Claims:

CLAIMS:
WE CLAIM:
1. A polypropylene composition obtained by recycling of polymer food packaging characterised in that the polymer food packaging comprises a blend of:
a) a propylene BOPP in the range of 35% to 95% by weight;
b) a Polyethylene terephthalate layer in the range of 2% to 40 % by weight;
c) a polyethylene layer in the range of 2% to 20% by weight, and;
d) a Printing weight in the range of 0.5% to 3% by weight;
the said composition obtained in the form of granules comprises of not less than 50% by weight of polypropylene and residual thermoplastics comprising of but not limited to polyethylene, polyethylene terephthalate.
2. The polypropylene composition as claimed in claim 1 wherein, the composition has a melt flow index in the range of 1.5-15 g/10 min.
3. The polypropylene composition as claimed in claim 1 wherein, the composition has a tensile strength in the range of 230-320 MPA.
4. The polypropylene composition as claimed in claim 1 wherein, the composition has a notched impact in the range of 3-8 KJ/m2.
5. The polypropylene composition as claimed in claim 1 wherein, the composition granule size ranges from 5-10 mm.
6. A polypropylene composition obtained by recycling of polymer food packaging characterised in that the polymer food packaging comprises a blend of:
a) a propylene BOPP in the range of 77% to 97.5% by weight;
b) a Polyethylene layer in the range of 2% to 20 % by weight;
c) a Printing weight in the range of 0.5% to 3% by weight;
the said composition obtained comprises of not less than 50% by weight of polypropylene and residual thermoplastics comprising of but not limited to polyethylene.
7. A polypropylene composition obtained by recycling of polymer food packaging characterised in that the polymer food packaging comprises a blend of:
a) a propylene BOPP in the range of 97% to 99.5 % by weight;
b) a Printing weight in the range of 0.5% to 3% by weight;
the said composition obtained in the form of granules comprises of not less than 50% by weight of polypropylene.
8. A polypropylene composition obtained by recycling of polymer food packaging characterised in that the polymer food packaging comprises a blend of:
a) a propylene BOPP in the range of 40% to 80% by weight;
b) a Polyethylene terephthalate layer in the range of 2% to 40 % by weight;
c) a Printing weight in the range of 0.5% to 3% by weight;
the said composition obtained in the form of granules comprises of not less than 50% by weight of polypropylene and residual thermoplastics comprising of but not limited to polyethylene terephthalate.

9. A polypropylene composition obtained by recycling of polymer food packaging characterised in that the polymer food packaging comprises a blend of:
a) a propylene BOPP in the range of 35% to 95% by weight;
b) a Polyethylene terephthalate layer in the range of 2% to 40 % by weight;
c) a polyethylene layer in the range of 2% to 20% by weight, and;
d) a Printing weight in the range of 0.5% to 3% by weight;
e) a metalizing agent in the range of 0.1% to 5% by weight;
the said composition obtained in the form of granules comprises of not less than 50% by weight of polypropylene and residual thermoplastics comprising of but not limited to polyethylene, polyethylene terephthalate.

10. A polypropylene composition obtained by recycling of polymer food packaging characterised in that the polymer food packaging comprises a blend of:
a) a propylene BOPP in the range of 77% to 97.5% by weight;
b) a Polyethylene layer in the range of 2% to 20 % by weight;
c) a Printing weight in the range of 0.5% to 3% by weight;
d) a metalizing agent in the range of 0.1% to 5% by weight;
the said composition obtained in the form of granules comprises of not less than 50% by weight of polypropylene and residual thermoplastics comprising of but not limited to polyethylene.

11. A polypropylene composition obtained by recycling of polymer food packaging characterised in that the polymer food packaging comprises a blend of:
a) a propylene BOPP in the range of 97% to 99.5 % by weight;
b) a Printing weight in the range of 0.5% to 3% by weight;
c) a metalizing agent in the range of 0.1% to 5% by weight;
the said composition obtained in the form of granules comprises of not less than 50% by weight of polypropylene.
12. A polypropylene composition obtained by recycling of polymer food packaging characterised in that the polymer food packaging comprises a blend of:
a) a propylene BOPP in the range of 40% to 80% by weight;
b) a Polyethylene terephthalate layer in the range of 2% to 40 % by weight;
c) a Printing weight in the range of 0.5% to 3% by weight;
d) a metalizing agent in the range of 0.1% t0 5% by weight;
the said composition obtained in the form of granules comprises of not less than 50% by weight of polypropylene and residual thermoplastics comprising of but not limited to polyethylene terephthalate.
13 The polypropylene composition as claimed in claim 6-12 wherein, the composition has a melt flow index in the range of 1.5-15 g/10 min.
14. The polypropylene composition as claimed in claim 6-12 wherein, the composition has a tensile strength in the range of 230-320 MPA.
15. The polypropylene composition as claimed in claim 6-12 wherein, the composition has a notched impact in the range of 3-8 KJ/m2.
16. The polypropylene composition as claimed in claim 1 wherein, the composition granule size ranges from 5-10 mm.
17. A process for recycling of polymer food packaging to form polypropylene composition as claimed in any one of the claims 1-16, comprising the steps of:
a) Shredding (120) of an input waste in an industrial shedder to reduce the plastic waste into a uniform size for further recycling to form an initial raw material;
b) Cleaning (130) of the said initial raw material to form an impurity free substrate waste;
c) Drying (140) of the said impurity free substrate waste in an industrial drier to protect surface characteristics and prevent hydrolysis to form a dried substrate, characterised in that;
d) Densifying (150) the said dried substrate by shredding and heating in an industrial densifier to make a densified product which is compact and free of ink;
e) Mixing (160) said densified product further to enhance the melt flow properties to form a mixed blend;
f) Extruding (170) the said mixed blend in a specialised extruder to form an extruded molten mass which is passed through cold water to form a hardened mass;
g) Granulating (180) the said hardened mass to form granules of uniform size of 5-10 mm.
18. The process for recycling polymer food packaging as claimed in claim 17; wherein the cleaning (130) is carried out by washing of the initial raw material in a float separation tank where impurities having density above 1 settle down to form an impurity free substrate that floats on top surface of float separation tank or can be alternatively done by disposing the initial raw material into a dust separator.
19. The process of recycling polymer food packaging as claimed in claim 17; wherein densifying (150) the dried substrate in an industrial shredder is done at a temperature of at least 100 degree centigrade.
20. The process for recycling polymer food packaging as claimed in claim 17; wherein mixing (160) of said densified product is done with specialised chemicals consisting of polyolefin elastomers but not limited to polyethylene malic anhydrate grafted, polyisobutylene (PIB), poly(a-olefin)s, ethylene propylene rubber (EPR), ethylene propylene diene monomer (M-class) rubber (EPDM rubber) in the range of 0.5% to 5% weight by volume of total raw materials.
21. The process for recycling polymer food packaging as claimed in claim 17; wherein extrusion (170) of the mixed product is done in a twin-screw extruder having screw- barrel system and different heating zones set at progressively increasing temperatures; wherein the temperature of the heating zone is increased from 190 degree to 230 degree centigrade gradually.
22. The process for recycling polymer food packaging as claimed in claim 17; wherein extrusion (170) of the mixed product is done in a mother baby extruder having a single screw- barrel system and different heating zones set at progressively increasing temperatures; wherein the temperature of the heating zone is increased from 190 degree to 230 degree centigrade gradually.

Date: February 26, 2021
Place: Mumbai
, Description:Form 2
The Patent Act 1970
(39 of 1970)
COMPLETE SPECIFICATION
(Section 10; rule 13)

Title of invention
"POLYPROPYLENE COMPOSITION DERIVED FROM RECYCLING OF POLYMER FOOD PACKAGING”

APPLICANT:
SHAKTI CORPORATION
An Indian registered entity having address
15-16 GOVIND BHAVAN,
S.V. ROAD, MALAD (WEST).
MUMBAI-400 064

The following Specification particularly describes the nature of these invention and the manner in which it is performed

FIELD OF INVENTION
[0001] The present invention relates to economically recycling multilayer plastic waste used in food packaging industry. Further the present invention relates to formation of granules that can be further used in various applications.

BACKGROUND OF THE INVENTION
[0002] In food packaging industry packaging laminates are used. These laminates are made of polymer-polymer multilayer plastic, generally comprising of polymers ranging from Low density polyethylene (LDPE), High density polyethylene (HDPE), Polypropylene (PP) to Polyethylene terephthalate (PET), polyvinyl chloride (PVC), Polystyrene (PS) and Polyamide (PA). These multilayer packages also include Aluminium foils and copolymers like Ethylene-vinyl alcohol copolymer (EVOH) to provide barrier from atmosphere. After it is used, most packaging is discarded and is either buried in a landfill or becomes litter that is carried along by wind and water currents into the environment. Such packaging when sent to landfills, does not degrade quickly or, in some cases, at all, and chemicals from the packaging materials, including inks and dyes from labelling, can leach into groundwater and soil. It is estimated that 8300 million metric tons of plastic has been accumulated in water bodies. The severe impacts of plastic on the environment are not limited to ocean pollution, however. One study estimated that one third of all discarded plastic ends up in soil or in freshwater. The breakdown of these plastics in soil and water releases toxic chemicals like phthalates and bisphenol A which eventually enter the food chain. Therefore, there arises an urgent need in the field to employ a process of recycling of such food plastic waste to protect humans as well as environment.
[0003] Numerous methods have been developed for separating and recycling multilayer plastic waste materials. General methods involve separation by selective dissolution, by delamination or by compatibilization of non-miscible polymer types. Selective dissolution employs use of organic solvents which are costly and generally present safety and environmental problems which are costly and generally present safety and environmental problems and all polymer components that do not dissolve remain as a residue of little value. Whereas, separation by delamination is a costly and time-consuming process. Further, it needs a complex purification system for separation of more than one type of polymers in multilayer plastics. The process of compatibilization is costly and requires different quantity of compatibilizers for different types of waste. There is fluctuation in quantity of additives required and hence quantity cannot be predetermined. Moreover, these generally adopted process form plastic granules for wastes like BMC wastes. These processes have been unsuccessful in recycling of food plastic packaging.
[0004] United States Patent US Patent No. 4,728,045 discloses a process and apparatus for reclaiming reusable resin materials from bottles and scrap materials on the basis of specific gravity. This method is limited to copolymers and not applicable for multilayer plastic waste in food packaging.
[0005] Chinese patent No. CN107553775A discloses a method of recycling of polypropylene polymers through use of toughening agents and extrusion. CN107538641A discloses a method of recycling of multilayer plastic waste by extrusion of multilayer plastic waste and then adding modifiers to the extruded granules. These patents do not describe a way to recycle food packaging consisting of multilayers of blended polymers such as Polypropylene, polyethylene, polyethylene.
[0006] PCT application WO 2012/117250 Al discloses a method for recycling of single layer of Polypropylene polymer to a reprocessed food grade Polypropylene plastic by extrusion. US2007120283A1 employs a method of recycling of Polypropylene films employed in labels of food packaging through extrusion and incorporating the granules in a multilayer plastic film. Neither of the patent discloses any method to recycle multi-layered food packaging film comprising of blended polymers of different kinds.

[0007] European Patent No. EP 1683829, in 2005 described a method of recycling a multi-layered film which comprises a plastic layer including polyester, polypropylene and polyethylene as main components and an aluminium layer. The method comprises selective dissolution of aluminium, separation using a difference in specific gravity, selective extrusion using a difference in melting point and selective dissolution using an organic solvent. Japanese Patent No. JP2006205160A discloses a process of recycling of multilayer plastic food packaging consisting of at least one layer of Aluminium, polyethylene and polypropylene through selective dissolution and difference in specific gravity. These patents require the use of organic solvent, which are costly and generally present safety and environmental problems, and regeneration of these solvents is impractical and tedious. These patents also disclose reiteration of laborious steps to obtain any separation of constituent particles from bonded material.
[0008] European patent No. EP3031881A1 discloses a method of pyrolytic processing of polymer waste of food packaging. It employs the step of degrading the polymers at a temperature range of six hundred to eight hundred degree centigrade to form a dehydrated and purified gas used in chemical synthesis or as fuel.
[0009] United States Patent US9670344B2 discloses a polymeric material having a microstructure where one or more thermoplastics are serially encapsulated in one phase of a biphasic polymeric blend and a process of recycling blended polymers to produce this product. The encapsulation of polymeric materials is dependent on the interfacial tension of each polymer.
[0010] Hence, in terms of multilayer food packaging there is a need in the art to recycle food packaging that does not employ the use of traditional processes such as selective dissolution, thermal degradation leading to detreating environment impact or processes that employ recycling of a single layer alone and which leads to a composition comprising of more than 50 % by weight of polypropylene in the final granules formed that can be further used in various applications.
[0011] Therefore, for all these reasons the recycling of food packaging, especially through a process that does not lead to further detreating impacts is a real challenge.
OBJECTIVES OF THE INVENTION
[0012] It is the objective of the present invention to provide a process for recycling of multilayer plastic waste in food packaging industry leading to formation of granules comprising of at least 50% by weight of polypropylene.
[0013] Another objective of the present invention is to provide for a cost-effective process for recycling of multilayer plastic waste for biscuit packaging.
[0014] Yet another objective of the present invention is to provide for a cost-effective process for recycling of multilayer plastic waste for chocolate packaging.

SUMMARY OF THE INVENTION:
[0015] This summary is provided to introduce concepts related to a polypropylene polymer composition and process for recycling of polymer food packaging. This summary is not intended to identify essential features of the claimed subject matter nor is it intended for use in determining or limiting the scope of the claimed subject matter
[0016] The invention describes polypropylene composition comprising not less than 50% by weight of polypropylene. The said polymers are obtained from recycling of polymer food packaging characterised in that the polymer food packaging comprises a blend of:
a) a propylene BOPP in the range of 35% to 95% by weight;
b) a Polyethylene terephthalate layer in the range of 2% to 40 % by weight;
c) a polyethylene layer in the range of 2% to 20% by weight, and;
d) a Printing weight in the range of 0.5% to 3% by weight

[0017] The composition of polypropylene so obtained has granules in the size of 5-10 mm, a melt flow index in the range of 1.5-15 g/10 min, tensile strength in the range of 230-320 MPA and notched impact in the range of 3-8 KJ/m2.

[0018] The process for recycling of polymer food packaging to form polypropylene composition comprises the steps of:
a) Shredding (120) of the input waste in an industrial shedder to decrease the plastic waste into a uniform size and for further recycling to form an initial raw material;
b) Cleaning (130) of the said initial raw material to form an impurity free substrate waste;
c) Drying of the said impurity free substrate waste in an industrial drier to protect surface characteristics and prevent hydrolysis to form a desired dried substrate, characterised in that;
d) Densifying the said dried substrate by shredding and heating in an industrial densifier to make a densified product which is compact and free of ink;
e) Mixing the said densified product with specialised chemicals which enhance the melt flow properties to form a mixed blend;
f) Extruding (170) the said mixed blend in a specialised extruder to form an extruded molten mass which is passed through cold water form a hardened mass.
g) Granulating the said hardened mass to form granules of uniform size of 5-10 mm

BRIEF DESCRIPTION OF DRAWINGS
[0019] Figure 1, discloses a flow chart of the process followed in recycling of polymer food packaging as described in the present invention.

DETAILED DESCRIPTION OF THE INVENTION
[0020] Some embodiments of this disclosure, illustrating all its features, will now be discussed in detail. The words "comprising," "having," "containing," and "including," and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items.
[0021] It must also be noted that, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise. Within the context of the invention, the expression “multilayer plastic waste” refers to any article comprising a structure comprising two or more plastic layers. The second and subsequent layers can be obtained using any conventional techniques such as coating, lamination, co-extrusion and extrusion coating. Indeed, the invention can also be deployed on multilayer structures of dissimilar materials, such as plastic/aluminium or plastic/paper. “Input waste” used herein refers to the polymer food packaging waste to be recycled which includes but not limited to food wrappers, chocolate wrappers, biscuit wrappers, etc “Polypropylene composition” used herein refers to the formation of polypropylene composition formed in the form of granules on recycling of polymer food packaging. “Residual thermoplastics” include one and/or more of the following polymers in combination with polypropylene in the granules formed- Biaxially oriented polypropylene to be denoted as BOPP, Polyethylene to be denoted as PE, Polypropylene to be denoted as PP and polyethylene terephthalate to be denoted as PET. “metalizing agents” refer to the silver coating present inside polymer food packaging to protect the food material from external environment. “printing weight” refers to the amount of dyes, colours, or ink used in labels printed on the polymer food packaging. The annotation MFI used herein the specification stands for Melt Flow Index and is a measure of the ease of flow of the melt of thermoplastic polymer. It is defined as the mass of polymer, in grams, flowing in ten minutes through a capillary of a specific diameter and length by a pressure applied via prescribed alternative gravimetric weights for alternative prescribed temperatures. From herein Melt Flow Index will be signified as MFI, Biaxially oriented polypropylene will be denoted as BOPP, Polyethylene will be denoted as PE, Polypropylene will be denoted as PP and polyethylene terephthalate will be denoted as PET.
[0022] Although any methods similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present disclosure, the exemplary methods are now described. The described embodiments are merely exemplary of the disclosure, which may be embodied in various forms.
[0023] Various modifications to the embodiment will be readily apparent to those skilled in the art and the generic principles herein may be applied to other embodiments. However, one of ordinary skill in the art will readily recognize that the present disclosure is not intended to be limited to the embodiments illustrated, but is to be accorded the widest scope consistent with the principles and features described herein.
[0024] The present invention directs to polypropylene granules obtained from recycling of polymer food packaging. The granules obtained contain not less than 50% by weight of polypropylene and other residual thermoplastics. On further studying, it was found that recycling of polymer food packaging containing essentially a blend of BOPP, Polyethylene, Polyethylene Terephthalate, printing and metalizing agents.
[0025] The recycling of polymer food packaging results in polypropylene granules with enhanced mechanical properties such as better MFI, increased tensile strength and notched impact. It should be noted that the composition in the present invention is characterized not by any single mechanical property features such as MFI, but by their combination. By determining such properties of the recycled granules of final product, it is easier to use those granules in various applications as a raw material.
[0026] The amounts of the residual thermoplastics present in the material of the invention depend on the input composition of the initial raw materials and on the amount of polypropylene present in them. More the amount of Polypropylene in output granules, less will be the amount of residual thermoplastics present in the output granules. In embodiments discussed below, the output granules comprise up to at least 50% by weight of the residual thermoplastics based on the total % weight of the Polypropylene generated. For instance, if the output granules consist of 80% by weight of polypropylene and up to about 20% by weight of residual thermoplastics based on the total weight of the output granules. In this case, the above percentages refer to the sum of the percentage for all the residual thermoplastics present. Therefore, when it is said that the output granules comprise about 20% by weight of residual thermoplastics based on the total weight of the output granules; it simply denotes any combination but not limited to about 6.7% of three different “residual thermoplastics” or 10%, 5% and 5% of three different “residual thermoplastics', or 18% and 2% of two different thermoplastics are present.
[0027] An embodiment of the present invention is to disclose the process for recycling of polymer food packaging to produce polypropylene composition in the form of granules as a raw material. It discloses a process of recycling which does not employ use of organic solvents or harmful chemicals. The process efficiently recycles plastic packaging materials such as chocolate wrappers, food wrappers which are composed of a blend of Biaxially oriented Polypropylene (BOPP), Polypropylene (PP), Polyethylene terephthalate (PET), printing and metalizing agents.
[0028] The process for recycling of polymer food packaging to form polypropylene composition in the form of granules comprises the steps of:
a) Shredding (120) of the input waste in an industrial shedder to decrease the plastic waste into a uniform size and for further recycling to form an initial raw material;
b) Cleaning (130) of the initial raw material to form an impurity free substrate waste;
c) Drying (140) of the said impurity free substrate waste in an industrial drier to protect surface characteristics and prevent hydrolysis to form a dried substrate, characterised in that;
d) Densifying (150) the said dried substrate by shredding and heating in an industrial densifier to make a densified product which is compact and free of ink;
e) Mixing (160) the said densified product with specialised chemicals which enhance the melt flow properties to form a mixed blend;
f) Extruding (170) the said mixed blend in a specialised extruder to form an extruded molten mass which is passed through cold water form a hardened mass;
g) Granulating (180) the said hardened mass to form granules of uniform size of 5-10 mm.
The detailed process for recycling of waste as described in present invention is as follows:
[0029] Shredding: The input waste is shredded to form uniformly sized initial raw materials in an industrial shredder or crusher. The input waste in unwanted form is transformed into manageable and useful initial raw material that can be used for further recycling. Industrial shredders are equipped with different kinds of cutting systems such as vertical shaft design, horizontal shaft design, single shaft, two-shaft, three-shaft, and four-shaft cutting systems, which run at low speeds and have high torque. Consequently, the initial raw material is placed on a conveyor for cleaning.
[0030] Cleaning: At this step all the impurities are removed from the said initial raw material by washing or passing it through dust separator. The initial raw material is passed through a float separation tank comprising of cold water, where impurities are separated from the waste on basis of specific gravity. All impurities settle down whereas, only the clean raw materials having a density of less than one float to obtain an impurity free substrate.
[0031] In another embodiment the cleaning of initial raw material to remove impurities is done by passing it through a dust separator through this step all attached impurities like paper, dust, biscuits, chocolates are removed to achieve a clean product. The dust separator works by pulling air through the chamber of the dust collector toward the vacuum conveying pump at high speed, thereby spinning it in a cyclonic motion. The centrifugal force created by this fast, circular air flow drives the heavier plastic particles, fines, and dust outward toward the wall of the cyclone chamber. They hit the wall, lose velocity, and fall down into a bin located underneath the cyclone collector. Passing the waste through air separator before drying improves operating efficiency. The aim of cleaning is to not let any impurities be mixed in the final product and to form an impurity free substrate.
[0032] Drying: The said impurity free substrate after cleaning needs to be dried as polar polymers such as Polypropylene, Polyethylene terephthalate absorb moisture which can lead to hydrolysis of polymers. This mechanism breaks the covalent bonds in the polymer chain, reducing the molecular weight of the polymer and potentially resulting in a significant reduction in mechanical properties. Moisture on polymer resin also leads to change in surface characteristics. It leads to defects such as silver streaking which is a phenomenon in which flashy lines appear on the surface of the product due to residual moisture. Hence, the impurity free substrate is dried in an industrial drier. It uses hot air to dry the substrate. The substrate is mixed with hot air that travels through a transport tunnel composed of long set of stainless-steel tubing thus winding it back and forth. As the plastic material mixes and spans around within the transport tunnel, the waste is effectively dehydrated to form a desired dried substrate. The resulting dried substrate has a moisture content of less than 4%.
[0033] Densifying: this step is also known as the Agglomerating stage in which the said dried substrate is made compact by decreasing its size and increasing the weight. The dried substrate is passed through an agglomerator or a densifier where it is heated with the help of friction. As the temperature reaches close to 100 degree centigrade, the dried substrate starts to densify or agglomerate as the heat deflection point of polyethylene is in the range of 75 to 90 degree centigrade, and heat deflection point of polypropylene is in the range of 90 to 100-degree centigrade degree. Heat deflection point is the temperature at which the plastic polymer starts to deform and hence on reaching 100 degree centigrade the substrate starts agglomerating together to form a densified product. Densifying step is advantageous in increasing the output efficiency of the final granules formed. There will be a significant loss in the amount of total product formed if extrusion is carried out without the densifying step. The process of densifying occurs within 5 to 15 minutes.
[0034] Mixing: The densified product is fed into a high-speed mixer, wherein if required chemical additives in the range of 0.5 to 5% weight by volume of total weight of the densified product are added to enhance the mechanical properties of the final output granules. Along with mixing of chemicals, due to the heat generated by friction any leftover moisture in the densified product is dehydrated and a uniform mixed blend is formed. The chemical additives added depend on the composition of initial raw materials and consist of one or more than one polyolefin elastomers like polyethylene malic anhydrate grafted, polyisobutylene (PIB), poly(a-olefin) s, ethylene propylene rubber (EPR), ethylene propylene diene monomer (M-class) rubber (EPDM rubber). The addition of chemicals increases the tensile strength of the final granules by 20%. The addition of polyolefin elastomers also prevents over heating of the mixer. Overheating of the mixer leads to decrease in surface properties of the final granules formed.
[0035] In a preferred embodiment the densified product that contains less than 10% by weight of total contaminants, is added into a high- speed mixer, where the various polymers in the densified product get mixed and any residual mixture is dehydrated due to the heat generated by friction to form a mixed blend.
[0036] Extruding: As a next step, the said mixed blend is lead to the extrusion process. In the preferred embodiment the mixed blend is lead through a volumetric feeder into to a specially customised twin screw- barrel system consisting eleven heating zones set at different temperatures in a gradient of increasing temperatures. The first heating zone is controlled at a temperature of 190 degrees centigrade and the last one at 230 degrees centigrade. The mixed blend passes by each heater, and the different polymers inside the mixed blend melt and blend at different temperature, and the final product at 230 degree centigrade is an extruded hot molten mass. This molten mass then passes through screens having a mesh size in the range of 20- 60 mesh for filtration and finally passes out through a die consisting of 6-millimetre holes to form a filtered molten mass.
[0037] In a preferred embodiment the extruder rotates at a speed of about 1440 rotations per minute, having a motor capacity of about 132 KW and the energy consumption of the twin-screw barrel system is 0.19Kw to 0.40Kw per unit of processing.
[0038] In an embodiment of the invention the mixed blend is lead through a volumetric feeder into a mother baby extruder equipped with a single screw design, half a screw at the bottom to remove gas and dirt particles and two filters. The system further consists eleven heating zones set at different temperatures in a gradient of increasing temperatures. The first heating zone is controlled at a temperature of 190 degrees centigrade and the last one is at 230 degree centigrade. The mixed blend passes by each zone, and the different polymers inside the mixed blend melt and blend at different temperatures, and the final product at 230 degree centigrade is an extruded hot molten mass. This molten mass then passes through screens having a mesh size in the range of 20- 60 mesh for filtration and finally passes out through a die consisting of 6-millimetre holes as filtered molten mass.
[0039] The said filtered molten mass is then fed into a water tank where it is cooled and hardened with help of cool water having a temperature range of 15 to 50 degree centigrade to form a hardened mass.
[0040] Granulating: this hardened mass finally passes through cutters where it is cut in uniform sizes ranging from 5mm to 10mm and passed through a mesh to obtain uniformed size granules which can further have various applications depending on the end product requirements.
[0041] The following terms and methods apply for the above general description of the invention as well as to the below examples unless otherwise defined. The words “densifying” and “agglomerating” are intended to be equivalent in meaning and can be used interchangeably. The words “mixing” “blending” are intended to be equivalent in meaning and used interchangeably.
[0042] The process as described herein is beneficial to recycle food packaging material without the use of organic solvents. The process employed does not require a complex sorting or purification system. It forms a product that is pure and clean and acts as a recycled raw material for further use. There is no uncertainty with regards to the ratio of fillers to be added and use of laborious processes to regenerate solvents. The process as described herein is capable of being modified into a batch process or a continuous process.
[0043] With regards to FIGURE 1 (100), it describes the process for recycling of polymer food packaging as described in present invention: Input of polymer food packaging (110) such as food wrappers, chocolate wrappers. The said input waste is shredded to form uniformly sized initial raw materials in an industrial shredder or crusher (120). Next, all the impurities are removed from the said shredded waste by cleaning (130) through washing or passing it through a dust separator to form an impurity free substrate. The impurity free substrate is dried in an industrial dryer (140) to prevent hydrolysis and protect surface characteristics to form a dried substrate. This dried substrate is densified (150) in an agglomerator to reduce its volume and make it compact to form a densified product, which is less prone to contamination. This densified product is mixed (160) with specialised chemicals, if the need be to enhance the melt flow index and properties of the product to form a mixed blend. As a next step, the said mixed blend is added into a specially customised twin screw extruder or a mother baby extruder (170) consisting of 11 heating zones set at progressively increasing temperatures. The mixed blend passes by each heater, and the different layers are charred at different temperature, and the final product the final product is an extruded hot molten mass. The extruded hot molten mass is passed through cold water immediately to cool the mixture and Granulated (180) in industrial cutters to form granules of uniform size and shape which can be employed in various other applications.
A better understanding of the present invention may be obtained through the following examples which are set forth to illustrate, but are not to be construed as the limit of the present invention.

EXAMPLES AND PRODUCT PARAMETER:
The following definitions of terms and determination methods apply for the above general description of the invention as well as to the below examples unless otherwise defined.
I. Product Parameters
Melt Flow Index (MFI): The Melt Flow Index is a measure of the ease of flow of the melt of thermoplastic polymer. It is defined as the mass of polymer, in grams, flowing in ten minutes through a capillary of a specific diameter and length by a pressure applied via prescribed alternative gravimetric weights for alternative prescribed temperatures. The test was measured for examples 1-8 according to ASTMD1238 at 230 degree centigrade with a load of 2.16 kg.
Tensile strength: it is the amount of force that can be applied to a plastic before it yields that is stretches irreparably or breaks. The tensile strength was measured for examples I-8 according to ASTMD638.
Notched Impact: Notched Izod Impact is a single point test that measures a materials resistance to impact from a swinging pendulum. Izod impact is defined as the kinetic energy needed to initiate fracture and continue the fracture until the specimen is broken. The notched impact was measured for examples 1-8 according to ASTMD256 with specimen having thickness of 6.4mm.
Differential Scanning Calorimetry (DSC): Differential scanning calorimetry (DSC) is a technique used to investigate the response of polymers to heating. It is a physical characterization method used for determination of purity and composition characteristics. The final composition of the examples 1-8 was determined by Differential Scanning Calorimetry.
II. EXAMPLES
Example 1 In the preferred embodiment the polypropylene composition in the form of granules is obtained from recycling of a biscuit wrapper; the wrapper comprises a blend of:
a) a propylene BOPP in the range of 35% to 95% by weight;
b) a Polyethylene terephthalate layer in the range of 2% to 40 % by weight;
c) a polyethylene layer in the range of 2% to 20% by weight, and;
d) a Printing weight in the range of 0.5% to 3% by weight
the biscuit wrapper comprising less than total 10 % by weight of contaminants was recycled by employing the following steps:
a) Shredding; b) Cleaning; c) Drying d) Densifying; e) Mixing f) Extruding g) Granulating.
The wrapper was passed through a shredder having a horizontal shaft design and placed on the conveyor for cleaning. The shredded wrapper was passed in a float separation tank where impurities such as left-over biscuits settled down and the plastic waste was floating above. This was collected and passed through a drier where the substrate is mixed with hot air traveling through a long set of stainless-steel tubing that winds back and forth. As the plastic material mixes and spans around within the transport tunnel, moisture is effectively dehydrated to form a dried substrate. The resulting dried substrate has a moisture content of less than 4%. The dried substrate is passed through an agglomerator or a densifier where it is shred and heated with the help of friction. As the temperature reaches close to 100 degree centigrade, the dried substrate starts to densify or agglomerate as the to form a densified product. After which the densified product is mixed in a high-speed mixer to mix all polymers of the initial raw material and to remove all remaining moisture and to enhance the mechanical properties of the final product. As a next step, the said mixed blend is lead to the extrusion process lead through a volumetric feeder into to a specially customised twin screw- barrel system consisting eleven heating zones set at different temperatures in a gradient of increasing temperatures. The first heating zone is controlled at a temperature of 190 degrees centigrade and the last zone is at 230 degrees centigrade. The mixed blend passes by each heating zone, and the different polymers are melted at different temperatures, and the final product at 230 degree centigrade is an extruded hot molten mass. This molten mass then passes through screens having a mesh size of 40 for filtration and finally passes out through a die consisting of 6-millimetre holes as filtered molten mass. This filtered molten mass is fed into a water tank where it is cooled and hardened with help of cool water having a temperature range of 15 to 50 degree centigrade to form a hardened mass. This hardened mass finally passes through cutters where it is cut in uniform sizes ranging from 5mm to 10mm and passed through a mesh to obtain uniformed size granules which can further have various applications. The granules so formed contain 74% by weight of polypropylene, 15% by weight of polyethylene, and 11% by weight of Polyethylene terephthalate. The different mechanical properties of the granules obtained have been listed in the table (TABLE 1) below.

Example 2 In another embodiment the granules are obtained from recycling of chocolate wrappers, the wrappers are composed of a blend of:

a) a propylene BOPP in the range of 77% to 97.5% by weight;
b) a Polyethylene layer in the range of 2% to 20 % by weight;
c) a Printing weight in the range of 0.5% to 3% by weight;

the chocolate wrapper was recycled by employing the following steps:
a) Shredding; b) Cleaning; c) Drying d) Densifying; e) Mixing f) Extruding g) Granulating.
The wrapper was passed through a shredder having a horizontal shaft design and placed on the conveyor for cleaning. The shredded wrapper was passed in a dust separator. This was collected and passed through a drier where the substrate is mixed with hot air traveling through a transport tunnel tubing that winds back and forth. As the plastic material mixes and spans around within the transport tunnel, moisture is effectively dehydrated to form a dried substrate. The resulting dried substrate has a moisture content of less than 4%. The dried substrate is passed through an agglomerator where it is shred and heated with the help of friction. As the temperature reaches close to 100 degree centigrade, the dried substrate starts to densify or agglomerate as the heat deflection point of PP is in the range of 90-100 degree to form a densified product. After which the densified product is mixed in a high-speed mixer with pre heating to remove all remaining moisture and to enhance the mechanical properties of the final product. The densified product is mixed with specialised chemical - polyethylene malic anhydrate grafted in the range of 0.5% by weight by volume. As a next step, the said mixed blend is lead to the extrusion process lead through a volumetric feeder into to a mother baby extruder consisting eleven heating zones set at different temperatures in a gradient of increasing temperatures. The first heating zone is controlled at a temperature of 190 degrees centigrade and the last one is at 230 degrees centigrade. The mixed blend passes by each zone, and the different polymers are melted at different temperature, and the final product at 230 degree centigrade is an extruded hot molten mass. This molten mass then passes through screens having a mesh size of 60 for filtration and finally passes out through a die consisting of 6-millimetre holes as filtered molten mass. the said filtered molten mass is fed into a water tank where it is cooled and hardened with help of cool water having a temperature range of 15 to 50 degree centigrade to form a hardened mass. This hardened mass finally passes through cutters where it is cut in uniform sizes ranging from 5mm to 10mm and passed through a mesh to obtain uniformed size granules which can further have various applications. The granules so formed contain 85% by weight of polypropylene, 15% by weight of polyethylene, by weight. The different mechanical properties of the granules obtained have been listed in the table (TABLE 1) below.
Example 3: In yet another embodiment the granules of polypropylene are obtained from recycling of polymer food packaging comprising a blend of:
a) a propylene BOPP in the range of 97% to 99.5 % by weight;
b) a Printing weight in the range of 0.5% to 3% by weight;
the said composition obtained in the form of granules comprises of not less than 50% by weight of polypropylene
Example 4: In yet another embodiment the granules of polypropylene are obtained from recycling of polymer food packaging comprising a blend of:
a) a propylene BOPP in the range of 40% to 80% by weight;
b) a Polyethylene terephthalate layer in the range of 2% to 40 % by weight;
c) a Printing weight in the range of 0.5% to 3% by weight.
the said composition obtained in the form of granules comprises of not less than 70% by weight of polypropylene and residual thermoplastic- 30% by weight of polyethylene terephthalate.
Example 5: In yet another embodiment the granules of polypropylene are obtained from recycling of polymer food packaging comprising a blend of:
a) a propylene BOPP in the range of 35% to 95% by weight;
b) a Polyethylene terephthalate layer in the range of 2% to 40 % by weight;
c) a polyethylene layer in the range of 2% to 20% by weight, and;
d) a Printing weight in the range of 0.5% to 3% by weight;
e) a metalizing agent in the range of 0.1% to 5% by weight.
the said composition obtained in the form of granules comprises of not less than 50% by weight of polypropylene and residual thermoplastics comprising of 18% by weight of polyethylene, and 32% by weight of polyethylene terephthalate
Example 6: In yet another embodiment the granules of polypropylene are obtained from recycling of polymer food packaging comprising a blend of:
a) a propylene BOPP in the range of 77% to 97.5% by weight;
b) a Polyethylene layer in the range of 2% to 20 % by weight;
c) a Printing weight in the range of 0.5% to 3% by weight;
d) a metalizing agent in the range of 0.1% to 5% by weight.
the said composition obtained in the form of granules comprises of not less than 92% by weight of polypropylene and residual thermoplastics comprising of 8% by weight of polyethylene.
Example 7: In yet another embodiment the granules of polypropylene are obtained from recycling of polymer food packaging comprising a blend of:
a) a propylene BOPP in the range of 97% to 99.5 % by weight;
b) a Printing weight in the range of 0.5% to 3% by weight;
c) a metalizing agent in the range of 0.1% to 5% by weight;
the said composition obtained in the form of granules comprises of not less than 99.5% by weight of polypropylene.
Example 8: In yet another embodiment the granules are obtained from recycling of polymer food packaging comprising a blend of:
a) a propylene BOPP in the range of 40% to 80% by weight;
b) a Polyethylene terephthalate layer in the range of 2% to 40 % by weight;
c) a Printing weight in the range of 0.5% to 3% by weight;
d) a metalizing agent in the range of 0.1% t0 5% by weight;
the said composition obtained in the form of granules comprises of not less than 76% by weight of polypropylene and residual thermoplastics comprising of 24% by weight of polyethylene terephthalate.
The following table denotes the mechanical properties obtained of the foregoing examples E1-E8:

Table 1: Mechanical properties of the inventive examples
PARAMETERS Example1 Example2 Example3 Example4 Example5 Example6 Example7 Example8
Tensile Strength (in MPA) 320 300 315 277 299 304 268 244
MFI (in g/10mins) 15 11.6 13 7.4 1.5 6.9 4.2 10.3
Notched Impact (in KJ/m2) 8 6.7 5.1 4.6 3 7.2 7.7 5.4
Ash Content (in %) 2 3.4 7.8 8.4 5.1 9.8 6.6 4.1

The foregoing description shall be interpreted as illustrative and not in any limiting sense. A person of ordinary skill in the art would understand that certain modifications could come within the scope of this disclosure. The embodiments, examples and alternatives of the preceding paragraphs or the description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.