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PET foaming: development of a new class of rheological additives for improved processability
Summary
This paper describes development of rheological additives to improve PET foaming for lightweight packaging, as an alternative to hard-to-recycle foamed polystyrene. Replacing polystyrene foam with more recyclable materials is important for reducing ocean microplastic pollution from packaging waste.
Abstract. Polymer foaming is a process broadly used for manufacturing light weight packaging solutions. Polystyrene (PS) is the most widespread material for this application, as it combines easy processability, low cost and high performance of the resulting items. However, foamed PS is difficult to recycle and highly polluting for the oceans and aquatic environment. Polyethylene terephthalate (PET) is, instead, commonly recycled and R-PET is broadly used for several industrial applications. Yet, PET quickly loses viscosity during the foaming process, due to thermo-hydrolytic and oxidative degradation thus causing poor foaming. In this paper, an innovative combination of chain extenders, anti-oxidants and nucleating agents to modify PET rheology is studied. The additives were experimented both in off-line and in-line apparatus. The experimental results show PET rheology can be customized by appropriately modulating the content of the different additives, thus making PET suitable for foaming process of high-quality items.