Blowplast, a Nairobi-based converter, has successfully integrated up to 50% post-consumer recycled (PCR) content in its blow-molded lubricant bottles, surpassing a sustainability benchmark set by East African brand owners. This milestone was achieved through the partial replacement of traditional HDPE with ExxonMobil’s Enable™ 4002 performance polyethylene.
The challenge arose when local brand owners required at least 25% PCR content in lubricant bottles as part of a global sustainability initiative. However, incorporating higher levels of PCR with the incumbent HDPE HYA 600 caused brittleness, leading to bottle failures. Blowplast sought assistance from ExxonMobil to address the issue.
“When the brand owners modified their requirements, we were eager to retain their business,” said Sanjay Brahmbhatt, Group Managing Director of Blowplast. “ExxonMobil spent time understanding our needs and supported us during trials and development of a new solution.”
ExxonMobil introduced Enable 4002, a performance polyethylene, as part of the solution. Adding small amounts of Enable 4002 to the formulation enhanced the bottles’ strength and impact resistance, enabling PCR content to increase to 50%. The three-layer blow molding application incorporates PCR in the core layer, while the skin layers are made entirely from Enable 4002.
The integration of Enable 4002 also brought operational benefits. It allowed a reduction in extruder temperature by 20°C, potentially lowering energy consumption during production.
The new bottles outperform the previous design, which incorporated only 10% PCR content. According to Brahmbhatt, “The more flexible bottle does not impact the supply chain as the bottles are shipped in cardboard boxes after filling. This innovation has not only met sustainability goals but also reduced failure rates, thanks to improved impact strength and environmental stress crack resistance.”
The collaboration between Blowplast and ExxonMobil underscores the role of advanced materials in achieving sustainability goals while maintaining product performance.