In good form

Public research project on resource-saving processes for plastic products

melting temperature to room temperature? Which steps in the manufacturing process could be carried out more quickly? How can the resulting waste be reduced? “The core of our research work is complex computer simulations. In the process, we develop models that should lead to saving materials and energy in manufacturing,” explains head of the project, Christian Dresbach, Professor for Materials Science, particularly structural and functional materials and simulation.

Lower production costs and fewer emissions

From the shampoo bottle to the plastic tray in the fresh produce section of the supermarket – plastic packaging is pervasive in our lives. To save energy and resources in the future, something in its production has to change. Professor Christian Dresbach and his team are researching exactly what in the ROForm (Resource Optimized Forming) project.

ROForm focuses on the manufacturing processes of plastic packaging that is produced either by blow moulding (such as shampoo bottles) or thermoforming processes (such as the plastic trays at the deli counter). The packaging changes shape during the process. The researchers in the ROForm project are investigating exactly which factors play a role in this. Why does the shampoo bottle shrink when it cools down from

Melting down, shaping, cooling – these steps are clearly defined, but there is some uncertainty about the detailed characteristics of the material. ROForm aims to change this. “To be able to develop models that are as reliable as possible, we attach great importance to detailed material characterisation,” Dresbach explains. On the basis of the individual parameters that make up the plastic, more precise information can be obtained about where material can be saved and which steps in the process can be carried out faster. This is advantageous for companies, says Dresbach, a materials scientist: “Less material and shorter production times reduce production costs and lower the carbon footprint.”

ROForm is funded by the Federal Ministry of Education and Research and runs until 2024. The Dr Reinold Hagen Foundation, the Rikutec Germany Group and Silver Plastics GmbH are involved as external partners.

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