Recycling of Plastic Waste and Upcycling Process

Monomex develops advanced process solutions not only for recycling plastic waste, but also for transforming recycled materials into higher-performance and higher-value plastic compounds. In-house production waste, post-consumer plastics, film scraps, edge trims, fiber waste, regrind materials and low-cost recycling feedstocks can be converted into customized plastic granules with the right process design.

In conventional plastic recycling processes, quality fluctuations, reduced mechanical performance, color variation, moisture, gas formation, filtration requirements and raw material inconsistency are common challenges. Monomex addresses these challenges with an advanced upcycling approach that combines recycling and compounding in one integrated process.

More Than Recycling: Upcycling

The main objective of plastic waste recovery is not only to convert waste into granules. The real value comes from improving the properties of recycled material and making it suitable for a wider range of applications.

Monomex process technology enables recycled feedstock to be filtered, degassed, homogenized and then compounded with additives, fillers, reinforcing agents and performance-enhancing components. As a result, low-cost recycled materials can be transformed into higher-quality, more stable and commercially valuable plastic compounds.

This approach enables manufacturers to:

• Reduce raw material costs

• Improve the performance of recycled plastics

• Achieve more stable product quality

• Expand application possibilities

• Support sustainable production targets

Recycling and Compounding in One Process

Monomex places compounding capability at the center of the plastic waste recycling process. Filtered and degassed melt from the recycling stage can be fed directly into the MEX twin screw extruder. At this stage, the material is reformulated with additives, fillers, pigments, stabilizers, reinforcing agents and special performance components.

This transforms plastic waste from a simple recycled material into a customized, processable and higher-value plastic compound tailored to the customer’s application requirements.

Plastic Waste Materials That Can Be Processed

Monomex recycling and compounding systems can be configured for different types of plastic waste and recycled feedstocks.

Typical applications include:

• PE film waste

• PP nonwoven waste

• PE / PP edge trims

• PA fiber waste

• Regrind plastic materials

• Industrial production scrap

• Post-consumer plastic waste

• Low-cost recycled feedstocks

• Recycled raw materials with variable quality

The line configuration is customized according to material form, moisture level, contamination level, MFI value, filler content and target end product.

Tandem Recycling and Compounding System

The Monomex tandem process system combines recycling and compounding in a controlled process chain. In the first stage, plastic waste is melted, filtered and degassed to remove volatile components. The melt is then transferred to the MEX twin screw extruder, where it is reformulated with additives and performance-enhancing components.

This system is especially suitable for manufacturers that require high throughput, stable product quality and high process flexibility.

Value-Added Recycling with MEX Twin Screw Extruder

Monomex MEX twin screw extruders provide high mixing efficiency, effective dispersion and precise process control for compounding recycled plastics. Screw configuration, feeding points, vacuum zones, temperature profile and torque capacity are optimized according to the recycled material and target product requirements.

With the MEX twin screw extruder system, the following components can be accurately incorporated into the process:

• Fillers

• Pigments

• Stabilizers

• UV additives

• Impact modifiers

• Flow modifiers

• Fiber and mineral reinforcements

• Flame retardants

• Special performance additives

This makes it possible to use recycled plastics in higher-value and more demanding applications.

Flexible Process Configurations

Monomex provides flexible system solutions for different recycling feedstocks and process requirements.

Typical system alternatives include:

• Single screw extruder + twin screw extruder tandem system

• Recycling extruder + MEX twin screw compounding system

• Melting, filtration and degassing system

• Direct melt-fed compounding line

• Gravimetric dosing of additives and fillers

• Water-ring, strand or underwater pelletizing

• On-spec and off-spec material separation

• Automation and recipe management

This flexibility allows manufacturers to process different material types, formulations and final product requirements on the same production platform.

Energy Efficiency and Production Cost Advantage

In plastic recycling processes, energy consumption is one of the key factors affecting production cost. Monomex considers energy efficiency, mechanical durability and continuous production reliability together in the process design.

With optimized screw and barrel design, high-efficiency motor and gearbox systems, accurate heating and cooling control, and process engineering know-how, Monomex systems are designed to reduce specific energy consumption.

Monomex recycling and compounding systems offer manufacturers:

• Lower specific energy consumption

• Lower production cost

• Higher raw material utilization efficiency

• Reduced thermal stress

• More stable product quality

• Shorter process time

• Higher-value recycled plastic compounds

Sustainable and Profitable Plastic Recycling

Plastic waste recycling is not only an environmental responsibility, but also a strong economic opportunity. With the right process technology, low-cost plastic waste can be converted into reusable raw materials for automotive, packaging, construction, white goods, pipe, sheet, profile, film and technical plastic applications.

Monomex brings sustainability and profitability together in plastic recycling processes. The goal is to reduce waste, lower carbon footprint, decrease dependency on virgin raw materials and create higher commercial value from recycled plastics.

Turn Plastic Waste into Value with Monomex

Monomex offers engineering-driven process solutions for recycling, upcycling and compounding plastic waste. Material characteristics, target product, throughput, additive system, filtration requirements, degassing performance and pelletizing method are evaluated together to design the most suitable production line.

Contact the Monomex engineering team to convert low-cost recycled feedstocks into high-quality plastic granules, modernize your existing recycling line or build a new tandem recycling-compounding system.