Switching to recycled resin is a critical step toward sustainability, but for technical managers, it introduces a common set of anxieties. Will the material run smoothly? Will quality suffer? Will we incur costly downtime?
At Polymer Processors, we understand that trust is built on reliability, not just price. Our technical team and investment in an in-house laboratory are specifically geared toward diagnosing and eliminating the most frequent problems associated with recycled content, ensuring a seamless integration into your manufacturing floor.
Here are three common issues with recycled material and how our diagnostic process solves them before they affect your production:
Issue 1: Residual Odour
Post-consumer plastics, especially those from packaging, often retain residual odours from food, detergents, or previous uses. If not fully purged, this smell can make the final product unusable or unsaleable.
Our Solution: Advanced Decontamination & Additive Science
Residual odour is a contamination issue solved by rigorous cleaning and thermal processing.
- Intense Washing Lines: We utilise high-temperature washing and purification systems designed to strip away organic and chemical contaminants at the start of the process.
- Melt Filtration & Degassing: Our state-of-the-art extruders incorporate sophisticated degassing zones, which physically pull volatile organic compounds (VOCs) and moisture out of the molten plastic.
- Custom Formulations: For highly sensitive applications, we can incorporate specific deodorising additives into the final pellet blend, neutralising any lingering traces to meet demanding product specifications.
Issue 2: Colour & Aesthetic Variation
Recycled pellets often come in a mix of shades, making brand colour matching difficult. An inconsistent base colour forces manufacturers to use excessive amounts of expensive masterbatch or pigment to mask the variation.
Our Solution: Segregation and Blending Protocols
Achieving reliable colour starts with meticulous sorting, but true consistency is locked in during blending.
- Sourcing Discipline: We work with high-quality suppliers (like our HDPE partners) who segregate material by colour stream (e.g., natural, white, mixed).
- Controlled Colour Blending: Our internal systems accurately measure and blend different colour streams into standardised lots. This allows us to deliver a base pellet with minimal, predictable colour variation, dramatically reducing the amount of colour masterbatch our customers need to purchase.
- Customer-Specific Colour: We can batch-blend material specifically for a customer’s required density and base shade, minimising their own formulation adjustments.
Issue 3: Melt Flow Inconsistency
Plastic is processed based on its Melt Flow Index (MFI) and density. If the MFI is inconsistent across batches, your extrusion or injection moulding machines will struggle to maintain constant pressure, leading to non-uniform parts, reduced strength, and product failure.
Our Solution: The In-House Lab and Technical Dialogue
This is where our commitment to the in-house laboratory is non-negotiable.
- Pre-Batch Testing: We sample and test the MFI of every significant batch before it leaves our facility. This critical quality control step ensures the physical properties match the customer’s requirement (e.g., MFI required for thin-walled packaging is different from thick-walled pipe).
- Application-Specific Modification: If a batch needs a slight adjustment, our technical team can use precise additives during the extrusion phase to modify the Melt Flow Index, ensuring it fits the customer’s specific machinery requirements (like injection moulding or film blowing).
- The Direct Line: Our technical team is available for direct consultation to understand the customer’s application. This removes the guesswork and ensures the material we supply is chemically and physically suited to perform flawlessly on their production line.
Partnership Over Profit
For Polymer Processors, selling a pellet is the start of the relationship, not the end. By focusing on diagnostics and problem-solving at our facility, we take the risk out of using recycled plastic.
You gain more than a material supplier; you gain an expert partner dedicated to optimising your production efficiency and making your switch to sustainability a seamless, profitable success. Experience the difference for yourself, reach out today!