Due to growing environmental concern and decreasing resources the question of what we do with plastic at the end of its life is very important. Manufacturing products using waste plastic is not a simple task.
The two most significant stumbling blocks are material variability and the costs of identifying and separating waste plastics. Plastics are highly engineered products made to fit end use and manufacturing specifications, meaning that plastics with known properties and additives are the easiest to reuse. Technically you can seperate mixed plastics but commercially it is currently only economically feasible for high value plastics (eg PET or HDPE used in bottles). Many manufacturers will only use a small amount of well sorted recycled plastic due to the reduction of quality and properties.
However there are applications being developed to utilize lower grade mixed plastics:
Powder Impression Moulding (PIM): A process where low value and even highly diverse plastic blends can potentially be used to create a range of moulded items. This process is now being successfully used in the production of hoarding panels by the UK’s 2K Manufacturing.
Encapsulation: Using the recycled plastic as a “former” which is then encapsulated by a thin layer of higher value plastic. This enables the product to have the appearance and much of the performance of the higher value encapsulated plastic.
Fibre Plastic Composites (FPC): Have experienced significant growth since the early 1990’s in the US and have been successfully developed for niche applications in Europe. Composites can contain a wide range of both plastics fibres from high value PET with carbon nano-tubes to low value wood and other waste cellulosic fibres combined with mixed polyolefins. - CAn be used for low tech outdoor applications such as decking and fencing
Examples taken from manufacturing company Impact Solutions: www.impact-solutions.co.uk .
Article: http://www.bpf.co.uk/Sustainable_Manufacturing/Recycling/Reuse_and_Applications_for_Mixed_Plastic_Waste.aspx
100% recycled plastics are used for such applications as outdoor benches, bollards and fencing. For examples see http://www.britishrecycledplastic.co.uk/ and http://www.centriforce.com/
It is a tough, durable, maintenance free alternative to timber, offering a life span many times that of wood without the need for treatment. This means whole life costs are significantly reduced as maintenance and replacement costs are removed. Therefore as well as being environmentally friendly (made from 100% recycled post-industrial plastic, diverted from landfill) recycled plastic lumber offers significant commercial and technical benefits over traditional solutions.
Designed to replace traditional construction materials, recycled plastic (RCP’s) are impervious to water and allow for the easy and quick construction of fences, revetments, boardwalks, steps and pontoons, to name but a few applications, and is the ideal material for areas subject to flooding or standing water
One example of a 100% recycled product is from a British manufacturer. The company have become the worlds first company to develop cups, plates and tableware from 100% recycled plastic. Their product is food safe, rigid and made form recycled plastic bottles (PET), lids and milk cartons (HDPE). Up to now, manufacturers have used a blend of new, or 'virgin polymers’, with recycled polymers, to create injection moulded tablewear and toys.
For more information on this plus others like it please see the BBC article: http://www.bbc.co.uk/news/magazine-23230134
Wasted plastic products can also be re-used and rebuilt to provide other functions. One great example is plastic bottles being adapted to become a light source.
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