The evolution of recycling in recycled rigid plastics represents both a challenge and an opportunity for industry and the environment. In today’s market, where sustainable plastics and the circular economy are at the core of production strategies, understanding market trends and technological innovations is crucial. This article explores the concept of recycled rigid plastics, particularly in the extrusion of extruded plastic profiles and plastic gaskets, highlighting how the use of recycled plastic materials can meet the needs of an increasingly sustainability-focused market.

What are recycled rigid plastics?

Recycled rigid plastics refer to a group of plastic materials that, unlike packaging items (such as PET bottles or films), are not easily recovered through conventional recycling streams. These materials are typically sourced from:

• Post-consumer waste: items such as computer keyboards, bumpers, toys, electrical and electronic equipment components, and bottles.
• Post-industrial scraps: generated from manufacturing processes in construction (e.g., window profiles, pipes for water and gas, cables), electronics, automotive, and other sectors.

Understanding the origin and composition of these materials is essential because their recycling is often more complex than that of simpler, single-polymer items. The presence of multiple polymers, additives, and colorants requires advanced sorting and processing techniques, which are continuously evolving through advanced recycling technologies.

Why focus on recycled rigid plastics?

The increasing focus on environmental sustainability has underlined the importance of rethinking waste management processes, particularly for recycled rigid plastics. Key reasons include:

• Environmental Impact:
  failing to recycle these materials increases waste and pollution while consuming non-renewable natural resources such as petroleum.
• Recycling Challenges:
  rigid plastics, often composed of heterogeneous mixtures like polyethylene, polystyrene, polypropylene, polycarbonate, ABS, and their blends, require specialized technologies to be transformed into new products, making their recycling more challenging than PET bottles or films.
• Technological Innovations:
  the adoption of both mechanical and chemical recycling techniques allows for the recovery and valorization of these plastics. These methods provide different pathways to produce high-quality regenerated materials, meeting strict performance standards while supporting sustainable manufacturing.
• Economic and Environmental Benefits:
  using recycled materials typically requires less energy than producing virgin plastics, reducing energy consumption and greenhouse gas emissions. Moreover, integrating recycled rigid plastics into production processes minimizes the use of natural resources and contributes to a more efficient circular economy.

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Mavis’ approach to recycled plastic materials

At Mavis, our commitment to the circular economy is integrated into our plastic extrusion processes.

• We have developed specific methodologies to calculate the optimal blend of virgin and recycled materials, ensuring that the extruded plastic profiles and plastic gaskets meet the stringent design requirements of our customers.
• For every extruded profile, we identify the appropriate polymer type and the percentage of recycled material to be used, optimizing the final product’s performance.
• Our ability to custom-size profiles based on customer specifications ensures that even when using recycled rigid plastics, the product’s characteristics remain uncompromised.

Which recycled plastics materials do we use?

Our production process employs several types of recycled rigid plastics:

1. Post-industrial scraps:
   non-contaminated remnants are mechanically ground and blended with virgin material to produce products of comparable quality.
2. Post-consumer waste:
   these materials are separated and processed with additives; although they may exhibit slight variations, they are suitable for specific applications.
3. Chemical recycling:
   techniques that thermally and chemically break down the material into its constituent parts, which can then be re-polymerized into virgin-quality plastics, albeit at higher processing costs.

Which recycled rigid plastic profiles do we extrude?

Mavis produces a complete range of products in recycled rigid plastic profiles and appropriately regenerated plastics, offering innovative solutions that meet market needs and comply with strict quality standards. Our approach not only reduces raw material waste but also delivers high-performance products tailored for the construction, furniture, and industrial sectors.

• Recycled PVC profiles:
  Derived from industrial window frame scraps, these profiles guarantee superior quality and durability. They are ideal for applications in the construction, furniture, and general industrial sectors.
• Extruded regenerated rigid plastic profiles:
  Produced using off-cuts from plastic pipes and cables, these profiles are carefully processed, treated, and compounded during regeneration to ensure high mechanical and thermal performance.
• Mechanically recycled plastic profiles:
  Sourced from homogeneous industrial waste, these profiles are blended with virgin material to maintain elevated quality standards, ensuring consistent performance in demanding applications.
• Co-extruded profiles with recycled and virgin material:
  In these profiles, the visible outer layer is extruded with virgin material, while the inner, non-visible layer is made from recycled plastic. This co-extrusion technique optimizes the product’s aesthetic appeal and performance while reducing overall material waste.

This comprehensive approach enables us to offer recycled rigid plastic profiles that not only minimize the environmental impact but also meet regulatory requirements and provide high-performance solutions.

Contact us for innovative plastics solutions

If your company is looking for advanced solutions in the extrusion of recycled rigid plastics, including extruded plastic profiles and plastic gaskets made from recycled materials, Mavis is your ideal partner. Our technical expertise and state-of-the-art technologies support you in optimizing your production cycle while ensuring that your final products combine sustainability with high performance.

Request your quote now – fill out the form for a personalized offer or consultation and discover how we can help make your production process more sustainable and competitive.