Turn Rigid Plastics Into Consistent Recyclate

Rigid plastics are dimensionally stable items such as moulded parts, containers, crates, housings, production scrap and regrind. “Rigid” describes the form, not one polymer or quality. The polymer, additives, contamination, prior use and target application determine recyclability.

MAS can evaluate streams including PE, PP, PS, ABS, PA and other suitable polymers, regrinds and blends. Suitability is project-specific. Provide representative material and composition because incompatible mixtures, heavy contamination, degradation, moisture-sensitive polymers or demanding output targets may require separation, special preparation, re-compounding or a different end use.

Clean, homogeneous, segregated production scrap with stable feeding, no demanding additive/compounding duty and modest degassing or filtration requirements may be processed more economically with a simpler route. Test the actual material and target before adding complexity.

Common challenges include labels, dirt, metals and other solids; mixed or incompatible polymers; colour and batch variation; unstable particle size or bulk density; moisture, odour and volatiles; degradation; and demanding cleanliness or property targets. Quantify each problem before choosing equipment.

Cleaning, drying, size conditioning or controlled feeding may be required when loose contamination, moisture, low or variable bulk density, oversized particles or inconsistent flow would limit downstream stability or output. These steps should be selected from measured input conditions, not automatically included.

CDF filtration may be relevant when defined solid contaminants remain in the molten polymer and continuous filtration supports the required output. Confirm contaminant type, size and load, polymer rheology, filtration fineness, pressure behaviour and discharge capacity. Melt filtration cannot correct every mixed-polymer, odour or upstream-cleaning problem.

Re-compounding is considered when recycled material needs controlled additives, fillers, fibres, compatibilisation, blending or property modification. If clean, stable material only needs regranulation, a simpler route may be more suitable.

Depending on the problem, MAS may evaluate material preparation, conical twin-screw extrusion, degassing, CDF melt filtration, additive dosing, Twin-Compound or Regrind concepts, MAS 110, automation and testing. The final route should contain only the stages justified by evidence.

Both depend on polymer, bulk density, particle form, moisture, contamination, filtration load, formulation, configuration, operating window and output criteria. MAS should provide a project-specific range and comparison baseline after reviewing representative material—not a universal maximum or single energy number.

Main drivers include throughput, material preparation, cleaning/drying, feeding, extrusion size, degassing, filtration, additive dosing, compounding, pelletising, automation, utilities, installation, validation and output requirements. Compare lifecycle cost, yield and accepted-output value, not purchase price alone.

Yes. Agree a representative sample, material history, routes to compare, operating conditions, analytical methods and pass/fail criteria before the trial. Results should document limitations, scale-up assumptions and the evidence supporting the proposed configuration.

Provide polymer/blend, source, history, contaminants, moisture/volatiles, colour, particle form and bulk behaviour, additives/fillers, batch variability, current process, throughput, output/application target, available utilities, quality data and known constraints.

No. Incompatible polymers, uncontrolled composition, high degradation, persistent odour, difficult contamination or unrealistic output targets can prevent the desired result. MAS should identify these limits early and discuss separation, reformulation, a different application or rejection of the project.

Validate it using representative material, an agreed baseline, defined configuration and operating window, documented tests and acceptance criteria. Review output consistency, quality, yield, throughput, energy, consumables, maintenance and scale-up risk before final investment.