Recycled Plastics vs Virgin Plastics: Performance

Using recycled plastics in manufacturing is exciting but also a bit worrying for many companies. On one side, consumers, governments, and regulatory bodies are pushing for more recycled materials, and there are financial incentives to do so. On the other hand, businesses worry that using recycled plastics might lead to lower quality products.

These concerns are valid. Recycled plastics, especially mechanically recycled ones, often aren’t as strong or resistant to heat and impact as new (virgin) plastics. This makes companies hesitant to switch to materials that might not perform as well as the ones they’re used to.

However, we need to look at how these materials are actually used in the real world. While virgin plastic products can handle extreme conditions like high heat or heavy impacts, most products don’t need to meet such high standards. Many everyday items don’t require the durability that virgin plastics are tested for.

We often call this “over-engineering,” and it happens in a lot of industries. For example, does a simple, everyday product need to survive being dropped from a skyscraper or withstand freezing temperatures? Probably not, but these are the types of extreme tests that virgin plastics are put through. So, the real question is: is “good enough” actually enough? While brands and manufacturers that focus on high quality might struggle with this idea, finding a balance between quality, reliability, and sustainability is key.

Not your grandfather’s PCR.

The main reason recycled plastic weakens is due to contaminants that sneak in during the recycling process. These unwanted particles can make it through cleaning and sorting, causing the plastic to degrade.

But with growing demand and better technology, there are now ways to tackle this issue:

• New advancements in sorting and recycling are improving the quality of recycled plastic, making it purer and more reliable.
• More single-grade recycling feedstock is available, which means fewer concerns about mixed materials lowering the quality.
• By getting plastic from higher-quality sources in consistent amounts, recyclers can create a more efficient supply chain, leading to better and more predictable output in terms of both quality and volume.

Give it a fair chance

When comparing recycled plastics to new, virgin plastics, there will always be some differences. For instance, recycled polyethylene may become more flexible and easier to work with due to changes in its molecular structure. This can actually make it better suited for things like shrink wrap and packaging.

That’s why it’s important to carefully consider how these differences impact performance. In some cases, the changes might be too significant and affect the product’s quality, but often the variation is minor. Sometimes, these differences can even be a good thing, offering unexpected benefits for certain uses.

Options for matching virgin plastic performance 

Understanding the differences between recycled and virgin plastics opens up several options for reducing environmental impact without sacrificing quality.

When maintaining performance is critical, primary recycling is a great option. In this process, plastics with the same properties are recycled, ensuring consistent quality. This is often used in closed-loop recycling, like turning PET bottles into new bottles, where there’s no drop in performance.

Secondary recycling still has its place, especially for products with lower performance demands. Even then, additives like compatibilizers can be used to ensure recycled plastics meet the desired standards, sometimes even at a lower cost.

Another effective strategy is blending recycled plastic with virgin plastic. By adding just 30% virgin resin, the resulting material can perform almost as well as 100% virgin plastic. While this doesn’t eliminate the need for new plastic entirely, it significantly cuts down the amount needed.

Some may criticize this approach, pushing for the complete elimination of virgin plastic. However, this overlooks the substantial progress that can be made by using even a portion of recycled material. Every step counts toward reducing our reliance on new plastics.

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Overcoming hesitancy and embracing the possibilities

It’s time for all brands and manufacturers to stop hesitating and start using recycled plastic in their products and processes. We all know the harmful effects of virgin plastic, and by now, there are plenty of recycled plastic options available for almost any use.

The truth is, recycled plastic is just as good or “good enough” for most uses, and concerns about lower quality aren’t really valid anymore. Even for products that need the highest quality, solutions like blending, single-source recycling, and quality-enhancing additives are available.

By working with reliable suppliers and experts, companies can easily find the right recycled plastic for their needs. This can help them reduce their environmental impact, save money, and appeal to a market that’s increasingly looking for sustainable solutions.