From waste to worth: How to successfully adopt recycled materials

As sustainability rises to the top of corporate agendas, manufacturers across industries are seeking viable alternatives to conventional virgin plastics. Post-consumer recycled (PCR) materials offer a promising solution – but implementing them successfully requires navigating technical challenges, quality considerations, and regional market differences.
A recent study by global leader in spend management Ivalua found that only a quarter of UK businesses have implemented a circular economy model, while nearly half are in the process or planning to do so. However, the November 2024 study also showed that key decision makers within organizations lack comprehensive and fully implemented plans for buying recycled materials (76%) and exchanging resources with suppliers (81%).
While plastic rightly receives negative press from improper disposal, it remains an exceptionally versatile and efficient material to recycle. 

"Plastic does get a bad press because of the way humans discard it," explains David Nulty, Development Engineer at Essentra Components. "It's actually a really good material to use because it's recyclable. It can be used over and over again. It's used in absolutely everything because it's the most efficient way to make a product."

At Essentra Components' Center of Excellence in Kidlington, UK, technical experts are pioneering innovative approaches to incorporating PCR into industrial components without compromising performance. Through rigorous testing and development, it’s possible to turn what was once considered waste into valuable manufacturing materials. In this article we will cover: 

Understanding PCR vs. PIR: The recycled material spectrum
The regulatory landscape driving PCR adoption
From breakfast table to industrial components
Overcoming technical challenges of PCR 
Building internal advocacy for PCR materials
Best practices for successful PCR implementation
The rigorous testing framework for PCR materials
The future of PCR in manufacturing

Understanding PCR vs. PIR: The recycled material spectrum

Before exploring implementation strategies, it's essential to understand the key differences between post-consumer recycled (PCR) and post-industrial recycled (PIR) materials.

Post-Industrial Recycled (PIR) Materials:

•    Sourced directly from manufacturing waste before reaching consumers
•    Generally cleaner, more homogeneous, and consistent in quality
•    Offer greater control over material properties
•    Typically easier to process and implement in manufacturing

Post-Consumer Recycled (PCR) Materials:

•    Derived from products that have completed their consumer lifecycle
•    More varied in composition with greater batch-to-batch variation
•    Require more robust processing parameters to accommodate inconsistencies
•    Deliver stronger sustainability credentials and circular economy benefits

"There's a sliding scale in recyclate quality from virgin to post-industrial (cleaner due to direct manufacturing integration) to PCR, which is more challenging as it passes through the consumer cycle," explains Rebecca Wilson, Sustainability Manager at Essentra Components.

While PIR offers an easier entry point with fewer technical hurdles, PCR delivers better environmental impact to meet increasingly stringent regulatory requirements.

The regulatory landscape driving PCR adoption

Beyond consumer demand, regulatory pressures are increasingly driving the adoption of recycled materials:

"In January, the revision of the European packaging regulations came into force," explains Wilson. " The UK has extended producer responsibility regulations and plastic packaging taxes, with similar measures implemented across Europe. Other countries globally are implementing similar regulations such as Senate Bill 54 in California, USA."

These regulations are designed to phase out the most environmentally damaging materials and incentivize the use of recycled content. For example, the UK plastic packaging tax exempts materials containing at least 30% recycled content, creating a strong financial incentive for manufacturers to incorporate PCR.

From breakfast table to industrial components

One of the most exciting innovations emerging from Essentra's Center of Excellence is our work with PCR derived from cartons and other types of packaging – transforming everyday food and beverage packaging into valuable industrial components.

"Product from the packaging industry has a great circular story," says David Nulty, Development Engineer at Essentra Components. "It's on everyone's breakfast table. It's in the orange juice carton. It has been used for many years, but initially only the pulp and cardboard were recycled – the interior plastic lining was thrown away because they couldn't find a use for it."

Through advanced recycling technology, processors can now separate and recover the low-density polyethylene (LDPE) from these cartons. After extensive testing at our Center of Excellence, this material has proven suitable for numerous industrial applications, including:

•    Protective caps for threaded components
•    Gas tear caps for cylinders requiring tamper-proof seals
•    Corner protectors for shipping and packaging

"What's also good about this material is it's reusable itself, so it fits in nicely with all our recycling streams that we already have set up," adds Nulty. This creates a truly circular process where materials can be recycled multiple times.
 

Overcoming technical challenges of PCR 

Despite the clear benefits, transitioning to PCR materials presents several technical hurdles that manufacturers must address:

1. Material consistency and quality

The primary challenge with PCR is batch-to-batch variation. Unlike virgin materials where manufacturers have complete control over the formulation, PCR depends on the quality of its source materials and recycling processes.

"With post-consumer recycled content, it's gone to landfill, it's chipped up on a conveyor belt – there's a whole raft of different materials in there,” explains Nulty. 

This variability means manufacturers must:
•    Establish wider processing windows to accommodate material inconsistencies
•    Implement more robust quality control measures
•    Select applications wisely based on technical requirements

2. Processing facility variations

Another complicating factor of PCR is that recycling facilities themselves vary significantly in their capabilities and output quality.

"Recycling plants can vary from state-of-the-art facilities with advanced technology to older sites with limited capabilities,” Wilson notes.

This inconsistency in recycling infrastructure impacts the quality of PCR materials available to manufacturers. This is where working with reputable suppliers who can demonstrate consistent quality control becomes essential.

3. Color limitations

PCR materials typically have color constraints that manufacturers need to consider in their design and application choices.

"With post-industrial recycled material you can produce clean, clear parts and you can add nearly any colorant to it, whereas the PCR materials tend to be bit murkier and dirtier in appearance," explains Wilson.

This limitation means PCR may not be suitable for applications where aesthetic considerations or precise color matching is needed. 

4. Regional differences in PCR adoption

Manufacturers operating globally must recognise significant regional variations in attitudes toward recycled materials and tailor strategies accordingly. 

"Europe is leading in sustainable practices, the U.S. is making progress but faces some challenges, while in Asia there is varied adoption with some significant progress but also some challenges around perception of recycled materials," says Wilson

Building internal advocacy for PCR materials

Successfully implementing PCR requires building support across your organization – from the shop floor to the sales team. At Essentra, we've found that demonstrating tangible success stories is crucial for gaining internal buy-in.

"A proud moment was seeing the online catalogue for BMP TAPPI in Italy. The catalogue now has a whole section dedicated to PCR parts, and that wasn't there 18 months ago," recalls Nulty. "That was a result of the great work that's been done via all the trials at our Center of Excellence."

Consumer attitudes are also shifting, creating market pull for sustainable components. "The younger generation are pushing for it," notes Nulty, sharing an anecdote about a colleague's child choosing recycled-content toothpaste at the supermarket. "As an industry, we have to be doing it at least partly for the generational desire to live more sustainably."

Best practices for successful PCR implementation

Based on Essentra's experience pioneering PCR applications, here are key recommendations for manufacturers considering the transition:

1.    Start with appropriate applications: Begin with less demanding applications where wider tolerances are acceptable and aesthetic considerations are secondary.
2.    Engage production experts early: "I might go onto the shop floor and say, 'Look, I've got this material. What are your problem tools? What will it fall over on?'" explains Nulty. This practical knowledge is invaluable for identifying potential challenges.
3.    Establish wider process windows: Adjust manufacturing parameters to accommodate the greater variability inherent in PCR materials.
4.    Implement robust quality control: More frequent testing may be necessary to ensure consistent component performance.
5.    Educate customers on sustainability benefits: Ensure your sales teams can effectively communicate the environmental advantages of PCR to customers who may be at different stages of their sustainability journey.
6.    Document carbon footprint reductions: Quantify the environmental benefits to help customers meet their own scope 3 emission targets.

The rigorous testing framework for PCR materials

Implementing PCR successfully requires a comprehensive testing and validation framework. At Essentra's Center of Excellence, we've developed a structured approach to evaluating new recycled materials:

1.    Safety assessment: Before any testing begins, materials undergo rigorous safety evaluation. "The most important requirement is safety," emphasizes Nulty. "Any material that we test has to come with the safety data sheets and technical data sheets which are assessed by subject matter experts within Essentra."
2.    Initial trial: The first step is determining basic moldability and visual assessment of the resulting components.
3.    Process optimization: Secondary trials focus on determining the material's processing capabilities and establishing optimal parameters.
4.    Operational qualification: This phase establishes the nominal process settings and defines the upper and lower processing limits.
5.    Metrology testing: Components undergo dimensional verification to ensure they meet required specifications despite material variations.
6.    Extended reliability testing: For critical applications, extended molding trials may be conducted to confirm consistent part quality over time.
7.    Material certification: Once all testing is complete, a formal material certificate is issued documenting the material's capabilities, limitations, and recommended applications.

The future of PCR in manufacturing

As Essentra looks ahead, we see enormous potential for expanding PCR applications across our component ranges. With our Center of Excellence conducting an average of one new material trial weekly, we're continually pushing the boundaries of what's possible with recycled materials.

"Part of that scrutiny that we place on different materials is to ensure that if we use a material, it's not going to cause a problem during its life cycle, and so we can offer our customers a more circular, sustainable product," emphasizes Wilson. This forward-thinking approach ensures that today's sustainability solutions don't become tomorrow's environmental challenges.

For manufacturers embarking on their PCR journey, the path may present technical hurdles, but the environmental benefits and increasing regulatory pressures will make it a necessary transition eventually. 

By embracing the circular potential of PCR materials, manufacturers can transform what was once considered waste into valuable resources – creating components that perform technically while contributing to a more sustainable industrial future.
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This article features insights from David Nulty, Development Engineer, and Rebecca Wilson, Sustainability Manager Operations at Essentra Components.