The Polyfloss technology has been in development for 5 years, it a bespoke machine that produces Polyfloss: a floss-like (fiber) plastic material made by applying heat and spinning thermoplastics (specifically small format waste plastic such as bottle caps), in a process similar to candyfloss production.
A video of this process can be seen here.
The properties of the resulting material can be controlled by varying the applied temperature and the spin speed, each of the various output materials have multiple use-cases. Polyfloss shows great potential as a way to create value from waste material, by transforming plastic waste into useful new material for products such as building insulation.
The Polyfloss Factory has explored numerous uses for Polyfloss in addition to insulation, including packaging, knitted fibers, felted fibers and woven fibers to make textiles. Polyfloss can also be fully or partially re-melted to add structural and ‘multi-structural’ properties. This new multi-structural material shows the potential upcycle waste material into new plastic products without expensive or complicated manufacturing techniques and infrastructure, which is currently required in traditional plastic forming methods, such as injection molding.