Estercycle: advanced recycling technology for mixed bioplastics
EsterCycle offers a breakthrough recycling technology that decomposes mixed PET and biobased plastics into reusable building blocks. This process not only reduces emissions but also ensures recycled plastics match the quality of virgin materials, handling biohazards effectively.
Overview
EsterCycle presents a pioneering solution for recycling mixed bioplastics, specifically targeting PET (#1) and various biobased plastics (#7). The technology is designed to decompose these materials into fundamental building blocks, which can then be recovered and purified. This enables the production of recycled plastics that are both economically and environmentally superior to virgin plastics. The process ensures a 46% reduction in emissions and is effective across all polyester-based plastics and material forms, including rigids, films, textiles, and nonwovens. Additionally, the process sterilizes biohazards, making it ideal for recycling compostable hygiene products.
Technical specifications
- Mixed feedstock compatibility: Efficiently processes PET, PLA, PBAT, PBS, PHAs.
- Single pot process: Decomposes and purifies in one step using alcohol solvent and high temperatures.
- Material versatility: Works on all forms, including rigid and flexible materials.
- Biohazard sterilization: High temperatures ensure complete sterilization.
- Emissions reduction: Achieves a 46% reduction compared to virgin plastic production.
Technology readiness level
The technology is currently at TRL 4, having been validated in a lab environment. Future plans include testing individual polymers from K-C's compostable hygiene products and conducting a collaborative pilot program to demonstrate a fully circular recycling process.
About EsterCycle
EsterCycle is a chemical recycling company that has developed a platform for the low-energy recycling of mixed-polyester plastics. The technology utilizes an alcohol solvent and a catalyst to break down petroleum-based and bio-based polyesters, including complex or multi-layer packaging materials, into their fundamental monomer building blocks under mild conditions. These monomers are subsequently separated and purified to allow for the production of recycled plastics with properties comparable to virgin materials. By operating at lower energy levels and enabling the processing of mixed feedstocks, the process is designed to reduce greenhouse gas emissions and dependency on fossil-based raw materials compared to traditional recycling methods.
The company aims to solve the problem of plastic waste contamination in recycling streams and the limited acceptance of compostable plastics in existing composting facilities. By providing a scalable, circular recycling pathway for single-use packaging, EsterCycle seeks to help polymer manufacturers and consumer brands meet sustainability goals and improve the circularity of their material supply chains. Founded by Dr. Julia Curley as a spin-out from the BOTTLE Consortium at the National Renewable Energy Laboratory, the company is currently focused on validating the quality of its recycled products with industry partners and scaling its operations from laboratory to pilot-level facilities.
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