Maya Ellison
Plastic is everywhere, and it's cheap to make and profitable. However, it can take hundreds of years to biodegrade, between 500-1000 years for some types, meaning it takes up landfill space and pollutes the environment for longer. While many people are already recycling plastic, it can be confusing to understand how to recycle certain items, and not all plastic is widely recyclable. The process of recycling plastic is varied and complicated, and it's important to remember that different types of plastic require particular methods for turning them back into raw materials ready for reuse. So, what does plastic turn into when it's recycled?
| Characteristics | Values |
|---|---|
| Plastic recycling process | Collection, sorting, reprocessing, and moulding into new products |
| Sorting techniques | Manual picking, optical sorting, ballistic separation, magnet separation |
| Sorting locations | Material Recovery Facilities (MRF), Plastic Recovery Facilities (PRF) |
| Recycling methods | Mechanical recycling, chemical recycling |
| Mechanical recycling | Washing, grounding, melting |
| Chemical recycling | Breaking down into monomers to form new polymers |
| Recyclable plastics | PET, HDPE, PP |
| Non-recyclable plastics | Bioplastics, composite plastic, plastic-coated wrapping paper, polycarbonate, thin bags or films |
| Plastic waste alternatives | Repurpose, reuse, compost |
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What You'll Learn
Plastic is sorted and cleaned
Plastic is one of the most common waste products, and it is cheap to make and profitable. However, it is also one of the most polluting materials, and it is not biodegradable. The process of recycling plastic is complex and requires multiple steps to ensure the final product is safe and of good quality.
The first step in the recycling process is the collection of plastic waste. This is done by households, businesses, schools, and local recycling centres. It is important that the plastic is sorted correctly at the collection point to ensure the recycling system operates effectively. Once collected, the plastic waste is transported to sorting installations, where it undergoes an extensive sorting process.
The plastic is first sorted at a Material Recovery Facility (MRF), which separates plastic from non-plastic materials. This is done by hand or with the help of machines. Large items, non-recyclables, and obvious contaminants are removed. The remaining waste is then sent to a Plastic Recovery Facility (PRF) for further sorting into different types of plastic. Optical sorting machines and sink-float separators distinguish between plastic types based on thickness, colour, size, and type.
Infrared technology is also used to separate different types of plastic to ensure the quality and safety of the final product. For example, shampoo bottles need to be separated from drink cartons. Metals are also removed from the plastic at this stage using magnets. The plastic is then washed to remove any remaining impurities such as food waste, labels, glue, and dirt. This process ensures that the plastic is as clean as possible before it is recycled into new products.
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Plastic is shredded into flakes
The recycling process for plastic begins with the collection of plastic waste from homes, businesses, and schools. The plastic waste is then sent to a Material Recovery Facility (MRF) or a Plastic Recovery Facility (PRF) to be sorted. The plastic is then washed, shredded into flakes, and sorted further. The specific process for shredding plastic differs depending on the type of plastic being shredded. For instance, rigid plastics are shredded using a horizontal cutting machine, where the blades rotate on a horizontal axis, and the shredded plastic passes through a grid into a collecting tray. The size of the shredded plastic flakes ranges from 5 to 10 mm. In contrast, thin film plastics require a different type of shredder machine. To avoid feeding plastic films, bags, and sheets directly into a shredder, an agglomerator can be used to cut, preheat, and dry the plastics into granules. This process increases the density and quality of the material, ensuring a continuous flow in the extruder and improving efficiency.
The shredded plastic flakes can be used in a variety of applications, including compression molding, highly reinforced composites, powder coating, and 3D printing. The flakes can be used as-is or blended with other materials such as lubricants, modifiers, or additives before being molded into basic shapes. The size of the shredded plastic flakes can be customized to meet specific requirements, with 140 mesh being the most common sieving size.
The recycling process continues after the plastic is shredded into flakes. The flakes are then heated and extruded into new pellets, which can be sold and used to create new products. This stage of the process involves melting the plastic and forming it into filaments that can be used for making different recycled products. Overall, the shredding process is an important step in plastic recycling, as it transforms plastic waste into a form that can be further processed and reused.
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$14.88
Flakes are melted and formed into pellets
Once plastic is collected from homes, businesses, and schools, it is sent to a Material Recovery Facility (MRF) or a Plastic Recovery Facility (PRF) to be sorted. The plastic is then washed, shredded, and sorted further. It is then ready for the next step in the recycling process: being melted and formed into pellets.
The flakes of plastic are melted and processed into uniform pellets through extrusion techniques. This process is called pelletizing. The plastic is heated and extruded into new pellets. These pellets are small, uniform pieces of plastic that are sold to be used as raw material in the manufacturing of new plastic products.
The pellets are used in various industries, including automotive, electronics, construction, and consumer goods. For example, in the automotive industry, recycled plastic pellets are used to make interior trims, dashboards, and bumpers. In electronics, they are used for laptop casings, remote controls, and phone cases. In construction, they are used for pipes, fittings, and insulation materials.
Recycled plastic pellets are a cost-effective and environmentally responsible alternative to virgin plastic. They are more affordable while maintaining high performance, reducing production costs without compromising quality. The process of recycling plastic also contributes to sustainability goals by requiring less energy and fewer raw materials than virgin plastic production.
Additionally, the recycling process can be optimized by ensuring the plastic is dried to a very low moisture level before melt extrusion. This is especially important for PET polymer, which is sensitive to hydrolytic degradation, as drying the plastic to <100 parts per million (ppm) moisture minimizes hydrolysis during melt processing.
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Pellets are sold for use in new products
Once plastic is collected from homes, businesses, and schools, it is sent to a Material Recovery Facility (MRF) to be sorted. At the MRF, plastic is separated from non-plastic materials, and then sent to a Plastic Recovery Facility (PRF) to be sorted further by type. Sorting is done manually or using mechanized automated processes, such as optical sorting, or even by colour. After sorting, there are two main ways to recycle plastic: mechanical recycling and chemical recycling.
Mechanical recycling involves washing, shredding, and melting the plastic. The plastic is ground into flakes and heated to be extruded into new pellets. These pellets are then sold to be used in new products.
Chemical recycling, on the other hand, breaks down the plastic into monomers to form new polymers to be reused. This process is more complicated and expensive, and not all plastics are recyclable. The most easily recycled plastics are PET (found in soda and water bottles), HDPE (used in packaging products like milk and detergents), and PP (found in clothing, ropes, tubs, and bottles).
The recycled plastic pellets are sold to manufacturers who use them to create new products. These pellets are a valuable resource, as they conserve limited natural resources and energy. By using recycled plastic, manufacturers can reduce their need to create new plastic from raw materials, conserving oil and reducing plastic pollution.
The recycling process can be complicated and varied, as "plastic" is an umbrella term for a wide range of materials, each requiring a particular method for turning them into raw materials for reuse. Sorting and collection are key steps in the process, and new technologies, such as artificial intelligence and machine learning, are being used to improve these steps.
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Some plastics become microplastics
While recycling plastic is a challenge, with most plastic ending up in landfills, the plastic that does get recycled is transformed into new products. However, some plastics that are not recycled can break apart to form microplastics, which are pieces smaller than five millimeters in diameter. These microplastics have been found in marine environments, soil, air, and even in our food and drinking water.
Microplastics can come from a variety of sources, including synthetic textiles, city dust, tires, road markings, marine coatings, and personal care products. Synthetic textiles are the largest contributors to microplastics in the ocean, accounting for 35% of the total volume. Polyester, nylon, and acrylic are forms of plastic that make up 60% of the fabric content of our clothes. The washing of synthetic fibers has been identified as a significant way that households contribute to the microplastics problem.
Personal care and cosmetic products also contain a type of engineered microplastic known as microbeads, which are used for exfoliation, delivering active ingredients, and controlling viscosity. These microbeads can pass through water filtration systems and end up in waterways, contributing to the microplastics found in the ocean. A study found that microplastics were present in 23.3% of fish samples in the Mediterranean Sea, with fibers being the main source.
Additionally, tires are another source of microplastics, as they contain synthetic rubber, a plastic polymer. Through heat, friction, and weathering, tires can break down and release microplastics into the environment, which can then enter tributaries and eventually the oceans. The degradation of plastic in marine environments can lead to the release of estrogenic compounds and other additives, which can have unknown effects on human health.
The presence of microplastics in our environment and food systems is a growing concern, and there is increasing pressure on governments and industries to address this issue. While some companies have started initiatives to use recycled plastic in their products, the overall tonnage of plastic produced each year continues to be a significant problem.
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Frequently asked questions
Plastic is recycled into pellets, which are sold on to be made into new products.
The first stage of the recycling process is the collection of plastic from homes, businesses, schools and recycling centres. The plastic is then sent to a Material Recovery Facility (MRF) to separate plastic from non-plastic, and/or a Plastic Recovery Facility (PRF) to sort the plastic by type. The plastic is then washed, shredded and sorted further. Finally, the plastic is melted and extruded into new recycled plastic pellets.
The most easily recycled plastics are PET (Polyethylene Terephthalate), commonly seen in soda and water bottles; HDPE (High-Density Polyethylene), typically used for packaging products like milk, detergents and hair care products; and PP (Polypropylene), used in clothing and ropes, as well as tubs and bottles.
Plastic that cannot be recycled usually ends up in landfills. However, plastic waste can often be repurposed or reused, such as plastic bags that can be reused multiple times before disposal.
