Residual material as a raw material for new plastic products

Every injection molding process generates scrap. Think of start-up products, rejected parts or residual material released while setting up a mold. For a long time, that was simply waste. At Fleur Plastics, we see it differently. Our production scrap is valuable plastic, and together with our compounding partner we put it back to use as raw material for new products.

Why production scrap is too valuable to throw away

Plastic is a sustainable material, as long as it is handled responsibly. The problem only arises when it is discarded as waste or ends up in the environment.

Scrap from our own production process has one major advantage: we know exactly what material it is and where it comes from. That makes it particularly suitable for upgrading into a high-quality raw material.

How scrap becomes a usable raw material again

Grinding and homogenizing

The process starts with collecting the scrap, which is ground into small flakes. Once a substantial quantity has been collected, everything goes into a silo, where the material is homogenized. This creates one uniform mix. That is important, because the composition of scrap can vary from batch to batch.

Testing in the lab

The homogeneous mix is tested in the lab. Which properties does the material still have? And how far does it deviate from the specifications our products require? Based on those results, we determine what needs to be done to bring the material back to the required level.

Remelting and bringing to specification

The material then goes through an extruder, where it is remelted at around 240 °C. Where needed, additives, stabilizers and colorants are added to the melt. This gives the material the same properties as new (virgin) material. The end result is a pellet we can use for injection molding right away.

Quality comes first

Testing twice

Before the material comes back to us, it is tested again. Only when it meets the agreed values is it delivered, together with an overview of the technical specifications and processing advice. This double check is essential. Our production is largely automated, and that requires a consistent raw material. Large differences between deliveries would immediately cause problems in the process.

Clear agreements up front

Before the first material is processed, we jointly agree on a number of points:

• the parameters the material must fall within
• the products it will be used for
• the requirements the end product must meet
• which scrap streams will be supplied

If something does deviate along the way, for example a slightly different melt flow index than agreed, it is discussed immediately. This keeps the process under control.

What reusing production scrap delivers

Technically, the entire process can be completed in a single day. In practice, it takes a few weeks, because sufficient volume needs to be built up first. The result is that virtually all of our plastic scrap gets a new life. This offers several benefits:

• Less waste, because scrap is no longer disposed of
• Less virgin raw material, because recycled material replaces part of our purchasing
• Lower CO2 emissions across the entire chain
• Cost savings on both waste processing and material purchasing

Not every stream suits every application

Not all residual material is suitable for every application. Strict rules apply to products that come into contact with food, for example. Residual material that is no longer suitable for the original product is not thrown away. We look for another application it is suitable for. This way, every material ends up where it fits best.

Circular manufacturing is a joint effort

A circular process only works when all links in the chain work well together: the injection molder, the compounder and the client. Short lines of communication and clear agreements make the difference between a good idea and a working process.

Would you like to know how we can handle your products and residual material? Feel free to contact us.