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Polymer Reconstruction Paint Removal Process
In 1996 Polymer Sciences was engaged in a project for General Motors, repelletizing painted TPO material from bumper fascia scrap. During the molding process of the material we supplied, odor caused our customer to request we remove more, if not all, of the paint residue from the plastic.
It took four years and three patents to finalize a purely 100% mechanical process to remove all traces of the paint and make available the resulting TPO material without negatively effecting the virgin polymer properties. In some mechanical properties, our process actually enhances the performance of the material. The only consequential negative effect is in the melt flow change of the material during the repelletization process (adding approximately 1 to 1.5 additional points as measured by standard MFI).
The reconstruction process is a three part process involving liberation, separation and pelletization. We have processed and molded some 15 truck loads of material (600,000) to qualify our process molding bumper fascias and testing for possible paint contamination in the end parts. No resulting contaminates have been found after extensive testing and evaluation. In fact, several vehicles on the road have fascias with our Reconstructed material on them.
Our goal since finalizing our process has been to build a plant capable of toll processing TPO material for bumper fascia molders, and returning the TPO material at a significant savings for the molder. At our pricing levels, it is estimated that the average molder will save in excess of $1 MM per year utilizing our process and mixing in Reconstructed material with virgin.
This process is patent protected by U.S. and International Patents in 23 countries around the world. At this time, we have not undertaken the commercialization of this process and look forward to qualified investment to accomplish this goal. The economic and ecological impacts of this process are phenomenal and we hope to locate a partner to develop the commercialization of our technologies.
If you are an automotive bumper fascia molder, we are interested in talking with you about how we can improve your efficiencies and offer your firm substantial savings.
Licensing the Reconstruction Process
Recognizing that we can't accomplish all that we want overnight or that we may not be qualified in all geographic areas, we are given to license the Reconstruction Process for all non-TPO materials (PC, ABS, ABS/PC, Xenoy, etc) this includes most all types of coatings or layers - including metalized coatings and film. In some geographic areas we seek to licenses Reconstruction of TPO materials. If you are interested in looking into a licensing agreement with PSI for the Reconstruction Process, please call our offices or fill out the information request below.