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Lightweight, shock resistant Hollow-Sheet with 47% lower carbon footprint

Blue X-type hollow sheet pallet box used in industrial packaging and logistics applications.

GCR and OMIPA validate durable, reusable & recyclable X-type hollow sheets for Industrial Packaging and Building & Construction

Challenge
In these applications, hollow sheets must withstand heavy loads and impacts. Traditionally, converters rely on PP copolymer and recycled content sourced in a close loop from their own sheet production to secure these properties.
The challenge was to prove on OMIPA extrusion lines that recycled PP homopolymer could reach high recycled content levels while maintaining mechanical performance and process efficiency. But moving from copolymer to homopolymer meant a trade-off. Homopolymer brings stiffness but less impact resistance, so balancing properties with Granic® mineral masterbatches was key.

Applications
Formwork panels, protection boards, collapsible pallet boxes.

Solution

OMIPA and GCR validated a formulation on OMIPA’s X-wall hollow sheet extrusion lines, combining:

  • Ciclic® rPP: recycled PP for high recycled content
  • Granic® solutions: mineral masterbatches to enhance impact resistance, flexibility, dimensional stability of the sheet and processability

Hollow sheets with 47% lower carbon footprint can be reliably produced, with higher output, lower energy demand, and uncompromised strength.

The results

  • Compression and impact strength fully aligned with specifications
  • Long lifespan
  • Light weight
  • 20% higher line speed -> more output per hour
  • 14% increase in torque efficiency ->lower energy demand from the screw
  • 6% material savings -> equal performance with fewer resources
  • 47% lower CO2 footprint -> significant contribution to sustainability goals
  • 100% recyclable

OMIPA and GCR proved that demanding hollow sheet applications can achieve higher recycled content, improved efficiency, and a lower carbon footprint without compromise.

Download the Succes Case: Hollow Sheets for Industrial Packaging and Building & Construction

All data presented is for informational purposes only and does not constitute contractual specifications. The processor is responsible for processing conditions and final product use, including compliance with applicable regulations and third-party intellectual property rights.