Under the grant funding of the IEEA (Industrial Energy Efficiency Accelerator) working under DESNZ (the Department for Energy Security and Net Zero), Project Odour Accelerator is the second phase of a Luxus initiative aimed at significantly reducing the reliance on virgin polymers in various industries and applications by tackling one of the most significant barriers to using Post-Consumer Waste (PCW) materials: malodour caused by Volatile Organic Compounds (VOCs). The presence of these malodours is the largest barrier to the widespread use of PCW in new and existing products. By addressing and minimising these odours, the resulting material becomes a feasible option for a multitude of industries and applications, including automotive. For brand and product owners, the increased use of PCW also ties in with upcoming laws and legislation regarding the mandatory increased use of recycled material. Along with this, it also provides a step change in product sustainability and profitably, in increasing the use of non-virgin materials.
During this project, Luxus advanced its prototype odour-extraction (ODEX) technology to demonstrator scale. With this development, our mass production processes that already use high PCW content can meet the growing demand for deodorised product across automotive and other sectors. With the reduced requirement of virgin polymers, the technology significantly lowers carbon footprint and increases high-quality recycled content in our customer’s products, all of which is achieved whilst maintaining the required technical performance of the material.
The deodorising process uses a series of innovative steps to treat recycled materials and extract VOCs effectively. It involves careful control of temperature, pressure, and flow dynamics within the Luxus production process to ensure efficient odour reduction. The method has been refined following intricate laboratory testing and refinement, followed by careful scale up of the system from prototype to integration into one of the main production lines in the Luxus manufacturing facility. The second stage of the system further refines the odour reducing process to minimise VOC concentration before packaging and delivery to our customers. This stage involves crucial airflow management techniques to stabilise the recycled compound and maintain the consistent, high-quality output Luxus prides itself on. The streamlined process not only addresses odour but also improves the efficiency of manufacture by enabling faster handling and packing of material.
The project is set to conclude at the end of 2024, at which point the technology developed will become a fully integrated part of the Luxus’ compounding process. This advancement opens new opportunities for customers seeking sustainable, high-performance materials and demonstrates Luxus' commitment to leading the way in environmentally responsible manufacturing.
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