1. Dr Christel Croft, Project Manager, Luxus Ltd
The Fusion of....
High-performance lightweight recycled polypropylene materials for tomorrow’s auto interiors
Dr Christel Croft, Project Manager, Luxus Ltd

2. Developed the HycoleneTM range
The Recyclite project
The strength of the “Recyclite” Consortium :
Luxus is part of a consortium that secured €1.4m of investment co-funded by the EU Eco-Innovation initiative (Recyclite Project).
Luxus
Leading the project
Developed the HycoleneTM range
Coperion
Providing technical support in the compounding process to deliver key economic and environmental benefits.
JLR
Lead manufacturer who will help deliver components made from the rPP to the market .
IAC
A key injection moulding company delivering verification of process parameters.
The aim of the Recyclite project is to commercialise Luxus’ development of the Hycolene™ range of lightweight polypropylene (PP) compounds with up to 60% recycled content that targets Europe’s Class ‘A’ automotive interior trim market

3. Luxus – High performance PP for the automotive sector
Luxus’ recycled polypropylene compounds are already successfully used by key OEMs for various “A” surface visually critical applications.
Luxus Ltd provides high volumes of PP recycled based materials for automotive exterior and interior trim applications with:
Specification agreement
Recycled feedstock analysis and selection
Material property enhancement
Colour matching
Pre production laboratory evaluation against specification
Blending batches up to 150t lots
The new HycoleneTM range delivers additional benefits to the current offer of recycled based PP materials such as lighter weight and increased scratch performance.
PP for automotive interior Class A

4. The history
Project initiated by Luxus Ltd to meet specific needs of the automotive sector.
Weight Reduction
Less material required
Fuel economy
CO2 emission reduction
Material performance
High scratch performance
Visible parts applications
Recycled content
High level of recyclate
Legislation & competitive benefits
Target : Highly functional, directly visible, colour matched parts with low gloss, meeting the same requirements as current materials with additional benefits of lightweight and higher scratch resistance.
Key drivers:
Legislation & Compliance
Sustainability and Environmental Performance
Customer engagement & Corporate Social Responsibility
Material Performance
Cost
Key challenge: To increase OEMs & moulders confidence in using recycled materials for “Class A” interior trim applications in an increasing competitive environment.

5. Key elements of the project
Technical objectives:
Establish robust scratch testing and correlate with results from various OEMs’ tests.
Perform performance tests on various virgin and new recycled PP compounds and establish correlations or trends between properties where possible.
Micro analysis of virgin and recycled material to understand how surface scratches are formed, and therefore, the observed visual characteristics.
Optimise Luxus’ new Coperion twin screw extruder to scale up and increase performance of the HycoleneTM formulations. Develop knowledge database of process and additives effects on performance.
Prepare colour matched moulded test specimens for full validation tests.
Complete a Life Cycle Analysis (LCA) for the project.
Commercial and Market objectives:
Survey moulders & OEMs regarding in-cabin performance specifications.
Perform assessment tests and validation of the Hycolene TM range for defined applications.
Assess and communicate the environmental and cost benefits performance on the commercially produced material.
Develop licence agreements with partners for producing and accessing the Hycolene TM range globally.
Door pocket - Example of a potential future application for the HycoleneTM range

6. The achievements so far
Lab scale development demonstrated:
Weight reduction
Improved scratch performance
Increased recycled content
645 g
568 g
12% weight reduction
Crosshatch 20x20 10N - Erichsen
Reference material: current PP for Class “A” automotive interior trim. - 25% talc filled with a recycled content.
Industry standard

7. The achievements so far
Properties - HycoleneTM - PP16624 versus PP16407
Meeting mechanical properties
Meeting dimensional requirements: Drop-in solution
Property
Test Method
Units
PP16407
Reference
PP 16624
HycoleneTM
Melt flow
ISO 1133
g/10 mins
Izod at Room Temperature notched
ISO 180: 1993
KJ/m²
Izod at -40 C notched
1.7 +
Flexural Modulus
ISO 178
N/mm²
Density
ISO 1183: 1987
1 +
Filler %
8 - 11
HDT 0.45Mpa
ISO 75 °C
80 +
90 +

8. The offer
For over 50 years Luxus Ltd has offered unique knowledge and capability to work with a range of recycled feedstock to deliver products matching customer specifications with batch to batch repeatability.
The new lightweight HycoleneTM range with increased scratch performance will be offered to the market with the same ethos, working closely with customers to consistently supply the best product at the best price.
For more information – visit visit our stand A5126 or contact Luxus on +44(0)

9. Acknowledgements
We would like to recognise the support and contribution of :
The Eco-Innovation Initiative of the European Union.
Our Partners and in particular :
R. Crow, R. Punch, I. Lowe, W. Morris, C. Edwards, E. Davis (JLR)
M. Walddoerfer, D. Watmore, J. Schofer (Coperion)
D. Jenkins, P. Middleton (IAC)
Our Technical, Business and Project team and in particular :
T. Burton, G. Stephenson, L. Dalley, J. Ballantyne, A. Boyce, I. Pigot, I. Huskiewicz, P. Atterby, C. Barker, S. Coggle.