Maya Ellison
Polar Plastics Corporation, a manufacturer of polyethylene products, was acquired by Revolution, a company that creates sustainable plastic solutions, in 2020. Revolution markets a wide range of green plastic solutions for the agriculture, construction, foodservice, and retail sectors. The company uses an innovative closed-loop system to recover, clean, and process post-consumer recycled (PCR) resin to create new products such as trash can liners, carryout bags, and construction films. While it is not explicitly stated whether Polar Plastics sheeting is recycled, the company's focus on sustainability and closed-loop manufacturing suggests that recycled materials may be used in their products. Additionally, other companies such as Smile Plastics and PLASKOLITE offer recycled plastic sheets made from various waste streams, including discarded chopping boards, cosmetics bottles, and yoghurt pots, contributing to the circular economy.
| Characteristics | Values |
|---|---|
| Company | Polar Plastics |
| Acquired by | Revolution |
| Year | 2020 |
| Headquarters | St. Paul, Minnesota |
| Manufacturing | Plastic film, sheeting, custom rolls, bags, stretch film, and low-density polyethylene packaging products |
| Manufacturing since | 1967 |
| Production facility size | 100,000 square feet |
| Parent company headquarters | Little Rock, Arkansas |
| Parent company focus | Sustainable plastic solutions |
| Certifications | ISO 9001, ISO 14001 |
| Product features | 100% recycled and recyclable, VOC-free, safe, and eco-friendly |
| Product applications | Construction, agriculture, packaging, logistics, home improvement, and retail |
| Product range | Clear recycled sheets, coloured recycled sheets, custom recycled sheets |
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What You'll Learn
Polar Plastics' recycling process
Revolution Sustainable Solutions, LLC, a leader in sustainable materials and recycling solutions, acquired Polar Plastics in 2020. Polar Plastics, headquartered in St. Paul, Minnesota, manufactures plastic film and low-density polyethylene packaging products. The company has been committed to its customers and has a culture of excellence and collaboration.
The recycling process for plastic typically involves the following steps:
- Collection and Sorting: The process begins when plastic items are placed in recycling bins. The collected plastic waste is then sorted into different streams: the intended plastic (high value), missorted plastic containers (medium value), and waste (negative value).
- Baling: The sorted plastic is then baled into compressed rectangular blocks weighing 1000-1500 lbs and wrapped with wire. These bales are sold to recyclers or reclaimers.
- Grinding: The bales are cut apart, and the material is placed on a conveyor belt for another round of sorting to remove contaminants like glass or metal. It then goes into an industrial grinder and is cut into small pieces called flakes.
- Washing and Separation: The flakes are washed in hot water and detergent to remove dirt and dissolve adhesives. They are then rinsed again and air-dried. Different types of plastics are separated in a float-sink tank, where some plastics float while others sink.
- Decontamination and Processing: If the material is intended for food-contact packaging, it undergoes decontamination using vacuum and heat. The flakes are melted, filtered to remove solids, and processed into pellets.
- Reintroduction into Manufacturing: The recycled pellets can now be reintroduced into the manufacturing process to create new products.
While almost all plastic can theoretically be recycled, certain barriers exist in practice. These include the difficulty and cost of separating and recycling items made of multiple types of plastic and the contamination of plastics by food or other substances, making them unfit for reuse.
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Recycled plastic sheet products
Plastock also offers 100% recycled plastic sheets in a design called Greycious, featuring a classic grey colour with white specs and a matte finish that resembles natural stone. These sheets are suitable for bespoke patterns and can be customized to match any colour palette.
PLASKOLITE is another company that manufactures recycled sheets. Their R series of sheets, available worldwide, is made from recycled content, addressing the environmental concerns surrounding plastics. PLASKOLITE collects, separates, and reintroduces waste plastic back into the extrusion process, with their sheets containing up to 95% post-industrial recycled content. Their cast sheets can be made from 100% recycled MMA, and they even utilize plastic dust created during cutting to create new sheets.
The Good Plastic Company takes a different approach, specializing in transforming post-consumer plastic waste into valuable materials. Their Polygood® brand offers 100% recycled and recyclable large-format panels that are durable, lightweight, and waterproof. These panels are ideal for commercial projects in various sectors, including retail, hospitality, public sector, and education.
While not specifically a sheet product, it is worth noting that recycled PET (found in plastic bottles) is increasingly being used as a construction material in third-world countries. Plastic bottles are filled with sand, stacked, and cemented together to form walls, providing an innovative and sustainable housing solution.
These companies, among others, are leading the way in recycled plastic sheet products, showcasing sustainability, innovation, and a commitment to reducing plastic waste.
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Recycled plastic sheet uses
Recycled plastic sheets are an eco-friendly, cost-effective, and durable alternative to traditional materials like wood, steel, and aluminium. They are made from recycled plastic waste, such as containers, bags, and packaging, and can be recycled again at the end of their use. They are lightweight, versatile, and come in various sizes, colours, shapes, and thicknesses. They offer superior endurance, flexibility, and impact resistance compared to plywood.
Recycled plastic sheets have a wide range of applications across multiple industries, including construction, agriculture, and education. In construction, they can be used for cladding, roofing, partitioning, flooring, and fencing. They are an excellent ground protection solution, as they can withstand the impact of heavy equipment without damaging the surface below. They are also moisture-resistant, making them suitable for retaining walls and other landscaping projects.
In agriculture, recycled plastic sheets can be used for animal shelters, stables, and other structures. The sheets provide impeccable waterproofing and resilience against the elements, enhancing animal welfare standards. Their chemical inertness also allows for hassle-free cleaning, guaranteeing high hygiene levels and preventing the spread of diseases and infections.
Recycled plastic sheets are also suitable for educational purposes, such as multicoloured HDPE sheets for schools' play equipment. They can be made from various waste streams and across a wide variety of colour palettes, making them a sustainable and aesthetically pleasing choice for designers and architects.
Additionally, recycled plastic sheets can be used for scum boards in water treatment plants, marine wall jetty buffers, and packaging solutions. They are a green alternative to plywood, actively diverting single-use plastic from landfills and contributing to a circular economy.
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Recycled plastic sheet creation
The recycling of plastics is a complex process that involves multiple steps and requires specialised equipment. However, the creation of recycled plastic sheets is an innovative way to utilise this recycled material and reduce plastic waste.
One method to create recycled plastic sheets is through the Precious Plastic Sheetpress system. This system consists of three machines: the Sheetpress, a cooling press, and a prep table. The process begins with collecting and shredding the plastic waste, which can be sourced locally. The shredded plastic is then loaded into the Sheetpress, where it is melted and pressed into sheets. To improve efficiency and speed, the plastic sheets are then transferred to the cooling press and prep table for further processing.
The Sheetpress system has gained popularity globally, with people replicating and modifying the machine to suit their specific needs. For instance, the Fab Unit in France and Sheep on Wheels in Belgium have customised the Sheetpress to create exquisite stools and high-quality sheets, respectively.
Another approach to creating recycled plastic sheets is through a manual process that can be done at home. This method involves collecting and cleaning plastic bags, cutting them into sheets, and fusing them together using an iron or an oven. By layering and pressing multiple sheets, a thicker and more durable recycled plastic sheet can be created.
Companies like Smile Plastics and PLASKOLITE are also pioneers in the field of recycled plastic sheets. Smile Plastics offers 100% recycled and recyclable plastic sheets, contributing to the circular economy. Their materials are sourced from would-be waste, such as discarded chopping boards, cosmetic bottles, and yoghurt pots, and are designed to meet the specific needs of their clients. Similarly, PLASKOLITE collects, separates, and reintroduces waste plastic into the extrusion process to create recycled sheets with up to 95% post-industrial content.
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Recycled plastic sheet suppliers
There are several suppliers of recycled plastic sheets, which are made from 100% recycled and recyclable materials. These sheets are designed to contribute to a circular economy and reduce waste. Here are some of the notable suppliers:
Smile Plastics
Smile Plastics is a UK-based company that has been a pioneer in the recycled plastic sheet industry for over 30 years. Their sheets are made from 100% recycled and fully recyclable materials, contributing to sustainable practices. Smile Plastics offers a range of colours and designs, with the potential to divert up to 3000 tonnes of plastic waste per year. They hold ISO 9001 and ISO 14001 certifications, ensuring quality control and eco-friendly manufacturing. Their products are VOC-free and safe for both people and the planet.
Plastock
Plastock offers a wide selection of recycled plastic sheets, tubes, and rods in various materials, sizes, colours, and designs. Their Perspex and Green Cast Acrylic sheets are 100% recycled and recyclable, with the same characteristics as virgin acrylic/Perspex. The recycling process can be repeated endlessly, contributing to the conservation of raw materials. Plastock's PEF Felt is also made from recycled polyester, making it highly sustainable and durable.
PLASKOLITE
PLASKOLITE is another supplier of recycled plastic sheets, offering the R series made from recycled content. Their sheets are produced with up to 95% post-industrial recycled content, and they can even utilise plastic dust created during cutting. PLASKOLITE's cast sheets can be made from 100% recycled MMA, contributing to environmental initiatives. Their products are available worldwide and support sustainability efforts.
Kedel
Kedel specialises in recycled plastic boards and sheets designed for building and construction applications. Their sheets have a wide variety of uses, including water treatment plants, animal shelters, agricultural use, and play equipment. Kedel's recycled plastic sheets offer longevity and colour retention for decades, making them a durable and low-maintenance option.
These suppliers offer a range of recycled plastic sheets with different features, colours, and applications. By choosing these products, consumers can contribute to sustainability, reduce waste, and support the circular economy.
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Frequently asked questions
Polar Plastics is a manufacturer of plastic film and low-density polyethylene packaging products. The company was acquired by Revolution, a leading manufacturer of sustainable plastic solutions, in 2020.
Polar Plastics, now Revolution, markets a wide array of green plastic solutions for the agriculture, construction, foodservice, and retail sectors. The company recovers, cleans, and processes post-consumer recycled (PCR) resin to create new products such as trash can liners, carryout bags, and construction films.
Recycled plastic sheets are sheets of plastic that have been created from recycled content. These sheets can be made from post-industrial or post-consumer recycled plastic and are often used to create new products such as shampoo bottles, cosmetic caps, and packaging films.
