High molecular weight polyethylene (HMWPE) is a polyethylene grade known for its very low melt flow index and long molecular chain structure, which contribute to excellent toughness and wear resistance. As lithium-ion battery production continues to grow, separator film waste generated from battery cells is also increasing, creating a recoverable polyethylene-based feedstock stream for mechanical recycling.
Regenport’s HMWPE PCR pellet is produced from lithium battery separator film collected in South Korea. The recovered material is mechanically recycled and pelletized into a natural-colored resin for industrial use.

Material Data

What Is Lithium Battery Separator Film?

Lithium battery separator film is a thin, microporous polyethylene membrane used inside lithium-ion battery cells to physically separate the anode and cathode. It plays an important role in battery safety and performance.

As battery manufacturing volumes and end-of-life battery volumes increase, separator film has gained attention as a recoverable polyethylene-based waste stream. Compared with mixed post-consumer plastic waste, separator film scrap from battery manufacturing is typically more compositionally consistent because it is primarily polyethylene, which can support more predictable recycling outcomes when properly sorted and processed.

How the PCR Pellet Is Made

The separator film feedstock is collected from battery manufacturing facilities and sorted before undergoing mechanical preprocessing to remove contaminants. After cleaning, the material is melt-processed and extruded into pellet form.

The resulting pellet is natural in color and retains the low melt flow characteristics typically associated with high molecular weight polyethylene grades. These characteristics make it a material that can be considered for applications requiring controlled extrusion behavior and material toughness.

Application Considerations

With an MFI of 0.16 g/10min, this material is more suitable for extrusion processes than injection molding. Processors evaluating HMWPE PCR for high-impact extrusion applications should confirm compatibility with their equipment, processing conditions, and end-use requirements.

This material is offered as a PCR resin for industrial applications. As with all recycled resins, buyers should carry out their own testing and qualification according to product specifications and applicable standards.