Learn how our processes help work toward closing the production loop and building a more sustainable future from the waste of today.
With a holistic waste management infrastructure and pioneering polymer production processes, PreZero offers a true alternative to virgin raw materials by ensuring a stable supply of high-quality recyclate that meets customers’ specific needs.
Polymer manufacturing process at PreZero
Discover how recycled polymer is made at PreZero:
Waste material
The road to closing loops begins where the linear economy finishes: The end of the product life cycle.
First, a constant supply of post-consumer and post-industrial plastic waste is collected and sorted using PreZero’s varied fleet of specialized collection vehicles. It is then transported to one of our locally positioned recycling plants across Europe – a vital step in closing the material loop.
Shredding
Once delivered, end-user plastics go through our in-house polymer production process to become a sustainable recycled material.
First, the bales of pre-selected material are ground, and any ferrous contaminants or dust are removed. This allows us to process a wide variety of plastic types and products into premium recyclate.
Washing
Next, raw plastic is washed in a floatation tank where the material is further purified from contamination.
Our sophisticated density system also separates any non-recyclable plastics from the intended yield. This is how we guarantee a pure and clean starting material for the polymer recycling process and a flawless end product.
Sorting & drying
The material is then sorted and dried via a mechanical or thermal system, ready for the extrusion process. This final step in the initial preparation results in single variety clean raw material – the foundation for a high-quality end product.
Extrusion and decontamination
Our powerful extruders then melt and compress the waste material into a range of polymer recyclates.
Almost all of our recyclate is developed individually according to precise customer specifications. Hardness, elasticity, color, chemical resistance, and more can all be tailored during the polymers production process. Decontamination is the last part of the process, which reduces any volatile emission.
Final product
Throughout the entire polymer manufacturing process, our laboratory experts carefully test and monitor production to ensure rapid market readiness and a consistent high-quality of our recycled polymer plastic.
The result is customized plastic granules ready for the secondary raw material market – a viable alternative to virgin material procurement.
Types of recyclate
PreZero offers a range of polymer production methods to guarantee rapid availability, in significant quantities and to the highest standards, whatever polymer type you require. We currently offer:
Skyfil – Mineral-filled homopolymers and copolymer polypropylene
Skystyr – Impact-resistant polystyrene
Skytene – Low and high-density polyethylene
Skyplen – Homopolymer and copolymer polypropylene
Lab instruments & technologies
There are many machines and technologies used in the polymer production process at PreZero.
| Injection molding machine | To mold the material base on reference norm for proper quality control |
| Blow molding machine for film and bottles (for HDPE) | To blow the material making bottles or film to simulate the customer process |
| Cast line (for LDPE) | We have this instrument to make the film and make an optical control |
| Lab extruder | Small extruder to make the customer samples and develop new products simulating the industrial extruder condition |
| Spectrophotometer | For color inspection |
| MFR | To check the fluidity of material |
| Dynamometer | To check the mechanical characteristic as tensile/flexular modulus |
| Oven | To check ash content |
| DSC | To check the polymeric part and eventually the contamination |
| Impactometer | To check impact resistance |
| Water control instruments | To check the status of water from water treatment |
| Flakes Scan | To check the flakes in term of color and polymer |
| Vicat | To check some mechanical characteristic in hot environment |
Bales sorting | To sort and select the material based on color and polymer before shredding and washing |
| Hot washing line (for HDPE) | Can be used at different temperatures (35°C – 85°C – 25°C) in 5 different water tanks |
| Flakes sorter | To sort the flakes based on polymer and color after washing |
| PCU (pre-conditioning unit) | To remove humidity and odor before extrusion |
| Tandem | Twin-screw and single-screw extruders |
| Colorimeter | Extruder attachment to check the color |
| Refresher | To further remove the odor |
How can PreZero polymer production help your business?
Build a sustainable polymer supply chain with PreZero.
From guiding you through the process of how our polymers are manufactured to tailoring the material precisely to the needs of your business, our experts are here to help. We also support you when it comes to the legal obligations of using PCR material and can proudly guide you on your journey to becoming Zero Waste certified.
Secure your sustainable supply chain with PreZero Polymers
No matter the type of plastic or quantity that you need, our polymers production infrastructure can deliver the highest quality and most readily available alternative to virgin materials. Contact us today to see how we can contribute to your company’s success.