EconCore Teams up with Ultrapolymers and DuFor for Recycled PET Honeycomb Development

EconCore, the leader in thermoplastic honeycomb core production technology, collaborates with Ultrapolymers and DuFor in an R&D project funded by the Flemish Government to develop a new product: a thermoplastic honeycomb core made from recycled PET. The basis of this development is EconCore’s worldwide patented process for continuous and cost-effective production of thermoplastic honeycombs.

Ultrapolymers and DuFor, who have partnered with EconCore on this project, have extensive knowledge and expertise in processing PET and recycled PET (rPET) polymers. They show great flexibility providing custom-made solutions for their clients. DuFor’s advise was of key importance to find the optimal composition of the PET polymers and chemical additives that benefit the crystallization process, even during fast cooling, and keep the semi-crystalline state stable during and after the manufacturing process.

The two-year project was funded by the Flemish government who acknowledged the innovative technology and ecological aspect in this new product and process development. Using the existing patented ThermHex technology which allows for fast, continuous production, EconCore managed to further improve and upgrade the process to allow the use of recycled materials that are being converted into high performing cost-efficient honeycomb cores.

“We are delighted to work together with Ultrapolymers, one of Europe’s leading polymer distributors, and DuFor, a polymer developer and producer with over 40 years of experience. Thanks to their knowledge in polymers, EconCore managed to develop a sustainable honeycomb core which is made entirely from recycled PET materials.” said Wouter Winant, Technical Manager at EconCore. “These PET honeycomb cores and PET-based semi-finished sandwich panels can be used in a range of different applications, including transportation, building & construction, packaging, furniture and others, where sustainable, low-cost but performing solutions are desired. An interesting feature is that EconCore’s PET honeycomb materials are thermoformable and relatively complex shaped parts can be obtained. Furthermore, these honeycomb cores, although they remain very cost competitive, show enhanced stability at elevated temperatures. These products have a huge potential to become a more cost-effective alternative solution to solid polymer sheets and foam cores, particularly those based on PET.” continues Winant.

“By joining forces with EconCore, we are thrilled about the possibility to test and eventually bring to market a smart, innovative and sustainable product that contributes towards the circular economy of plastics” says Dieter Vogeleer, Account Manager at Ultrapolymers.

“Being involved in this project is in line with our focus to provide innovative and customized solutions for applications or products where recycled PET materials are used” said Marco Brons, Technical Director at DuFor.

About DuFor
Special applications require customized solutions. We offer these solutions by developing customized polyester raw materials combined with a high level of technical support. DuFor focuses on developing innovative solutions that are recyclable and made with renewable resources. This offers the opportunity for reuse of otherwise inferior materials, an optimal price/performance combination and, most important, saving the environment at the same time. Our goal is to establish a circular economy for polyesters by finding sustainable materials and creating a second life. We believe it is possible to replace traditional fossil materials with bio-based or recycled materials. Working closely with our customers and bringing together our complementary expertise and resources, we move faster in developing 100% renewable and recyclable polyesters on a commercial scale. More information: https://www.dufor.nl/dufor/about-us/

About Ultrapolymers
Ultrapolymers, founded in Belgium in 2002, offers a comprehensive product portfolio of raw materials covering Commodities, Engineering plastics, Specialties (of Specialty compounds), Recycled & Circular products and Thermoplastic elastomers. Together with our technical support we can supply a wide range of materials for almost every application. With offices and warehouses in most of the European countries, Ultrapolymers established a commercial network with a local presence to serve its customers and suppliers in the best possible way. More information: https://www.ultrapolymers.com/