The plastics industry faces a major challenge: it must increasingly use recycled materials while delivering the same quality as newly produced plastics. This is precisely where the “SmartReUSE” project comes in. Funded by the European Union and the Free State of Bavaria, it has a clear goal: to process plastics from waste in such a way that they can be reliably used in new products while maintaining high quality.
Recyclates refer to plastics recovered from production residues or used products. A distinction is made between “post-industrial recycled materials” (PIR), i.e., residues from industrial production, and “post-consumer recycled materials” (PCR), which come from used products such as packaging. Both types are to be used more extensively in the project in the future to conserve petroleum and reduce CO₂ emissions.
“We want to show that recycled plastics don’t have to be a compromise, but can be a genuine alternative to new materials.” – Prof. Dr. habil Michael Nase, project leader and director of the Institute for Circular Economy of Bio-Polymers at Hof University of Applied Sciences (ibp).
Data analysis instead of lengthy test series
In practice, the use of recycled plastics is often difficult because their properties vary. Sometimes they are particularly strong, sometimes less resilient, and sometimes they behave differently than expected when exposed to heat. These so-called thermal properties describe how the material behaves under temperature changes. The so-called rheological properties indicate how well a plastic flows in its molten state and how easily it can be processed. Physicochemical properties, for example, relate to the composition and structure of the material. Added to these are the mechanical properties, such as the strength or elasticity of the finished component. In the project, all these properties are closely examined and documented.
“It is crucial to understand the properties of the recycled materials holistically. We systematically analyze the materials to be able to make reliable statements about their processability. This is essential for all subsequent steps.” – Stefanie Rank, Research Associate at ibp.
The resulting material and process data are evaluated using pattern recognition software.
“The software identifies correlations between material condition, machine settings, and product properties and can derive concrete recommendations for action from them.” – Maurice Bäcker, Research Associate at iisys.
These recommendations include, for example, the mixing ratio of different plastics or the use of additives and stabilizers. Additives are substances that improve certain properties, such as durability. Stabilizers ensure that the material ages less quickly when exposed to heat or light.
“Our goal is to provide companies with clear and understandable recommendations for action. They should be able to decide more quickly which mixture and which machine settings will lead to the desired result.” – Prof. Dr. Jörg Scheidt, Head of the Analytical Information Systems Research Group at iisys.
Close collaboration between the ibp and iisys institutes
The project is being carried out at Hof University in close collaboration between the Institute for Circular Economy of Bio-Polymers, led by Prof. Dr.-Ing. habil. Michael Nase, and the Analytical Information Systems Research Group of the Institute for Information Systems, led by Prof. Dr. Jörg Scheidt.
Subprojects in cooperation with companies in the region
The project is divided into various subprojects, which are being implemented in cooperation with various industry partners. These partners include the recycler KomRec-ReCond GmbH, the plastics processing companies BKW Kunststoff GmbH, WIKUTEC GmbH, and Kunststofftechnik Schnitzler GmbH & Co. KG, the analytical instrument manufacturer Erich Netzsch B.V. & Co. Holding KG, and the software company smartlytic GmbH. Through recycling projects tailored to the companies, the developed pattern recognition software is validated and made usable for small and medium-sized enterprises (SMEs).
The project runs from 2025 to 2028. In the first subproject, various streams of used packaging plastics of the PCR-HDPE type are being examined. HDPE stands for “high-density polyethylene,” a particularly stable and widely used plastic that is frequently used for bottles or canisters. The goal is to process this material so that it can be used to manufacture holders for beer kegs.
Funding
“SmartReUSE” is a technology transfer program co-financed by the European Regional Development Fund (ERDF) of the European Union and the Bavarian State Ministry of Economic Affairs, Regional Development, and Energy.
Source
Hof University of Applied Science, press release, 2026-03-30.
Supplier
Bayerisches Staatsministerium für Wirtschaft, Landesentwicklung und Energie StmWi
BKW Kunststoff GmbH
Europäischer Fonds für Regionale Entwicklung (EFRE)
European Union
Hochschule Hof - University of Applied Sciences
Kunststofftechnik Schnitzler GmbH & Co. KG
smartlytic GmbH
WIKUTEC GmbH
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