Waste for Warmth Nepal seeks partners to utilize the Polyfloss technology for various product needs, helping communities manage their plastic waste by creating jobs and producing locally needed products. Plastic waste management has become a critical global issue, and Nepal faces significant challenges in this area. In Kathmandu alone, approximately 4,800,000 plastic bags are used daily, most of which end up in landfills, contributing to the low recycling rate in the country.
The Polypropylene Upcycling Project (PPUP) aims to enhance recycling efforts by upcycling discarded polypropylene waste into polyfloss (fiber). This innovative material is used for thermal insulation in both the Terai and Himalayan regions of Nepal. PPUP not only addresses the plastic waste problem but also creates job opportunities and provides a cost-effective alternative to gypsum boards available in the market, offering both environmental and economic benefits.
Polypropylene (PP) is a thermoplastic polymer produced by polymerization of monomer propylene which is obtained from high temperature cracking of petroleum hydrocarbons and propane and has a relatively low melting point (~170°C). PP has a significant place commercially because of its low cost and can be used in a variety of applications. It is capable of undergoing numerous manufacturing processes, such as general purpose extrusion, extrusion blow molding, even expansion molding and injection molding.
Methods for PPUP
1. Resource Extraction:
Recyclable Resources Collection: The initial step involves collecting recyclable polypropylene (PP) plastics. This can be done by setting up a dedicated collection center established in the community or or partnering with local recyclers and local government.
Segregation of Polypropylene Plastics: Once collected, the plastics must be sorted to separate polypropylene from other types of plastics. This segregation is crucial to ensure the purity and quality of the recycled material.
2. Pelletizing Machine:
Recycling Process: The segregated polypropylene plastics are fed into a pelletizing machine. This machine melts the plastics and extrudes them into small, uniformly-sized pellets. These pellets serve as the raw material for further processing and can be easily transported and stored.
3. Polyfloss Machine:
Polyfloss Production: The polypropylene pellets are then fed into a polyfloss machine. This machine processes the pellets into a fibrous, cotton candy-like material known as polyfloss. Polyfloss has excellent insulating properties due to its fibrous nature and can be used in various applications.
4. Usage of Polyfloss:
- Thermal Insulation:
Terai Region: The primary use of polyfloss is for thermal insulation. In the Terai region of Nepal, where temperature regulation in schools is a significant challenge, polyfloss offers an affordable and effective solution. Its lightweight and excellent insulative properties help maintain comfortable indoor temperatures, reducing the reliance on heating and cooling systems. This can lead to substantial energy savings and a more conducive learning environment for students.
Himalayan Region: In the colder Himalayan region, polyfloss can be used to insulate homes, schools, and other buildings against the harsh winter temperatures. The material’s high thermal resistance helps keep interiors warm, reducing the need for extensive heating and contributing to energy conservation. Its lightweight nature makes it easier to transport and install in remote and mountainous areas, where logistics can be challenging. - Sound Insulation:
Acoustic Benefits: Besides thermal insulation, polyfloss also provides effective sound insulation. Its fibrous structure absorbs sound waves, reducing noise transmission through walls, floors, and ceilings. This makes it suitable for use in:
Educational Institutions: In schools, sound insulation can create a quieter and more focused learning environment by minimizing external noise and sound transmission between classrooms. - Residential Buildings:
Homeowners can use polyfloss to reduce noise from outside or between rooms, enhancing living comfort. - Commercial and Industrial Settings:
Offices, studios, and factories can benefit from reduced noise levels, leading to a more productive and less disruptive work environment.
5. Development of Poly+ Rolls:
Poly+ Rolls: Poly+ rolls are a product derived from polyfloss. The material is processed into rolls, which makes it easy to handle, transport, and install. These rolls can be cut to size and used for various insulation applications, including wall and roof insulation in schools and other buildings.
Ease of Installation: The roll form factor ensures that the material can be quickly and efficiently installed, reducing labor costs and installation time. This makes it an attractive option for large-scale insulation projects.
