BOSS & PRE mechanical recycling technology for high-purity post-consumer recycled plastics

Overview

BOSS (Baffled Oscillation Separation System) and PRE (Plastic Recycling Enhancer) are patented mechanical recycling technologies that together produce high-purity post-consumer recycled (PCR) plastic pellets suitable for direct substitution of virgin material. BOSS is a water-based density separation process that recovers HDPE, LDPE, and PP from unsorted mixed plastic waste streams, including black plastics that typically defeat optical sorting systems. The PRE additive is a monomer-based solution that tailors the Melt Flow Rate (MFR) of PCR to specific molding requirements, enabling processing at lower temperatures and supporting re-coloring of the recycled material. Together, these technologies address two of the most persistent barriers to PCR adoption: inconsistent feedstock quality and unpredictable processing behavior.

Technical specifications

BOSS separation technology:

• Water-based, mechanical density separation using oscillating baffles that create whirlpools in a separation tank
• Exploits density differences between polymer types to stratify plastics, with heavier fractions sinking as a third stream
• Color-agnostic process capable of separating black and dark plastics that near-infrared optical sorters cannot identify
• Achieves up to 95% purity PCR output, with up to 98% purity achievable for PE and PP fractions
• Non-reactive process that preserves polymer mechanical properties, including Environmental Stress Crack Resistance (ESCR)

PRE additive technology:

• Monomer-based additive that adjusts MFR up or down through shear thinning and shear thickening behavior
• Rheologically active under shear and temperature, forming a boundary-layer "sausage-skin" at the compounding machine wall
• Non-reactive, avoiding dye head build-up or tool staining associated with peroxide alternatives
• Enables molding at lower processing temperatures, preserving melt strength and consistent density
• Compatible with primary and secondary oxidisers for enhanced degradation resistance
• Maintains polymer mechanical properties while enabling further recyclability per APR Guidance

Commercial output specifications:

• HDPE pellets for extrusion blow molding (mono-layer bottles, oil cans, water drums) and multi-layer containers (250-litre drums), plus injection molding applications
• PP pellets for injection molding of medical industrial packaging and thin-walled long flow-path products
• LDPE pellets for blown film applications including 12-micron flexible packaging

Technology readiness level

Both BOSS and PRE technologies are at Technology Readiness Level 9, the highest stage of commercial readiness. Three large-scale recycling facilities are operational in the United Kingdom, each processing 15,000 to 25,000 tons of mixed post-consumer plastic waste per year. The company has established commercial-scale sales with multiple UK molding companies across diverse applications, demonstrating validated performance in real-world production environments. The technology is ready for immediate commercial deployment, licensing, or co-development partnerships to scale globally.