Optimisation & Circularity of Waste Materials
Culture of continuous improvement
Total Plastic Solution (TPS), a forward-thinking custom plastic injection moulding manufacturing, machine building & automation and precision engineering company, based in Dromcollogher, Co. Limerick, embarked on a transformative journey with the MET Technology Gateway at ATU Galway. TPS manufactures and validates high precision, custom, moulded components for their OEM and Tier 1 customers, with best-in-class production metrics
TPS recognised a significant opportunity to enhance its sustainability and reduce operational costs by effectively managing the high-moisture powder waste generated during polypropylene production. Traditional disposal methods were environmentally unsound and represented a loss of valuable resources. The core challenge lay in identifying, separating, and processing this unwieldy, up to 65% liquid content waste stream efficiently and cost-effectively for reintegration into the production cycle.
Overcoming Technological Bottlenecks
MET Technology Gateway acted as a strategic innovation partner, providing TPS with a multi-faceted solution:
Material Analysis & Circular Solutions: MET’s material engineers meticulously assessed the moisture content and composition of the PP waste powder, providing critical data for targeted intervention. They proposed practical circular economy solutions, aligning with EU Green Deal objectives, to minimise waste and maximise resource utilisation.
Best-in-Class Recycling Technology Guidance: Leveraging their knowledge of advanced recycling technologies, MET guided TPS in identifying and implementing more efficient and eco-friendly processes for waste drying, separation, and reintroduction into the production stream.
Technological Bottleneck Breakthrough: MET’s expertise directly addressed the technological bottleneck of recycling high-moisture PP powder. Their tailored advice on drying and sorting technologies, coupled with realistic strategies for waste identification and reutilisation, enabled TPS to transition from costly disposal to successful raw material recovery.
Digitalisation Strategy Influence: The partnership extended beyond immediate waste management, influencing TPS’s overall digitalisation strategy and laying the groundwork for future integration of advanced technologies.
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Multi-faceted solution
“Beyond Conventional Solutions, a pivotal moment in the collaboration occurred when MET’s team swiftly addressed the unforeseen challenge of the exceptionally high moisture content (up to 65%) in the PP waste stream. Their prompt, evidence-based approach to focused moisture elimination measures not only resolved the immediate capacity issue but also unlocked new possibilities for material recombination and circularity, demonstrating MET’s proactive and future-focused strategy”.
Jason McLaughlin, Chief Operating Officer at TPS
Total Plastic Solution & MET Technology Gateway partnership
A Paradigm Shift in Sustainability and Efficiency, the collaboration with MET Technology Gateway delivered significant and far-reaching impacts for TPS:
Accelerated New Product Introduction & Process Optimisation: By effectively tackling the high-moisture waste challenge, TPS significantly accelerated its ability to recycle and reintegrate production waste, directly supporting our circular economy and sustainability goals. This also drove process innovation in advanced moisture removal and recycling.
Reduced Waste & Operating Costs: Efficient waste processing led to a substantial reduction in waste disposal and the creation of a valuable secondary raw material source, resulting in significant cost savings and improved stock control.
Upskilling & Enhanced R&D Capabilities: An unforeseen yet invaluable benefit was the widespread upskilling of the TPS team in advanced circular economy practices and digital process innovation. This fostered a culture of continuous improvement and opened up new avenues for internal R&D.
Enhanced Competitiveness & Sustainability Leadership: The successful implementation of circular economy principles and the integration of digital innovation have cemented TPS’s leadership in competitiveness and sustainability within the plastics manufacturing sector, driving higher returns for potential capital infusion and fostering impactful strategic collaborations.
Justified Internal Processes: The partnership validated TPS’s internal processes by introducing advanced circularity and digitalisation concepts, streamlining production and strengthening their business performance.
MET facilitated knowledge transfer through focused technical guidance, hands-on consultancy, and structured training sessions in circular economy, materials engineering, and process improvement. This empowered the TPS team to confidently implement innovative solutions and drive ongoing improvements. The collaborative nature of the projects fostered an environment of trust and transparency, encouraging TPS to challenge established practices and embrace new ideas, embedding a culture of continuous improvement and cross-functional learning within the organisation.