GCR Plastic Solutions and RIGK GmbH have launched a strategic collaboration on advanced recycling trials for post-consumer industrial packaging from the German PAMIRA system and the sector-specific GVÖ scheme. The objective of the project is to ensure high quality, full traceability and safety of recyclates intended for technical applications, taking into account the upcoming requirements of the EU Packaging and Packaging Waste Regulation (PPWR).
RIGK is one of Germany’s leading operators of collective extended producer responsibility (EPR) systems and operates under the German Packaging Act. The company works with major chemical industry groups such as BASF, Covestro, Lanxess, Evonik and Wacker Chemie. Together with industry, RIGK operates take-back and recycling systems for industrial, commercial and agricultural packaging, including PAMIRA, the sector-specific system for used plant protection product and liquid fertiliser packaging. These schemes are characterised by high collection rates, pre-washing procedures and extensive traceability. GVÖ, an independent operator of a sector-specific system for lubricant packaging, functions in a similar way. For the described trials, RIGK (via PAMIRA) and GVÖ provided a controlled collection and pre-treatment framework for the waste stream, resulting in high source traceability and stable input quality for recycling.
Advanced mechanical recycling processes
The recycling trials were carried out at one of the most advanced mechanical recycling plants in Europe, operated by GCR Plastic Solutions. The facility is part of a strategic investment programme worth 100 million euros, aimed at adapting to future PPWR requirements and developing industrial, high-quality circular solutions.
The tests used the latest available technologies in hot washing, advanced sorting systems and extrusion, including systems that enhance mechanical properties and high-efficiency deodorisation units. The goal was to ensure that the recycled material could be safely reintroduced into the production cycle, enabling genuine circularity without the risk of undesirable interaction with residues of chemical substances originally present in the packaging stream.
In response to future PPWR requirements and the growing responsibility of packaging producers, highly demanding and cost-intensive processes were implemented to guarantee a high level of material quality, consistency and safety. The advanced treatment stages proved essential for complex post-consumer industrial packaging streams to meet stringent technical and regulatory requirements for new circular applications.
Research facilities and analytical control
The project was supported by GCR’s innovation division, a specialised technical unit with 58 experts and extensive laboratory infrastructure that is unique in its integrated approach to circular materials. In addition to advanced material characterisation, including mechanical testing, rheological analysis and contaminant analysis, the innovation division can simulate customers’ production processes at pilot scale. This enables validation not only of material purity and compliance, but also of its real performance under conditions close to target industrial applications.
GCR’s facilities are equipped with advanced gas and liquid chromatography equipment, enabling in-depth analytical control of recycled pellets with a level of precision rarely available on the market. This allowed full verification of material purity, volatile compound content and potential contaminants, strengthening confidence among converters and brand owners seeking reliable circular raw materials.
After successful validation of the process and material quality, several leading European industrial packaging converters declared their willingness to proactively adapt to PPWR requirements by gradually integrating these recyclates into their production, once full technical compliance and parameter stability are confirmed.
Pictured during the testing at GCR’s facilities are Mr. Markus Dambeck, Chairman of the Management Board at RIGK GmbH, and Mr. Santiago Sans, Industrial and Innovation Director at GCR.
Importance for the industrial packaging sector
The initiative aims to provide the European industrial packaging sector with greater security, predictability and reliability by confirming that complex post-consumer packaging streams can be reintegrated into the production cycle using robust technical solutions, advanced analytical control and strict traceability. This is in line with the objectives of the upcoming PPWR on packaging and packaging waste.
The trials took place at GCR Plastic Solutions’ facilities at the end of February and included a visit by Markus Dambeck, chairman of the management board of RIGK GmbH, which highlighted the technical significance of the project within the German industrial packaging ecosystem. During the two-day trials, intensive washing, separation and advanced analysis processes were carried out to confirm the quality of the recyclate.
Santiago Sans, industrial and innovation director at GCR, comments: "This project represents an important step towards demonstrating that complex industrial streams, when properly managed at source, can be transformed into high-value recycled raw material with full analytical control and traceability. Our objective is to offer major European converters technically reliable and consistent material."
Markus Dambeck adds: "For RIGK, it is essential to work with partners capable of meeting demanding quality and verification standards. These trials enable us to move towards increasingly robust and transparent recycling solutions for industry."
Reduction of volatile compounds and contaminants
The project was launched with a clearly defined objective of eliminating contaminants and volatile compounds, which has not been achieved in traditional recycling systems so far. Initial test results indicate that volatile substances have been successfully removed, preventing cross-contamination and achieving purity levels previously considered unattainable. In the coming months, an extensive series of further trials will be carried out in cooperation with leading sector stakeholders to further verify the results obtained.
The joint initiative of GCR Plastic Solutions and RIGK contributes to raising industrial recycling standards in Europe, demonstrating that the combination of traceability at source, rigorous processing technologies and strict analytical validation is key to building strong and credible circular value chains in the industrial packaging sector.
Pictured during the testing at GCR’s facilities are Mr. Markus Dambeck, Chairman of the Management Board at RIGK GmbH, and Mr. Santiago Sans, Industrial and Innovation Director at GCR.
