AI Application Hub on Plastic Packaging

In Europe, around 40 percent of plastic demand is used for packaging. For technical and economic reasons, only a small part of these plastics is returned to the recycling cycle as secondary raw materials. In order to meet the target of at least 30 percent recycled plastics (recyclates) for more sustainable packaging, various challenges must be overcome throughout the entire value chain. Artificial intelligence (AI) methods offer great potential for solving the complex problems that exist. With its funding measure “AI Application Hub for Plastic Packaging – Sustainable Circular Economy through Artificial Intelligence,” the German Federal Ministry of Education and Research (BMBF) is promoting the application of AI methods for a resource-efficient circular economy in the field of plastic packaging in Germany.

The AI application hub for plastic packaging consists of two innovation laboratories: KIOptiPack (design and production) and K3I-Cycling (closing the loop). KIOptiPack focuses on materials, design, and production. K3I-Cycling looks at the processes of collection, logistics, sorting, separation, and reprocessing. Together, the two innovation laboratories cover the entire value creation cycle of plastic packaging. A total of more than 50 partners from industry, science, and society work closely together in the AI application hub.

Fraunhofer LBF is leading a work package in the K3I-Cycling innovation laboratory and is also contributing its many years of practical experience with plastic recyclates to other work packages.

Sensor-based sorting of lightweight packaging waste

Fraunhofer LBF's work begins with improving sensor-based sorting of lightweight packaging waste (LVP). Based on real data, sorting data is collected in close, interdisciplinary collaboration and annotated to provide the best possible support for the subsequent recycling of the recyclate. Ideal detection, separation, and recycling of pure plastics is not possible in practice. Instead, methods must be found that can produce valuable secondary raw materials from mixtures of different compositions that may be contaminated.

Additives for higher-quality applications

The targeted use of additives can prevent further degradation of the polymer during thermomechanical processing (= restabilization). Closely linked to this is stabilization for long-term use, which requires adjustment of the additive mixture depending on the operating temperatures and other harmful influences (e.g., sunlight). This also enables upcycling to higher-value applications. Techniques and additives can also be used to reduce odors, as washing does not remove all odor-causing substances from a recyclate.

Definition, determination, and communication of material and processing properties

An overarching topic is the improved generation and exchange of data on recyclates. In terms of price, these are now often more attractive than new materials. However, plastics processors demand narrowly defined material and processing properties for high-quality applications. Defining, determining, and passing on these properties to players in the value chain is also part of the activities of Fraunhofer LBF and a central aspect of K3I-Cycling.