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project info
Start date: 1 January 2024
End date: 31 December 2025
funding
Fund: Just Transition Fund (JTF)
Total budget: 1 963 320,00 €
EU contribution: 981 660,00 € (50%)
programme
Programming period: 2021-2027
European Commission Topic
European Commission Topic

Healix: Closed loop big bag recycling

Big bags (also known as bulk bags or flexible intermediate bulk containers (FIBC)) are used in many industries for storing and transporting dry bulk goods. These include agriculture, food, construction, mining and chemical applications. These big bags, mostly single use, are made of polypropylene (PP), which makes them very suitable for recycling, were it not for the fact that in about half of the cases an innerliner (lining) made of Low Density Polyethylene (LDPE) is used. These two parts must first be separated before high-quality recycling is possible. In addition, after using the big bag, a remainder of the content for which it was used is always left behind. These are often difficult contaminants such as fertilizers, chemicals, powders, etc. In the Netherlands, around 9.5 million big bags are sold per year, which is about 8% of the European market (120 million pieces), a market that is still growing. The average weight of the big bag itself is 2.5 kg, i.e. around 300 KT of waste per year. To prevent all these big bags from being landfilled or incinerated, there are various initiatives for reuse and/or recycling. Although reuse is preferred, this is not always feasible and eventually there comes a time when the big bag is still discarded. From the point of view of sustainability, high-quality recycling is the best option, but the complexity of separating PP and LDPE and the pollution present complicate this process. Current recycling initiatives therefore mainly focus on open loop recycling/downcycling where the recycled material can only be used for lower quality applications. If big bags can be recycled closed loop, this contributes significantly to reducing the use of (fossil) raw materials and thus the emission of CO2. Healix, a Maastricht-based company specialized in the high-quality recycling of plastic fibres, currently focuses mainly on the recycling of agricultural ropes and fishing nets. The challenge here is to remove dirt that contaminates these fibers. Healix has developed an advanced system consisting of environmentally friendly drycleaning and washing processes to remove almost 100% of this dirt. This expertise can be applied to the recycling of other contaminated plastic waste, such as the aforementioned big bags. The aim of this innovation project is to carry out the R&D preparation work on the basis of the current factory in Maastricht, in order to eventually build a dedicated big bag recycling factory in South Limburg. Chemelot Innovation and Learning Labs (CHILL) is involved as a project partner and, together with Healix, carries out important R&D related to the recycling process within this project. This innovation project contributes significantly to the objectives of the JTF programme, both in the area of raw materials transition and climate transition. The use of fossil raw materials is reduced because circularly recycled plastic can replace an important part of the raw material for the production of new big bags. Residual flows are therefore used as raw materials again. This reduces CO2 emissions, both by using less fossil raw materials and by reducing the combustion of discarded big bags. The planned capacity of the new recycling plant (16 KTon input, 12 KTon output) would reduce greenhouse gas emissions by almost 40 KTon per year, making a significant contribution to a climate-neutral Europe. In addition, regionally available talent is used. This transition provides a seamless transition for employees with knowledge of production processes in chemical/plastic production that become redundant elsewhere in the transition to more sustainable production in South Limburg.

Flag of Netherlands  Zuid-Limburg, Netherlands