At Sinclair & Rush, we are continuously striving to enhance sustainability by increasing the use of regrind materials in our products. Our latest trials focus on making as many items as possible from 100% regrind plastic, ensuring both efficiency and environmental responsibility.
Optimising Regrind for Small Parts Production
One of our key targets for regrind usage is nut caps, specifically M10 and M12 sizes, along with other small inserts. These parts are ideal for incorporating 100% regrind material, as they do not require specific colour consistency. By adjusting machine settings and production parameters, we have successfully manufactured nut caps using 100% regrind LDPE (Low-Density Polyethylene).
Challenges and Adjustments
While regrind material performs well in many applications, there are some differences compared to virgin plastic. For example, nut caps made with 100% regrind are slightly softer and may lose a small amount of structural integrity. However, our trials indicate that the differences are minimal and do not affect the function of the product.
To ensure high-quality production, our process involves:
- Feeding regrind material directly into the loader machine.
- Adjusting machine settings for optimal melting and flow.
- Conducting multiple trials on different parts to assess strength and consistency.
Global Insights and Industry Comparisons
Earlier this year, our Managing Director Mark visited manufacturers in Italy, where it was confirmed that some companies already use 100% recycled material in their machines. This aligns with our sustainability goals and reassures us that our trials are on the right path.
So far, we have conducted three different trials on three different parts, including nut caps and small inserts—each yielding positive results. These efforts help reduce waste and enhance our contribution to the circular economy.
Along with these trials, Sinclair & Rush partner with Horizion Polymers, a plastics brokerage, in a nutshell we sell our scrap to them, they grind it and sell it on to manufacturers making items such as Hazmat Boots and playground surfaces!
The Role of Regrind and Processing Techniques
Regrind plastic typically comes from scrap material, such as sprues, which need to be finely ground before being reintroduced into the production process. The key challenge is ensuring that the regrind melts properly within the barrels, preventing blockages and maintaining smooth flow. To achieve this, the plastic must be ground into pellets of the correct size.
Paul Witcher Production Manager at Sinclair and Rush commented:
“We’ve been trialling regrind materials for years. While some applications require further refinement, these trials prove that for small parts like nut caps, 100% regrind is a viable and sustainable solution.”
Next Steps in Our Sustainability Commitment
Our current focus is on black-coloured parts, as colour uniformity is less critical in these applications. By continuing to refine our processes and expand our regrind usage, we aim to manufacture more of our products using 100% recycled materials without compromising performance.
We are proud of our progress and will keep testing and innovating to reduce our environmental footprint. Stay tuned for more updates on our sustainability journey!
