Originally published on LinkedIn April 10th, 2025.
Recycling flexible film into a product that can be used again in flexible packaging is a complex process. Despite the challenges, NOVA Circular Solutions is making significant strides to increase the supply and improve the quality of recycled polyethylene (rPE) made from flexible films to enable circularity. Here's why recycling plastic film is so challenging and why we continue to pursue it.
The Challenges of Plastic Film Recycling
1. Securing the Feedstock: Plastic films are thin and light and often intermingled with other materials making collection and sorting a critical task. Ensuring a consistent supply of clean plastic film feedstock requires either meticulous manual sorting or state-of-the-art
automated sorting technology to ensure the consistency of feedstock necessary to produce a high quality rPE.
2. Specialized Equipment: Recycling plastic film requires specialized processing equipment that can shred, wash, dry and extrude the thin, flexible material without causing jams at high production rates.
3. Quality Control: Maintaining the quality of rPE to meet industry standards for flexible packaging requires robust manufacturing practices and sophisticated quality control testing.
4. Regulatory Compliance: Navigating the complex web of regulations governing plastic recycling for food-grade materials requires meticulous attention to detail and adherence to stringent traceability standards. It is important to make sure rPE is certified and compliant for its intended use, especially for food contact applications.
Despite these challenges, the benefits of recycling plastic film are undeniable:
1. Environmental Impact: Recycling reduces the amount of plastic waste in landfills and oceans, mitigating pollution and conserving natural resources.
2. Economic Benefits: Creating a market for recycled plastic film can stimulate economic growth and create jobs in the recycling industry.
Our Approach
NOVA Circular Solutions is at the forefront of tackling these challenges. Our first mechanical recycling facility for PE film is now online. The SYNDIGO1 facility located in Connersville, IN represents a significant step forward in the recycling industry, aiming to produce high quality SYNDIGO recycled PE. We employ cutting-edge technologies and rigorous manufacturing processes to ensure the quality and safety of the recycled products. By working closely with regulatory bodies and industry partners, NOVA Circular Solutions is setting new standards for plastic film recycling.
While recycling plastic film is challenging, the environmental and economic benefits make it a worthwhile endeavor. NOVA Circular Solutions is leading the way, demonstrating that with innovation and commitment, we can overcome these obstacles and make a positive impact on our planet.
See the full article on LinkedIn
here.
Greg DeKunder serves as the Vice President of NOVA Circular Solutions. In this role, he is focused on expanding the company’s recycled polyethylene product offerings and growing its mechanical recycling business to become one of the leading recyclers in North America.