NCL develops pilot to upcycle medical grade PPE waste

In a move toward plastic circularity, the Council of Scientific and Industrial Research–National Chemical Laboratory (CSIR-NCL) has successfully demonstrated a pilot project to upcycle decontaminated medical-grade PP waste from PPE suits into high-value industrial products.

During the height of the Covid-19 pandemic, PPE kits, made of non-woven PP were destined for centralised incineration or landfills. Dr Pol explained that NCL intervened by developing a protocol that begins with hospital-level decontamination via autoclaving, which is a decontamination protocol used for medical-grade waste.

“Our findings show that autoclaving at 125 degrees Celsius does not alter the mechanical or thermal properties of the material,” said Dr Pol. “This allows for effective recycling without compromising the polymer's integrity,” he added.

The process involves removing non-polymer components like metal zippers and buttons before shredding the material. NCL's research confirms that the recycled PP can be blended with virgin PP in various ratios, providing formulators the flexibility to tune properties for specific applications.

To further enhance performance, NCL incorporates functional fillers such as talc and glass fibre, which increase the strength of the recycled substrate.
 
The technology has already seen real-world application in the automotive sector. In a partnership with an injection moulding company in Pune, NCL produced front panels for three-wheeler tanks. Dr Pol noted that the properties of the parts made from 100% recycled PPE, with added black pigment, are equivalent to those made from virgin materials.

Beyond traditional moulding, NCL is pushing the boundaries of material science by upcycling PP for 3D printing. Because PP is highly crystalline and prone to warpage, it is rarely used in 3D printing. “We introduced long-chain branching on the PP backbone using reactive extrusion. This increases melt elasticity and acts as nucleating sites, reducing warpage and improving toughness,” Dr Pol explained.

The pilot project was supported by an industry partnership with Reliance Industries and Pasco Environmental Solutions, which provided 100-kg of decontaminated waste under Maharashtra Pollution Control Board (MPCB) supervision. This material was successfully converted into non-food contact items like flower pots, mugs, and automotive components.

The technology was licensed in 2022 to Plasticycle, a startup founded by NCL alumni, which now operates a commercial supply chain for non-woven PP recycling in Pune.

Dr Pol concluded with a 10-year roadmap, calling for mandatory source segregation for all polymer waste and the inclusion of medical-grade non-woven PP in EPR frameworks. He also announced that NCL plans to establish a consortium for post-consumer recycled waste to align regulatory bodies, manufacturers, and end-users with India’s sustainability objectives.