Plastic Recycling Plants: Processes, Equipment and Benefits

Plastic recycling plants are critical in waste management and promoting sustainability. These facilities make it possible to transform discarded plastics into new raw materials, thus contributing to the circular economy. In addition, its operation supports the reduction of waste in landfills and minimizes environmental impact. Through specific processes, an improvement in the quality of life is achieved and a more responsible use of resources is encouraged.

Importance of Plastic Recycling Plants

Facilities dedicated to plastics recycling play an essential role in environmental sustainability and in promoting a more responsible economic model.

Contribution to the circular economy

Recycling plants are critical to the functioning of the circular economy, where products and materials are reused, repaired, and recycled instead of being discarded. This approach not only maximizes the use of resources, but also minimizes waste. By transforming plastics into new raw materials, a more sustainable supply chain is supported.

It facilitates the reduction of dependence on virgin resources.
It drives the creation of markets for recycled products.
It allows the industry to obtain raw materials at a reduced cost.

Environmental benefits

Proper management of plastic waste through recycling plants brings with it numerous benefits for the environment. These benefits can be seen in several dimensions:

Reducing pollution: Recycling plastic helps reduce the amount of waste that ends up in landfills and the environment, thus decreasing soil and water pollution.
Energy savings: The production of raw material from recycled plastic requires significantly less energy than that of virgin plastic, which contributes to the reduction of greenhouse gas emissions.
Conservation of natural resources: By reusing plastics, the extraction of fossil resources is reduced, thus contributing to the preservation of ecosystems and non-renewable resources.

These aspects highlight the importance of recycling plants as allies in the fight against climate change and in the search for a more sustainable future.

Structure and operation of a recycling plant

Recycling plants have a specific design and follow a clear procedure for processing plastics. This process involves several fundamental stages, each of which plays a crucial role in the transformation of plastic waste into reusable materials.

Plastics recycling process

The recycling procedure is divided into several stages that ensure the correct management and conversion of plastic materials. Each of them focuses on different aspects of waste transformation.

Waste collection and sorting

First, plastic waste is collected by established collection systems, usually through specific containers. Once in the plant, materials are sorted according to their type, using advanced technology that allows plastics to be separated from other polluting materials, such as paper or metal.

Decontamination and shredding

Subsequently, a decontamination process is carried out, where the plastics are cleaned to remove any impurities. This step is critical to maintaining the quality of recycled plastic. After cleaning, the plastics are shredded into smaller particles, which facilitates their subsequent processing.

Transformation into raw materials

Finally, the shredded plastics are subjected to reprocessing that turns them into reusable raw material. Pellets or granules are formed that can be used by industry for the manufacture of new products, thus closing the life cycle of plastic.

Recycling equipment used

The success of recycling depends largely on the equipment used in the plants. Key instruments and machinery include:

Feeder Doser: Regulates the flow of material input to the plant, avoiding overloads and ensuring constant supply to the equipment.
Bag opener: Open bags containing waste without shredding the contents, freeing up the plastics for later separation.
Primary Crusher: Reduces the size of bulky plastics (such as carafes, large parts) into smaller fragments, manageable for subsequent stages.
Screen Trommel: Separates materials by size, letting small fragments pass through and retaining larger fragments for reprocessing.
Ballistic Separator: Distinguishes flat materials (such as films and bags) from rigid materials (bottles, caps) by a rebound and shape motion.
Overband Magnetic Separator / Pulley: Removes ferrous metals (irons, nails, sheets) that could damage downstream equipment or contaminate plastic.
Induction Separator: Removes non-ferrous metals (such as aluminum) through induction, ensuring that only plastics move forward.
Optical Separator: Uses advanced sensors to sort plastics by polymer type (PET, HDPE, PP) and color, achieving high-purity separation.
Air Separator – Zigzag: Separates light materials (such as labels, films) from heavier fragments using air currents.
Robotic Picking: Robots with artificial intelligence support separation, removing specific materials quickly and accurately.
Conveyor Belts: Interconnect all equipment and transport materials from one stage to another, ensuring a continuous and orderly flow.
Press: Compacts the plastics already separated into bales, ready to be stored or transported to the processing plants.
Container Press: Specific for compacting large plastic containers, reducing their volume before sale or reprocessing.
Structures and Walkways: They provide physical support to the plant and allow safe access for personnel for maintenance and operation.

This equipment is essential to ensure that the recycling process is efficient and meets the established quality standards.

Situation of plastic recycling in Spain

The current situation of plastic recycling in Spain shows significant advances for waste management and sustainability. A strong regulatory framework has been implemented to support its development and growth.

Distribution of recycling plants in the country

In Spain, the proliferation of facilities for the management of plastics has increased considerably in the last decade. Currently, there are a total of 121 recycling plants scattered throughout various autonomous communities. The regions that concentrate the largest number of these facilities are:

Andalusia
Catalonia
Community of Valencia

This distribution reflects a regional commitment to improving recycling processes and promoting sustainable practices.

Most common recycled materials

The types of plastics that are processed in these plants are varied, although some stand out for their greater frequency in recycling. The most common recycled plastics include:

PET (Polyethylene Terephthalate)
LDPE (Low Density Polyethylene)
HDPE (High Density Polyethylene)

These materials are essential in various industrial applications, thus contributing to the reduction of waste and the promotion of a circular economy.

Challenges in plastics recycling

Plastic recycling faces several challenges that can hinder its effectiveness and efficiency. As the industry evolves, it is crucial to address these issues to improve recycling processes and outcomes.

Pollution and mixing of plastics

One of the biggest challenges in recycling plastics is contamination of the collected materials. The presence of impurities in plastic waste can decrease the quality of recycled material, complicating its reuse in the production of new products. This not only affects the purity of the material, but also increases processing costs.

Problems of mixed plastics

Mixed plastics present a specific problem in recycling. These materials combine different types of plastics, making them difficult to separate during sorting. The high diversity of collections and the lack of uniformity in the properties make recycling unprofitable. This situation leads to many mixed plastics ending up in landfills, which aggravates environmental pollution.

Public awareness and education

Another significant challenge lies in the lack of awareness and education about plastic recycling. The public often does not fully understand the importance of depositing waste in the right containers, which has an impact on the effectiveness of recycling plants. A lack of information and understanding on how to properly separate plastics from other materials contributes to pollution in recycling streams.

Public education initiatives are vital to promote proper recycling practice. These campaigns can encourage citizens to be more responsible with their consumption habits and waste disposal. Implementing educational programs in schools and communities is essential to increase participation and improve recycling rates, thus generating a cultural change in plastics management.

Future of plastics recycling

The plastics recycling landscape is constantly evolving, driven by the need for sustainable development and a commitment to reducing environmental impact. The integration of new technologies and proactive regulations play an essential role in this transformation.

Technological innovations

Innovations in the recycling sector are gaining strength and are diverse. New technologies are emerging to make the recycling process more efficient and effective.

Improvements in material separation: Advanced technologies are facilitating the accurate separation of recyclable plastics from other materials, including composite plastics.
Chemical recycling: This process allows plastics to be broken down into their original components, offering the possibility of recreating high-quality plastics.
Automation: The introduction of automated systems reduces operating costs and increases efficiency in plants, allowing for more effective handling of large volumes of waste.

Policies and regulations in place

Public policies are critical to guiding plastic recycling towards a more sustainable future. The creation of specific regulations and their reinforcement are essential to ensure responsible practices.

Regulation of single-use plastics: With stricter guidelines on the use and production of disposable plastics, it seeks to incentivize reduction and facilitate recycling.
Extended producer responsibility initiatives: These initiatives force manufacturers to take responsibility for the life cycle of their products, including their recycling.
Recycling targets at the European level: The EU has set ambitious targets, such as reaching 70% recycling of plastic packaging by 2040, which promotes more active engagement in related industries.

Economic Impact of Plastics Recycling

Recycling plastics not only brings environmental benefits, but also has a significant economic impact. The transformation of waste into new products fosters the growth of the local economy and creates multiple job opportunities.

Job creation and economic opportunity

The plastics recycling sector generates a significant number of jobs. These jobs range from waste collection to processing and transformation into new raw materials. Key economic benefits include:

Direct jobs: Recycling plants require personnel to carry out various functions, from operating machinery to distribution logistics.
Indirect jobs: Opportunities are created in associated sectors, such as transport and waste management.
Boost to local companies: The demand for recycling services promotes the creation of small and medium-sized companies that offer complementary services.

Energy savings and emission reduction

Recycling plants contribute to a considerable reduction in energy consumption. The production of recycled plastics requires less energy than the production of virgin plastics, resulting in a positive impact on the environment.

Reduced energy costs: By recycling plastics, companies can reduce their energy costs, which improves their competitiveness.
Lower CO₂ emissions: By reducing the need to produce raw materials from fossil resources, the carbon footprint associated with the production process is reduced.

The combination of job creation and energy savings is helping to forge a more sustainable economy, where plastic waste management becomes a key opportunity for economic growth.

Are you interested in implementing sustainable solutions for plastics recycling? At Reverter Industries we design and supply plastic recycling plants equipped with advanced technology to maximize material recovery and optimize every stage of the process.