An Innovative Approach to Closing the Loop in a Circular Plastic Economy by Upcycling Single-Use Post-consumer Thin Film Plastic Packaging Waste into Durable Plastic Products

Abstract The waste system requires a circular economy business solution to upcycle millions of tonnes of contaminated post-consumer single-use multi-material, multilayer, plastic packaging films/foils. This waste is rarely collected for recycling, firstly because the market for such waste is new and very small, and secondly due to technical issues and cross-contamination at waste recycling facilities. Conventionally, two linear disposal routs exist, energy recovery through incineration or landfill, both having an economic cost. Being very lightweight, plastics are blown around and end up contaminating terrestrial and marine environments. This paper evaluates intrusion extrusion moulding technology with agglomeration to make products. With a 50-year first lifespan and nine more life cycles, they can be used multiple times as a substitute for wood and concrete. Public bodies can catalyse the intrusion extrusion moulding manufacturing industry by including such products during their procurement processes. The technology works and the business can be profitable.