination from flexible packaging recycling streams
• Process compatibility with injection molding, enabling evaluation across a range of PCR loadings from 10% to 50%
• Built on proven Polarfin technology platform developed by Interface Polymers for polyolefin compatibility solutions

Validation approach:

• Collect and characterize PCR feedstocks to map composition profiles
• Benchmark existing diblock technology to identify performance gaps
• Design, synthesize, and characterize new diblock candidates
• Process and test formulations in injection molding, comparing results across multiple PCR loading levels

Technology readiness level

The underlying diblock copolymer approach has been developed and validated over an extensive five-year programme for PE/PA and PP/PA flexible packaging recycling, establishing a strong technical foundation. The current six-month study is focused on optimizing the diblock formulation specifically for maximizing PCR content in injection molded products, with all synthesis, characterization, and processing work to be carried out by Interface Polymers. The next phase will benchmark current technology, design improved candidates, and validate performance across a range of PCR loadings.