Circular thermoplastic composite sandwich panels made from 100 % recycled plastics for flooring and formwork
GRAF PolymerPark GmbH
HerbolzheimNew on Amplifa
About PolymerPark
GRAF PolymerPark GmbH develops and produces circular thermoplastic composite sandwich panels using its proprietary One-Step process in continuous manufacturing. The panels are produced without adhesive joints as an integral, materially homogeneous system in thicknesses of 8 to 25 mm and dimensions up to 4,200 x 2,000 mm. The core consists of 100 % post-consumer plastics from household waste (Yellow Bag); at the end of their service life, the company takes the products back and fully recycles them on its own recycling line. The products substitute materials such as plywood and aluminium and, depending on the application, reduce the CO₂ footprint by up to 50 %. Application areas include scaffolding decks, bus floors, universal floors for commercial vehicles, trailers and boats, as well as formwork panels (TALLEAS). Founded in 2000, the company has been part of the GRAF Group since 2020 and has been producing in Herbolzheim since 2021; more than 1.85 million square metres of composites are in use.
- Site
- Herbolzheim
- Processes
- Production of Circular Composites / thermoplastic composite sandwich panels, Recycling of composites (own recycling line, 100% take-back and recycling), Production of thermoplastic integral foams (One-Step technology, VarioLine), Tailor-made product development from initial development to large-scale series, Take-back and 100% recycling of products at end of life, Upcycling of post-consumer plastic waste
- Materials
- Post-consumer plastics (100% recycled material), Recycled plastics from household waste, Aluminium (substituted material), Wood / plywood (substituted material), Post-Consumer Plastics, Circular Composites, Thermoplastic Integral Foams (VarioLine), Substitution of Wood and Aluminium
- Certificates
- EPD (Environmental Product Declaration), EPD (Stages A1-A3), EPD (Stages A1-D, TALLEAS), DIBt Building Approval for Scaffolding Deck, ISO 9001
- Founded
- 2000
- Industries
- Bus/Rail, Scaffolding, Formwork, Flooring applications (commercial vehicles, trailers, boats)
- 01
Post-consumer plastic waste from the Yellow Bag
- 02
Processing/upcycling (own recycling line)
- 03
Continuous composite panel production (One-Step technology)
- 04
Product development from initial development to large-scale series
- 05
Take-back and 100% recycling at end of life
Materials and Processes
Post-Consumer Plastics
100 % recycled material from household waste forms the core of all composite products.
Circular Composites
Thermoplastic composite sandwich panels with a complete material cycle through take-back and recycling.
Thermoplastic Integral Foams (VarioLine)
One-Step production of thermoplastic integral foams as the basis for the composites built upon them.
Substitution of Wood and Aluminium
The composite products replace plywood and aluminium and significantly extend service life.
Locations
Herbolzheim
DEProduction facility and company headquarters (since 2021)
- Materials
- Post-consumer plastics
- Continuous composite panel production line (One-Step technology)
- Recycling line for composites (since 2024)
Products and Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Production of Circular Composites / thermoplastic composite sandwich panelsPlastics | – | 4,200 mm × 2,000 mm × 25 mm | – | – | Post-consumer plastics (100% recycled material) |
| Recycling of composites (own recycling line, 100% take-back and recycling)Plastics | – | – | – | – | Post-consumer plastic waste from the Yellow Bag |
| Production of thermoplastic integral foams (One-Step technology, VarioLine)Plastics | – | – | – | – | thermoplastics |
2 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Continuous composite panel production line (One-Step technology) | – | – | – | 2010 | Herbolzheim |
| Recycling line for composites | – | – | – | 2024 | Herbolzheim |
Additional services
Quality and Sustainability
Environmental Product Declarations (EPD) apply to the composite products: for production according to Cradle-to-Gate (stages A1-A3), and for selected TALLEAS versions over the entire life cycle (stages A1-D). Composite bus floors are certified and homologated, and the composite scaffolding deck was the first to receive a building approval from the DIBt in 2012.
| Evidence | Herbolzheim |
|---|---|
| EPD (Stages A1-A3) | |
| EPD (Stages A1-D, TALLEAS) | |
| DIBt Building Approval for Scaffolding Deck | |
| ISO 9001 |
History
- 2000
Founded by Ulrike Hoesch-Vial and Dr. Sven Hansen; started with One-Step production of thermoplastic integral foams (VarioLine)
- 2010
Entry into continuous composite panel production using One-Step technology
- 2012
First building approval for a composite scaffolding deck from the DIBt and start of series production
- 2015
Beginning of the partnership with the GRAF Group
- 2016
Launch of the first generation of ceiling formwork in Europe
- 2019
Conversion of the entire core production to post-consumer plastics
- 2020
Merger with the GRAF Group under the leadership of Otto Graf
- 2021
Relocation from Dresden to Herbolzheim into the new production facility
- 2022
Launch of TALLEAS 2nd generation; series start and certification of composite bus floors
- 2024
Investments in technology and capacity; commissioning of the company's own recycling line
- 2026
Renaming to GRAF PolymerPark GmbH; relocation of headquarters to Herbolzheim, closure of the Radebeul site