Dr Christel Croft, Project Manager, Luxus Ltd

High-performance lightweight recycled polypropylene materials for tomorrow’s auto interiors

The Fusion of....

The Recyclite projectThe strength of the “Recyclite” Consortium :

LuxusLeading the project

Developed the HycoleneTM range

CoperionProviding technical support in the compounding process to deliver key economic and environmental

benefits.

JLRLead manufacturer who will help deliver components made from

the rPP to the market .

IACA key injection moulding company delivering verification of process

parameters.The aim of the Recyclite project is to commercialise Luxus’ development of the Hycolene™ range of lightweight polypropylene (PP) compounds with up to 60% recycled content that targets Europe’s Class ‘A’ automotive interior trim market

Luxus is part of a consortium that secured €1.4m of investment co-funded by the EU Eco-Innovation initiative (Recyclite Project).

Luxus’ recycled polypropylene compounds are already successfully used by key OEMs for various “A” surface visually critical applications.

Luxus Ltd provides high volumes of PP recycled based materials for automotive exterior and interior trim applications with:

• Specification agreement• Recycled feedstock analysis and selection• Material property enhancement• Colour matching• Pre production laboratory evaluation against specification• Blending batches up to 150t lots

The new HycoleneTM range delivers additional benefits to the current offer of recycled based PP materials such as lighter weight and increased scratch performance.

Luxus – High performance PP for the automotive sector

PP for automotive interior Class A

The history

Key drivers:

• Legislation & Compliance• Sustainability and Environmental Performance • Customer engagement & Corporate Social

Responsibility• Material Performance • Cost

Target : Highly functional, directly visible, colour matched parts with low gloss, meeting the same requirements as current materials with additional benefits of lightweight and higher scratch resistance.

Project initiated by Luxus Ltd to meet specific needs of the automotive sector.

Weight

Reduction

•Less material required

•Fuel economy

•CO2 emission reduction

Material

performan

ce

•High scratch performance

• Visible parts applications

Recycled

content

• High level of recyclate

• Legislation & competitive benefits

Key challenge: To increase OEMs & moulders confidence in using recycled materials for “Class A” interior trim applications in an increasing competitive environment.

Key elements of the projectTechnical objectives:

• Establish robust scratch testing and correlate with results from various OEMs’ tests.

• Perform performance tests on various virgin and new recycled PP compounds and establish correlations or trends between properties where possible.

• Micro analysis of virgin and recycled material to understand how surface scratches are formed, and therefore, the observed visual characteristics.

• Optimise Luxus’ new Coperion twin screw extruder to scale up and increase performance of the HycoleneTM formulations. Develop knowledge database of process and additives effects on performance.

• Prepare colour matched moulded test specimens for full validation tests.

• Complete a Life Cycle Analysis (LCA) for the project.

Commercial and Market objectives:

• Survey moulders & OEMs regarding in-cabin performance specifications.

• Perform assessment tests and validation of the Hycolene TM range for defined applications.

• Assess and communicate the environmental and cost benefits performance on the commercially produced material.

• Develop licence agreements with partners for producing and accessing the Hycolene TM range globally.

Door pocket - Example of a potential future application for the HycoleneTM range

The achievements so far

Lab scale development demonstrated:• Weight reduction • Improved scratch performance• Increased recycled content

645 g568 g

12% weight reduction

Reference material: current PP 16407 for Class “A” automotive interior trim. - 25% talc filled with a recycled content.Industry standard

Crosshatch 20x20 10N - Erichsen

The achievements so far

Property Test Method Units PP16407Reference

PP 16624HycoleneTM

Melt flow ISO 1133 g/10 mins 25 - 29 22 - 26

Izod at Room Temperature notched ISO 180: 1993 KJ/m² 4.5 - 7 4.5 - 7

Izod at -40 C notched ISO 180: 1993 KJ/m² 1.7 + 1.7 +

Flexural Modulus ISO 178 N/mm² 1450 - 1850 1600 - 2100

Density ISO 1183: 1987 1 + 0.96 - 0.985

Filler % 23 - 26 8 - 11

HDT 0.45Mpa ISO 75 °C 80 + 90 +

Properties - HycoleneTM - PP16624 versus PP16407• Meeting mechanical properties• Meeting dimensional requirements: Drop-in solution

The offerFor over 50 years Luxus Ltd has offered unique knowledge and capability to work with a range of recycled feedstock to deliver products matching customer specifications with batch to batch repeatability.

The new lightweight HycoleneTM range with increased scratch performance will be offered to the market with the same ethos, working closely with customers to consistently supply the best product at the best price.

For more information – visit www.recyclite.eu, visit our stand A5126 or contact Luxus on +44(0)1507 604941.

AcknowledgementsWe would like to recognise the support and contribution of :

• The Eco-Innovation Initiative of the European Union.

• Our Partners and in particular :– R. Crow, R. Punch, I. Lowe, W. Morris, C. Edwards, E. Davis (JLR)– M. Walddoerfer, D. Watmore, J. Schofer (Coperion)– D. Jenkins, P. Middleton (IAC)

• Our Technical, Business and Project team and in particular :– T. Burton, G. Stephenson, L. Dalley, J. Ballantyne, A. Boyce, I. Pigot, I. Huskiewicz, P. Atterby, C. Barker,

S. Coggle.