he FlexPack2Circle project started in December 2018, with a pilot line in Bielefeld, North Rhine-Westphalia, capable of producing 50 kg per batch. Throughout the project, a total of 2250 kg of LDPE recyclate and 353 kg of aluminum were generated from various input materials, including aluminum barrier laminates (such as PE/Al/PET) and used beverage cartons (UBC).
Saperatec's research and development team conducted extensive adhesive screening for laminated multilayer materials, establishing benchmark values for highly sustainable adhesive types. In collaboration with Henkel, saperatec announced two adhesives which are highly recommended for the new delamination recycling process.
Originally focused on recycling post-industrial waste scraps, saperatec expanded the project scope to include post-consumer waste streams, specifically used beverage cartons. As a result, modifications at the saperatec process allowed the handling of impurities present in UBC waste streams (such as spouts and caps) as well as the removal of paper fibers.
The quality of the produced materials was evaluated by partner companies and deemed to be of high standard. The LDPE recyclate, known as Saperalen, was successfully reused for manufacturing new detergent packaging, exemplifying saperatec's circular approach—packaging to packaging. Saperatec, Henkel, and Wentus showcased the example of true sustainability at the world's largest plastic trade fair, K2022, held in Düsseldorf. The aluminum produced, named SaperAl, with its high metal content (>95%) and exceptional quality (oxygen amount <2%), was also exhibited at trade shows K2019 and K2022. Numerous companies expressed interest through signed letters of intent to purchase these high-quality LDPE recyclate and aluminum products.
Simultaneously, alongside the technological advancements in Bielefeld, saperatec applied for a federal building permit for the recycling process in Dessau-Roßlau, Saxony-Anhalt, and begun construction of the corresponding industrial facility. The groundbreaking ceremony for saperatec's the plant took place in December 2021. The entire facility was installed in approximately 18 months, with the commercial launch in summer 2023. As part of the consolidation process, the company's headquarters was relocated from Bielefeld to Dessau-Roßlau, allowing for the concentration of the entire workforce at a single site. Throughout this process, the number of employees increased from 4 to 19.
In parallel with the plant's construction, documentation for future company and plant certification was prepared. Additionally, an initial eco-balance model was implemented, highlighting the environmental advantages of the saperatec process for producing secondary resources compared to the sole energy recovery through waste incineration.
Over the years, saperatec actively promoted its technology through various PR channels, resulting in numerous news articles, press releases, and conference contributions. The recycling process also underwent validation and proof in collaboration with the CEFLEX consortium, receiving attention and support from its over 100 members. Furthermore, saperatec's technology has been safeguarded with intelligent property rights at both European and international levels.
