ExxonMobil collaboration adds recycled content to flying disc toys

In the effort to boost the performance of flying disc toys made in part with recycled-content plastic, German recycling solutions provider Der Grüne Punkt recently collaborated with global petrochemical company ExxonMobil and the China-based Haitian Plastics Machinery Group, which manufactures injection molding machines.

According to ExxonMobil, Der Grüne Punkt sought a way to help brand owners meet their sustainability goal of incorporating more recycled content into their products. However, the company notes that achieving the right combination of mechanical strength and flexibility from products with recycled-content plastic remains a challenge.

RELATED: ExxonMobil will add to chemical recycling capacity

The three companies partnered to tackle this challenge by developing flying disc toys that incorporated a 5 percent to 10 percent dose of ExxonMobil’s Vistamaxx performance polymers on Haitian’s fifth-generation injection molding machines. ExxonMobil says its performance polymers compatibilized well with recycled polypropylene (PP) supplied by Der Grüne Punkt as they worked to optimize the right Vistamaxx ratio to use to balance the properties of the toys.

Haitian optimized settings on its fifth-generation injection molding machines, achieving 20 percent to 40 percent energy savings compared to the previous machine generation, ExxonMobil says.

ExxonMobil adds that blending 10 percent Vistamaxx with Systalen PP-C15001 recyclate from Der Grüne Punkt allowed for significant improvement in both the mechanical properties of the flying disc toys and their processability. Results include:

• Improved strength: ExxonMobil says the impact strength of the product with recycled content at room temperature improved by 38 percent, while at 0 degrees Celsius it was boosted by 39 percent, making the discs tougher and more durable.
• Better flexibility: The company says flexural modulus decreased by 25 percent, giving the final product a sound balance between strength and flexibility.
• Faster, efficient production: The melt flow rate increased by 14 percent, potentially allowing for faster production times and reduced energy consumption.

In a project case study, ExxonMobil states, “Thanks to the innovative value chain collaboration involving Der Grüne Punkt’s materials with recycled content, Vistamaxx performance polymers from ExxonMobil and Haitian’s fifth-generation injection molding machines, the flying disc toys incorporating polypropylene recyclate boosted by Vistamaxx performance polymers met stringent performance standards while incorporating recycled content.

“This success showcases how collaboration across the value chain and creative material solutions can help businesses meet their sustainability goal of incorporating recycled content in their products while efficiently delivering high-quality products.”