Recycled Plastic – Lightweight Structural Panels

Developed with MeSentia, our lightweight structural panels explore new applications for mixed recycled plastics and suitable fibre-containing secondary materials. Prepared feedstock blends are shaped into ribbed and hollow-core structures, connecting material formulation with product geometry.

MeSentia, our Swiss technology partner, brings specialist expertise in forming technology, machine development and structural product design. Ocean Material contributes feedstock knowledge, circular sourcing and application development. Together, we connect challenging material streams with practical product opportunities.

For selected projects with promising technical and commercial potential, we can assess your feedstock, develop a tailored formulation and produce trial panels using prototype equipment and existing tooling. This creates an opportunity to evaluate your material in a physical demonstrator and identify potential synergies for further development.

Specifications

The starting point is a prepared blend of mixed recycled plastics, including lower-value mixed plastic streams. Suitable fibre-containing secondary materials can be considered depending on the formulation and project. Material selection, necessary preparation and formulation are part of the assessment; not all mixed plastic waste is suitable or can be processed without preparation.

Open ribbed structures use a panel surface supported by a network of ribs. Closed hollow-core panels enclose internal cavities between their surfaces. These are possible configurations within one development offer, not standard panel grades available from stock.

Dimensions, structural configuration, formulation and test requirements are agreed for the intended application. Initial trial panels are produced within the capabilities of existing prototype equipment and tooling. The pictured demonstrator does not define a fixed composition or specification for your project; weight, density, strength, load capacity, fire performance and service life need to be established for the selected design.

Applications

Potential development fields include logistics components, transport systems, industrial carriers and panel applications. The work connects feedstock formulation with a structural geometry suited to the proposed use; it is not limited to pallets.

These are applications to develop and test, not approved uses. Ocean Material helps define the material and application requirements with the customer, while MeSentia assesses the forming and structural-design options. Project-specific testing is needed before suitability for an intended use can be established.

Origin

Material origin depends on the selected project feedstock. Customer-supplied materials and suitable secondary material streams can be assessed, taking account of their known composition, previous use and preparation needs.

The pictured panel is not presented as having a confirmed maritime origin. Feedstock origin and the information needed to document it are clarified for each development project.

Sustainability & Impact

The approach explores how material streams currently used in lower-value applications can become inputs for new products. Combining material formulation with ribbed or hollow-core geometry allows material use and product function to be considered together during development.

The actual environmental benefit depends on the formulation, necessary preparation, processing and eventual application. This page does not assign a universal recycled-content percentage or a quantified carbon saving to the panels. The outcome must be assessed for the selected material and product system.

Quality & Traceability

Feedstock composition, formulation development, trial-panel production and application assessment form a connected development process. The project team establishes what is known about the input material, identifies gaps in the available information and agrees the preparation and testing needed for the trials.

MeSentia is responsible for machine and process development and contributes expertise in forming technology and structural product design. Ocean Material contributes feedstock knowledge, circular sourcing and the connection to applications and partners. Together with the customer, we define the development scope and the information needed to assess the resulting demonstrator.

Trial results relate to the material, formulation and geometry tested. They do not establish a general performance guarantee or series-production qualification for other blends or panel designs.

Carbon Footprint & LCA

Environmental assessments are project-specific. A life cycle assessment (LCA) is not assumed to be available for each formulation or prototype panel.

Any assessment needs to account for the selected feedstock, preparation, processing, transport, use and end-of-life scenario. Comparisons require a relevant reference product, consistent system boundaries and an equivalent functional basis. The scope, data needs and feasibility of an assessment can be discussed within the development project; no carbon-saving figure is promised.

Inquiry & Support

Contact Ocean Material with your intended application, processing method, grade or construction requirements, desired quantity and delivery destination. We coordinate material selection, specification review, sample enquiries and sourcing support. Technical data sheets, detailed specifications and supporting documentation are available on request.

Browse the Other Streams catalogue.

FAQ

What is being offered?

Prototype lightweight panel development with MeSentia using selected prepared feedstocks, not a standard panel grade available from stock.

Which panel structures can be explored?

Ribbed and hollow-core structures, subject to feedstock, tooling and the development project.

Can my feedstock be evaluated?

Yes. Share known composition, previous use, preparation and quantities so the project scope can be assessed. Not every mixed waste stream is suitable.

Are load ratings or series volumes confirmed?

No. Project-specific testing and commercial development are required for the chosen formulation and geometry.

Which colours or grades are offered?

MeSentia; ribbed or hollow-core prototypes

How can I request samples and technical documents?

Technical data sheets, detailed specifications and supporting documentation are available on request. Use the material inquiry button with your application, specification, quantity and delivery destination. Sampling conditions are set out in Ordering & Lead Time.