Understanding the Plastic Recycling Process

 Recycling plastic involves a multi-faceted journey, transforming discarded materials into valuable resources ready for reuse. This comprehensive process begins with the essential step of waste collection and culminates in the practical application of recycled plastics in various industries. At its core, the recycling process can be classified into two primary methods: mechanical recycling and chemical recycling. Each method plays a unique role in managing plastic waste, but both share common initial phases. 

 The first step begins with plastic collection, which varies depending on the source of the waste. This waste is categorized into two distinct types: post-industrial waste, which refers to materials collected during different stages of production, and post-consumer waste, which includes items discarded by consumers after their intended use. Understanding these categories is crucial, as they determine the subsequent recycling journey. 

Once collected, the plastic waste undergoes sorting. This critical phase involves separating the materials into specific recycling streams—such as transparent HDPE, coloured HDPE, PP, PET, and others—using advanced methods like infrared analysis to ensure accuracy and efficiency. Following sorting, the plastic enters the pre-treatment stage, where it is subjected to physical and/or chemical treatments. This step is vital for removing contaminants such as inks or other small plastic fragments that could compromise the quality of the recycled product. 

Now we delve into the differing methods of plastic recycling. Mechanical recycling involves shredding the sorted plastic into small flakes, which are then melted while preserving their chemical structure. This melted plastic is extruded into new pellets, making it ready for industrial use. Despite being the most commonly employed technology, mechanical recycling faces challenges, especially when dealing with contaminated or low-quality materials. It also has limitations on the number of recycling cycles a plastic can undergo, as repeated treatments can lead to structural degradation. 

On the other hand, chemical recycling presents a more advanced approach. This innovative technique chemically transforms plastic waste back into its fundamental components, breaking down the material into shorter molecules suitable for new chemical reactions. The primary advantage of this method is the superior quality of the recycled material. By reverting plastics to their basic constituents, chemical recycling creates products that are virtually indistinguishable from those produced from virgin petrochemical sources. This quality aspect is particularly important in industries such as food and beverage, where regulatory standards demand high-grade materials. In contrast, pellets produced through mechanical recycling often do not meet the same high standards. 

The next stage in the recycling process is the conversion of recycled plastic pellets into new products. At this point, these pellets are introduced into the production cycle, where they can comprise varying percentages—sometimes up to 100%—of the inputs for new items. 

However, a question looms over the sustainability of chemical recycling. Currently, there is no unified regulatory framework defining what constitutes chemical recycling, making it challenging to assess its true environmental impact. Moreover, the effectiveness of this method can differ significantly based on the type of waste being processed, especially concerning its quality and contamination levels.  

Even though chemical recycling is still in its infancy—with many facilities operating at a pilot scale—it holds great promise for enhancing a circular supply chain, particularly in scenarios where mechanical recycling falls short. Looking ahead, it is anticipated that industrial-scale development of chemical recycling technologies will ramp up between 2025 and 2030, thereby establishing a robust foundation for the future. 

  At Fedrigoni Self-Adhesives, we are committed to advancing sustainable practices in our industry. As a proud member of RecyClass since April 2022, we participate in this cross-sectoral initiative aimed at promoting the recyclability of plastic packaging and ensuring the traceability of recycled plastic across Europe. By collaborating with stakeholders across the value chain, we strive to establish a harmonized approach to designing for recycling, while also providing reliable certifications for circular product initiatives. 

 To sum up, the landscape of plastic recycling is dynamic and continually evolving. Both mechanical and chemical recycling methods play vital roles, each with its own strengths and challenges. As we move toward a more sustainable way of doing business, understanding and improving these processes will be crucial in addressing the plastic waste challenge.