{"id":12402,"date":"2024-06-14T12:09:28","date_gmt":"2024-06-14T10:09:28","guid":{"rendered":"https:\/\/www.alcion.com\/?p=12402"},"modified":"2026-04-10T13:43:12","modified_gmt":"2026-04-10T11:43:12","slug":"mechanical-recycling","status":"publish","type":"post","link":"https:\/\/www.alcion.com\/en\/mechanical-recycling\/","title":{"rendered":"Mechanical recycling: Technical overview and role in circular packaging"},"content":{"rendered":"\n

According to the European Union's Agenda 2030<\/strong><\/a>, all plastic packaging must be recyclable<\/a> or reusable by that date. Mechanical recycling <\/strong>arises as a core industrial process to meet these new requirements and regulations that are having a strong impact on the development of the plastic sector.<\/p>\n\n\n\n

This process comprises several sequential operations -collection, sorting, washing, shredding, melting and reprocessing of plastic waste<\/strong><\/a>, aiming to get a secondary raw plastic material<\/strong> ready to be used again.Therefore, this plastic waste process <\/strong>of <\/strong>mechanical recycling offers a technically mature , economically viable and environmentally efficient route to retaining material value.<\/p>\n\n\n\n

In this article, you will learn what mechanical recycling<\/strong> is, how the process of recycling<\/strong> works, why it matters for the recycling of plastic products<\/strong>, and how it compares with chemical recycling<\/strong>.<\/p>\n\n\n\n

<\/div>\n\n\n\n
    \n
  1. Mechanical recycling: Definition<\/a><\/li>\n\n\n\n
  2. Advantages of mechanical recycling<\/a><\/li>\n\n\n\n
  3. How does the process of recycling work in mechanical recycling?<\/a><\/li>\n\n\n\n
  4. Mechanical recycling vs. Chemical recycling: What are their differences? <\/a><\/li>\n\n\n\n
  5. How does mechanical recycling improve circular economy? <\/a><\/li>\n<\/ol>\n\n\n\n
    <\/div>\n\n\n\n

    Mechanical recycling: Definition<\/strong><\/h2>\n\n\n\n

    Mechanical recycling<\/strong> is a method of reprocessingplastic waste<\/strong> into reusable raw material<\/strong><\/a> without significantly changing the polymer structure. In simple terms, plastic is collected<\/strong>,sorted<\/strong>, cleaned<\/strong>, shredded<\/strong>, melted<\/strong>, and reprocessed<\/strong> so it can be used again in new applications.<\/p>\n\n\n\n

    This approach plays a central role in waste plastic recycling <\/strong>because it helps recover value from used plastics and reintroduce them into production cycles<\/strong>. <\/p>\n\n\n\n

    The result is a secondary raw material<\/strong> that can be used in the manufacture of new plastic products <\/strong>such as packaging, bags, construction materials, automotive components, and other everyday items.<\/p>\n\n\n\n

    As companies face growing pressure to improve sustainability<\/strong><\/a> and design packaging for circularity<\/strong>, mechanical plastic recycling<\/strong> has become a key strategy for turning waste into resources.<\/p>\n\n\n\n

    <\/div>\n\n\n\n
    \n

    Keep learning: <\/strong><\/em><\/a>Advantages of recycling plastic packaging<\/em><\/a><\/em><\/strong><\/p>\n<\/blockquote>\n\n\n\n

    <\/div>\n\n\n\n

    Advantages of mechanical recycling<\/h2>\n\n\n\n

    Mechanical recycling <\/strong>of plastic products offers great advantages for the environment<\/strong>, avoiding the accumulation of waste, which is one of the biggest pollution problems worldwide.<\/p>\n\n\n\n

    In addition, this practice also brings advantages for communities and great benefits to companies that opt for recycled or recyclable products<\/strong><\/a>.<\/strong> <\/p>\n\n\n\n

    Let's look at themost important advantages<\/strong> that mechanical recycling of plastic materials provides to society, the planet and businesses.<\/p>\n\n\n\n

    <\/div>\n\n\n\n

    1. Reduction of plastic waste<\/h3>\n\n\n\n

    One of the biggest advantages of waste plastic recycling<\/strong> is that it prevents used plastics from becoming long-term waste. Instead of ending their life after a single use, materials can return to the value chain and be converted into new products.<\/p>\n\n\n\n

    <\/div>\n\n\n\n

    2. Conservation of natural resources<\/h3>\n\n\n\n

    By replacing part of the demand for virgin raw materials, mechanical plastic recycling<\/strong> helps protect fossil-based resources and supports a more efficient use of materials.<\/p>\n\n\n\n

    <\/div>\n\n\n\n

    3. Energy efficiency <\/h3>\n\n\n\n

    In many cases, producing recycled plastic<\/strong> can require fewer resources than manufacturing virgin plastic from scratch. This makes the process of recycling<\/strong> especially relevant for companies aiming to reduce both environmental impact and production costs.<\/p>\n\n\n\n

    <\/div>\n\n\n\n

    4. Economic contribution<\/h3>\n\n\n\n

    The method of recycling<\/strong> used in mechanical recycling<\/strong> involves collection, sorting, washing, reprocessing, and manufacturing. These activities support jobs, industrial development, and investment across the recycling value chain<\/strong>.<\/p>\n\n\n\n

    <\/div>\n\n\n\n

    5. Strengthening Circularity<\/h3>\n\n\n\n

    Perhaps the biggest benefit is that mechanical recycling<\/strong> makes circularity<\/strong> <\/a>tangible. It turns used packaging into a resource, supports reuse of materials, and helps businesses move from a linear model to a circular one.<\/p>\n\n\n\n

    <\/div>\n\n\n
    \n
    \"CTA<\/a><\/figure>\n<\/div>\n\n\n
    <\/div>\n\n\n\n

    How does the process of recycling work in mechanical recycling?<\/strong><\/h2>\n\n\n\n

    The process of recycling<\/strong> plastic through mechanical methods involves several stages. Each step is important to ensure the final recycled material<\/strong> is clean, consistent, and suitable for new applications<\/p>\n\n\n\n

    <\/div>\n\n\n\n

    1. Sorting<\/h3>\n\n\n\n

    The first step in mechanical recycling is sorting plastic<\/strong> by resin type, color, format, and sometimes by application. Materials such as HDPE<\/strong><\/a>, LDPE, LLDPE, <\/strong>and PP<\/strong> are typically separated to improve recycling quality.<\/p>\n\n\n\n

    This stage is critical because the better the sorting, the better the performance of the recycled material.<\/p>\n\n\n\n

    <\/div>\n\n\n\n

    2. Shredding<\/h3>\n\n\n\n

    Once sorted, the plastic is reduced into smaller pieces<\/strong>. Shredding makes the material easier to handle and prepares it for the cleaning and reprocessing stages.<\/p>\n\n\n\n

    <\/div>\n\n\n\n

    3. Washing<\/h3>\n\n\n\n

    The shredded plastic is washed to remove impurities and contaminants.. Effective washing is essential in the recycling of plastic products<\/strong>, especially when the waste stream comes from post-consumer applications.<\/p>\n\n\n\n

    <\/div>\n\n\n\n

    4. Drying<\/h3>\n\n\n\n

    After washing, the material is dried until it reaches the controlled moisture level of 3-5% <\/strong>required for subsequent processing. This controlled drying<\/strong> helps maintain quality and improves efficiency during extrusion<\/strong>.<\/p>\n\n\n\n

    <\/div>\n\n\n\n

    5. Extrusion<\/h3>\n\n\n\n

    In the final stage, the clean and dry plastic flakes are melted and processed <\/strong>through an extruder<\/strong>. The molten plastic is then shaped into strands, cooled, and cut into pellets.<\/p>\n\n\n\n

    These pellets become the recycled raw material used in the production of new plastic goods. This is the stage where waste plastic recycling<\/strong> is converted into real industrial value.<\/p>\n\n\n\n

    <\/div>\n\n\n\n
    \n
    \n

    Keep learning: <\/strong><\/em>Circular Packaging: the commitment to circular solutions in packaging<\/em><\/strong><\/a><\/p>\n<\/blockquote>\n<\/blockquote>\n\n\n\n

    <\/div>\n\n\n\n

    Mechanical recycling vs. Chemical recycling: What are their differences?<\/strong><\/h2>\n\n\n\n

    Both mechanical recycling<\/strong> and chemical recycling<\/strong> aim to recover value from plastic waste, but they do so in different ways.<\/p>\n\n\n\n

    The main difference lies in how the material is treated:<\/p>\n\n\n\n