IKK Hannover Develops Recycling Solution for PE foams
Case Study
- Customer: Leibniz University Hannover, IKK - Institute of Plastics and Recycling Technology, Faculty of Mechanical Engineering
- Location: Garbsen, Germany
- Industry: Institute & Academia
- Topic: Circular economy: Process development for the mechanical recycling of cross-linked foam waste
October 2025
When recycling foam waste, it's important to assess how well the reused material can be processed. To achieve this, the IKK – Institute for Plastics and Recycling Technology at Leibniz University Hannover – utilizes the Mflow extrusion plastometer. It measures how easily the material flows under specific conditions – a crucial factor in determining the quality of new products.
Research for sustainable plastics technology and a modern circular economy
The IKK - Institute for Plastics and Circulation Technology is part of the faculty of Mechanical Engineering at Leibniz University Hannover and focuses on the entire value chain of plastics. Research encompasses a wide range of topics, from the development of new materials to modern, energy-efficient processing methods and innovative recycling concepts. The goal is to make plastics more sustainable and improve their recycling, both ecologically and economically.
A particular focus is on the circular economy: The IKK is researching how plastics can be used, repaired, recycled and reintroduced into the production process for as long as possible. Digital technologies, process simulations, and environmental impact assessments also play a significant role. The institute collaborates closely with industry partners and other research institutions, and is located within the Hannover Center for Production Technology, one of Europe’s largest research centers for production technology.
Recycling of PE foams: Sustainable solutions for industry waste
Recycling cross-linked foam waste presents a unique challenge, particularly for companies committed to sustainability and resource conservation. The reason: Cross-linked foams cannot be easily melted and reshaped. Traditional chemical recycling methods are often complex, costly and harmful to the environment. The “R-Schaum” project, funded by the DBU (German Federal Environmental Foundation), is currently developing a new process based on mechanical recycling. The goal is to selectively shred foam waste made of cross-linked polyethylene (PE) and use it as a filler in new plastic blends. These recyclates are intended to possess high-quality properties, enabling their use in industries such as the automotive, packaging and furniture sectors.
A key aspect is the material’s flow properties, which determines how well the recycled material can be processed, for example, in injection molding or extrusion. Special tests are used to examine how different compositions, particle shapes and the degree of cross linking affect the melt rate and material quality. This allows us to identify early signs of potential material changes or degradation processes, and to improve the recycling strategy in a targeted manner.
To investigate these properties, IKK Hannover relies on the modular Mflow extrusion plastometer from ZwickRoell. It enables quick and efficient analysis of the melt flow properties of new types of plastic recyclate formulations. The adapted device design in the extrudate section area is particularly advantageous, as it facilitates the measurement of highly flowable and fluorine-containing materials. And due to its compact design, the device can also be used directly on the production line.
Using the ZwickRoell Mflow extrusion plastometer
