Recycled biodegradable films converted into melt-blown nonwoven products

Overview

This research addresses a growing sustainability challenge in the biodegradable packaging market. While biodegradable films are increasingly adopted as alternatives to conventional polyolefin packaging, they are costly to produce and do not degrade quickly enough for simple landfill disposal. This project proposes an upcycling pathway that converts post-consumer biodegradable films into melt-blown nonwovens, adding value to recovered materials and reducing reliance on virgin biopolymer production.

The approach draws on a well-established circular bioeconomy principle: extending the useful life of polymers through recycling, similar to how post-consumer PET bottles are recycled into textile products. By leveraging regrinding and pelletizing techniques already proven for conventional plastics, the research team aims to demonstrate that recycled biodegradable films can serve as viable feedstocks for nonwoven fabric manufacturing, opening new revenue streams for packaging waste while supporting sustainability goals.

Technical specifications

Process workflow:

• Collection and sorting of post-consumer biodegradable films
• Regrinding and pelletizing of recovered films in collaboration with industrial partners
• Comprehensive characterization of regrind feedstock, including purity, molecular weight, thermal properties, and rheology
• Conversion to nonwovens using a 6-inch melt-blown pilot line located in an industrial facility

Key technical advantages:

• Melt-blown processing favors lower molecular weight resins, making recycled film regrinds an ideal feedstock
• Prior research indicates recycled polymers can perform comparably or better than virgin materials in melt-blown applications
• PLA-based biopolymers have already demonstrated potential for electret filter media production

Evaluation criteria for produced nonwovens:

• Fiber diameter and morphology (via SEM imaging)
• Permeability and filtration efficiency
• Absorbency
• Mechanical properties
• Thermal analysis

Technology readiness level

The project is at an early-to-mid stage of development. The underlying pelletizing and melt-blowing processes are commercially proven for conventional plastics such as polyolefins and PET, and prior studies have demonstrated the feasibility of converting recycled polymers into melt-blown nonwovens. The current research extends this knowledge specifically to biodegradable film feedstocks. The team possesses the necessary pilot infrastructure, including a dedicated melt-blown line in an industrial setting, and plans to partner with established recyclers such as Accel Polymers for feedstock supply. Successful validation of processability and nonwoven properties would position this technology for scaling into commercial extrusion processes and broader industrial adoption.