Foam Core Materials from Recycled PET by Armacell

While being a leading pioneer in developing polyethylene terephthalate PET  technology for years, Armacell is recognised today for a couple of impressive breakthroughs. This includes establishing PET foams as a structural core material within the composite materials sector as well as driving significant growth in PET recycling.

Armacell started off designing and manufacturing PET foams from virgin PET. However, after years of dedicated research and prototyping, they’ve been able to find a process that produces the same quality products from 100% recycled PET (rPET). Today, Armacell’s entire PET foam product range is created using this breakthrough technology, making them leaders of PET recycling in the composite materials sector.

The Impact of Plastic Production

Despite significant recycling initiatives, approximately only 9% of plastics are recycled. This poses several problems from an environmental perspective. The production and transportation of new plastic products involves high levels of emissions. Even worse, a high percentage of those plastic products end up in the ocean. Around 500 million tons of plastic will enter marine ecosystems around the planet in 2020 alone. This is having and will continue to have a detrimental impact on marine life, human health and the environment at large.

As a result, there’s been a boom in research and innovation in recent years surrounding the design and recycling of PET products and materials. The advancement of programs for the recycling of this material will be instrumental in reducing the carbon footprint associated with PET plastic products, which are widely used in multiple industries and for the production of consumer products like plastic drink bottles.

PET Products are a Major Segment of Plastic Manufacturing

According to recent research, the production of just one 500ml plastic bottle produces 82.8 g of carbon dioxide. Recycling more PET products will drastically reduce the carbon footprint of both the plastics manufacturing industry and the industries closely related to it.



While PET plastic is recycled at a relatively high rate of approximately 20% (compared to PVC plastic, which has a 2% recycling rate), the recycled PET generally isn’t used for building and construction like virgin PET. This limits repurposing possibilities given the opportunity the rapidly growing green building materials market represents.

Armacell Creates Foam Core Materials from Recycled PET

Armacell is responsible for a game-changing innovation by producing high-value foam core materials for the composite industry from using recycled PET drink bottles. This is revolutionising the way PET plastics can be repurposed, helping to reduce emissions and the impact of plastics on the environment.

Instead of finding their way to the ocean, PET bottles are transformed into high-quality foam core materials that can be used in composite sandwich structures. Armacell has already converted well over one billion recycled PET bottles that would have otherwise gone to waste.

Advancing the Process of PET Bottle Recycling

Armacell is a world leading pioneer in polyethylene terephthalate green PET foam technology as the first manufacturer to succeed in qualifying recycled PET as a core material. The composite industry now relies heavily on these materials today to reduce vehicle weight and maximise mechanical strength, residual flexibility, and service life while remaining eco-friendly.

Armacell’s materials produce 34% less carbon dioxide emissions compared to traditionally made PET foams. This represents a pivotal opportunity to not only reduce the amount of plastic entering landfills and the world’s oceans, but to also show the significant opportunity to reduce carbon emissions related to construction material manufacture drastically. Armacell’s recycled PET foam materials are 100% recyclable if they are no longer needed for their construction purposes.

Contributing to a Greener Future

By converting PET bottles into core materials, Armacell has added to a number of techniques that are advancing the trend of recycling plastic into high quality, eco-friendly building materials. Armacell has set a precedent for the future of green building material manufacture, which will encourage new government initiatives to incorporate the use of recycled materials to reduce emissions and prevent environmental damage.

The future will see the expansion of these techniques, so recycled PET is used in a wider variety of construction materials as well as developing new techniques to construct core materials from other types of plastic, such as PVC, that currently aren’t getting recycled enough.

Armacell’s Leading Green PET Foam is Supplied By Liner

Armacell is committed to innovative, high-performance products that create sustainable value for their customers. Armacell develops innovative and safe thermal, acoustic and mechanical solutions that create sustainable value for its customers

At Liner, we share the same passion and dedication for supplying manufacturers with the highest quality green materials. Contact us today for a quote, product sample, consultation or for more information about Armacell products.

Related Questions

What are the applications of PET foam cores?

PET foam cores can be used in a wide range of applications including but not limited to the commercial vehicle, recreational vehicle, building panel, rail, marine and wind energy sectors.

Why is only 20% of PET recycled?

Since recycled PET is eventually sold to manufacturers, they must meet certain standards. They can’t have too many impurities, since recycled materials compete with virgin materials for use in manufacturing. So, some of it might end up in landfill if it isn’t clean enough or has certain additives which disqualifies it from reuse.

What else is recycled plastic used for?

Other techniques that include the use of recycled plastics include constructing roads, tiles, fencing, roofing materials and scaffolding planks.