Reverse Material & Product Requirement Planning
Lead Organization: FORCE Technology
Project Periode: August 2023 - December 2025
Pool: TRACE Pool 1 Project Status: Finalized
The aim of the project is to adopt and reverse material resource planning approach to increase the inclusion, utilization, quality and circularity of recycled plastic. Exploring the possibilities of introducing flexibility in recycled material demand and supply without compromising material value and recyclability is a key objective of the project.
Market regulation and customer demands are increasingly calling for recycled content, but the ability to deliver on demands is challenging as it is restricted by respectively:
The ability to operationally integrate recycled plastic materials due to rigid product and process requirements, and limited access to high-volume, stable supplies of homogenous quality recycled plastic. Depending on product type and production technology, a min. of >10% increase in the inclusion of recycled materials is expected.
Pilots will be made to demonstrate the optimization of production processes that in turn allow for greater flexibility in the sourcing and use of recycled raw materials. This will lead to a reduction of CO2footprint and increase growth and export in the Danish plastic recycling value chain by increasing the utilization, ability to integrate recycled content and value of recycled plastic.
Project partners: Aalborg University, FORCE Technology, RC Plast A/S, Letbæk Plast A/S, Handi Life Sport ApS, Danish Fibers A/S,
Project Results
The RevMat project has uncovered how the integration of recycled plastics in production chains is influenced by three central pillars: market and legislation, materials and upskilling, as well as production and processes.
The market is characterized by complex legislation, regulation, and standards which—together with historically strict material requirements from plastic manufacturers—have contributed to setting high barriers for the quality levels that material streams must be converted into. These requirements form the foundation for quality and safety but can at the same time limit flexibility and hinder the development of the supply chain.
The market for recycled plastics is dominated by polyolefins (PP and PE) and PET, where mechanical recycling accounts for the vast majority of capacity. Variation in quality and a lack of traceability remain significant barriers to broader application.
The project's cases have illustrated that market development is largely hindered by procurement challenges. The demand for recycled plastic exceeds the supply, and the material streams currently being processed cannot meet all needs. From a process standpoint, integrating recycled plastics requires increased focus on process control and may, in some cases, require redesigning products or tools. Not all production processes are equally receptive to all material streams, but new techniques are continuously being developed to regulate and control processes with the aim of increasing robustness to variation.
Reflection
Experience from RevMat shows that the market for recycled plastics is in a transition phase. Recyclers with a historical background in waste management are in the process of transforming themselves into material suppliers. Whereas recycled plastic was previously regarded primarily as a waste product, it is now increasingly seen as a scarce resource in high demand. This development is driven by new legal requirements mandating increased use of recycled plastics in new plastic products, growing media attention, and political objectives aimed at increasing the amount of recycled plastic in the value chain.
This transition places higher demands on supply reliability, traceability, and control over materials. These tasks must be addressed as effectively as possible by recyclers to create a stable foundation for market maturation. At the same time, manufacturers must accept a higher degree of variation and adapt their processes accordingly—both technically and organizationally—and prepare for increased requirements concerning the presence or absence of problematic substances due to regulatory demands.
Future Outlook
Looking ahead, the experiences point to two key development pathways:
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Strengthened coordination between the three pillars: More standardized quality parameters (as proposed by the JRC), increased data sharing, and formalized collaborations can reduce friction between the market, materials, and processes.
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Upskilling of material streams: Investments in advanced sorting, collection, and pre-treatment technologies can make recycled plastics more predictable, thereby increasing the value created by recyclers and reducing challenges for manufacturers.
The RevMat project shows that the foundation for this development has already been laid: the technologies exist, market interest is increasing, and updates to plastics regulation are pushing toward greater circularity. The next phase consists of creating more dynamic and predictable coordination between the actors.
For more information about the results from the project, see the project final report linked below.
Project Leaders
Anette Skyt
Mail: ansk@forcetechnology.com
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