The Journey of Recycled Plastic: From Waste to New Products

In the UK, plastic waste has become a significant environmental concern. As we strive to reduce our impact on the planet, understanding what really happens to plastic when it’s recycled is crucial.
This article will take you through the journey of recycled plastic, from the moment it leaves your recycling bin to its transformation into new products.
How does the plastic recycling process begin?
The journey of recycled plastic starts with proper sorting. When you place plastic items in your recycling bin, you’re taking the first crucial step in the recycling process. It’s essential to rinse containers and remove any non-plastic components to ensure the highest quality of recycled materials.
What happens after plastic is collected from recycling bins?
Once collected, plastic waste is transported to Materials Recovery Facilities (MRFs) or Plastic Recovery Facilities (PRFs). At these facilities, the real work of sorting and processing begins. Advanced technologies, including optical sorters and manual inspection, are used to separate different types of plastic.
How are different types of plastic identified and sorted?
Plastic items are sorted based on their resin type, which is indicated by the recycling symbol (a number from 1 to 7 inside a triangle) on most plastic products. The most commonly recycled plastics are:
- PET (Polyethylene Terephthalate) [1] – Used for soft drink bottles and food packaging.
- HDPE (High-Density Polyethylene) [2]– Used for milk jugs and shampoo bottles.
- PVC (Polyvinyl Chloride) [3] – Used for pipes and window frames.
- LDPE (Low-Density Polyethylene) [4] – Used for plastic bags and squeeze bottles.
- PP (Polypropylene) [5] – Used for bottle caps and food containers.
Each type of plastic has different properties and requires specific recycling processes. For instance, PET bottles are often recycled into new bottles or polyester fibres for clothing, while HDPE can be transformed into plastic lumber or new containers.
What is mechanical recycling, and how does it work?
Mechanical recycling is the most common method used to recycle plastic in the UK. This process involves several steps:
- Shredding: Plastic items are ground into small flakes.
- Washing: The flakes are thoroughly cleaned to remove any contaminants.
- Separation: Different types of plastic are separated using various techniques, including float-sink tanks where heavier plastics sink and lighter ones float.
- Drying: The clean, separated flakes are dried.
- Melting and Extrusion: The flakes are melted and extruded into pellets, which become the raw material for new plastic products.
Mechanical recycling is particularly effective for thermoplastics like PET and HDPE, which can be melted and reformed multiple times without significant degradation of their properties.
What challenges does plastic recycling face?
Despite advancements in recycling technologies, several challenges persist:
Contamination
Contamination is a significant issue in plastic recycling. Food residue, mixed materials, and other contaminants can compromise the quality of recycled plastic.
Complexity
Many plastic items contain multiple types of plastic or are made with composite materials, making them difficult to recycle. For example, multi-layer packaging used for food products often combines different types of plastic that cannot be easily separated during the recycling process.
Economic viability
The cost of collecting, sorting, and processing plastic waste can sometimes exceed the value of the recycled material. This economic imbalance can make it challenging for recycling facilities to operate profitably, especially when oil prices are low, making virgin plastic production cheaper.
Limited demand
Many manufacturers still prefer using virgin plastic due to its consistent quality and lower cost. The lack of demand for recycled plastic can lead to an oversupply of recycled materials, driving down prices and making it even more difficult for recycling operations to remain economically viable.
To address these challenges, innovations in recycling technologies and increased public awareness are crucial.
What is chemical recycling, and how does it differ from mechanical recycling?
Chemical recycling is an emerging technology that breaks down plastic into its chemical components. This process can handle mixed and contaminated plastics that are difficult to recycle mechanically. The resulting chemicals can be used to produce new plastics or other materials.
While chemical recycling shows promise, it’s currently not as widely used as mechanical recycling due to higher costs and energy requirements. However, as the technology develops, it may play a larger role in addressing plastic waste.
What happens to plastic that can’t be recycled?
Unfortunately, not all plastic can be recycled. Non-recyclable plastics often end up in landfills or incineration facilities. Some may be exported to other countries, although this practice is becoming increasingly regulated.
To address this issue, there’s a growing focus on reducing plastic production and use, particularly for single-use items. Many companies are exploring alternative materials and packaging designs to improve recyclability.
Packaging Reuse’s Recycling Services
At Packaging Reuse, we understand the complexities and challenges of plastic recycling. Our services are designed to address many of these issues, particularly in the realm of industrial packaging. We specialise in the reconditioning and recycling of various types of industrial packaging, including plastic containers like IBCs (Intermediate Bulk Containers).
By partnering with us, businesses can contribute to a more circular economy for plastics, reducing their environmental impact while also potentially lowering their waste management costs. Contact Packaging Reuse today to learn how our expert services can help your business reduce its environmental impact, ensure regulatory compliance, and potentially cut costs.
Sources:
Source 1: https://en.wikipedia.org/wiki/Polyethylene_terephthalate
Source 2: https://en.wikipedia.org/wiki/High-density_polyethylene
Source 3: https://en.wikipedia.org/wiki/Polyvinyl_chloride
Source 4: https://en.wikipedia.org/wiki/Low-density_polyethylene
Source 5: https://en.wikipedia.org/wiki/Polypropylene