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How can you recycle injection molding materials?

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Injection molding is a common and versatile manufacturing process that involves injecting molten plastic into a mold cavity to create a desired shape. However, it also generates a lot of waste, such as sprues, runners, gates, flash, and defective parts. These materials can be recycled and reused in various ways, depending on their type, quality, and condition. In this article, you will learn how to recycle injection molding materials and what benefits it can bring to your business and the environment.

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1 Identify the material type

The first step to recycle injection molding materials is to identify the type of plastic you are working with. Different plastics have different properties, melting points, and compatibility, so you need to separate them accordingly. You can use various methods to identify the material type, such as labels, codes, markings, density tests, burn tests, or infrared spectroscopy. You should also check the additives, fillers, colorants, or reinforcements that may affect the recycling process.

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Henning Dahl Nielsen

Innovative hygienic design for food processing and packaging systems, Certified machine leveling feet and waterproof bearings units, Sustainable development, Responsible growth, Strategy development and execution.
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Recycling injection molding materials involves several key steps. Initially, segregate scrap by material type to maintain purity. Grind the segregated scrap into uniform pellets or flakes using a granulator or shredder. This recycled material can then be reintroduced into the production process, often mixed with virgin material to ensure the final product meets quality standards. It's important to conduct quality control tests to assess the properties of the recycled material, ensuring it meets the necessary specifications. Implementing a closed-loop system within the manufacturing process minimizes waste and optimizes material use, contributing to sustainability and cost efficiency.

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2 Clean and sort the materials

The next step is to clean and sort the materials to remove any dirt, dust, metal, or other contaminants that may interfere with the recycling process. You can use manual or mechanical methods to clean the materials, such as washing, drying, shredding, or granulating. You should also sort the materials by color, size, shape, and quality, and store them in separate containers or bags. This will help you optimize the recycling process and reduce the waste.

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Suhas Dixit

Inventor in Pyrolysis & PyOil Purification | CEO of APChemi | Transforming waste into opportunity and value, for people and planet.
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By the end of the sorting process, you will arrive at the following Types of End-products and their respective Application: 1) Type: plastic fraction that's mechanically recyclable via compression moulding; Application: make granules for compression moulding via extrusion 2) Type: plastic fraction that's not-recyclable via compression moulding; Application: identify the mechanical/chemical recycling method that can work.

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Rick Demko

Director of Recycling and Sustainability at PolyFlex Products / Nefab Group. Leading by example, fostering a positive culture and adhering to principles of continuous improvement.
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The most important step in any type of recycling is proper identification. Once you know what you're working with, it comes down to decontaminate / disassemble, sort, grind, test properties if need be and then re-use accordingly. As soon as you confirm that you're working with a "thermo plastic" and not a "thermo set", the road is pretty simple.

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3 Choose the recycling method

Recycling injection molding materials can be done in three main ways: regrind, reprocess, or sell. Each method has its own advantages and disadvantages, and the best choice depends on your needs, resources, and goals. Regrind involves grinding the materials into small flakes or pellets that can be fed back into the injection molding machine. This is the simplest and most cost-effective option, but it may affect the quality, strength, and appearance of the final product. You should only regrind the same type and color of materials, and use them in a limited proportion with virgin materials. Reprocessing involves melting the materials and extruding them into new pellets that can be used for injection molding or other applications. This is a more complex and expensive method, yet it can improve the quality, consistency, and versatility of the recycled materials. You can also mix different types and colors of materials, as well as add additives or modifiers to enhance their properties. The third option is to sell the materials to a third-party recycler or buyer who can regrind or reprocess them for their own use. This is a convenient and profitable method; however, it requires finding a reliable and trustworthy partner who can offer you a fair price and handle the materials properly.

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4 Evaluate the benefits

The final step is to evaluate the benefits of recycling injection molding materials for your business and the environment. Recycling can help you reduce your material costs, save energy, improve your efficiency, and enhance your reputation. It can also help you reduce your environmental impact, conserve natural resources, prevent pollution, and comply with regulations. You can measure the benefits by using indicators such as material savings, energy savings, waste reduction, carbon footprint, and customer satisfaction.

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Rangarajan raghavachari

Work is its own reward
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Injection Molded items are easy to recycle by mechanical recycling after sorting and cleaning because they are generally heavy and sought after by rag pickers. They can be recycled back to many application similar to prime virgin materials.In the process of recycling some reduction of mechanical properties which can br brought back by adding certain additives. However, if they are contaminated, then the best way is to recycle back to original starting raw materials like pyrolysis oil by chemical recycling. Both technologies are now well established in commercial scale operations

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5 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How can you recycle injection molding materials?

1

2

3

4

5

1 Identify the material type

2 Clean and sort the materials

3 Choose the recycling method

4 Evaluate the benefits

5 Here’s what else to consider

Manufacturing

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How can you recycle injection molding materials?

1

2

3

4

5

1 Identify the material type

2 Clean and sort the materials

3 Choose the recycling method

4 Evaluate the benefits

5 Here’s what else to consider

Manufacturing

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