At Sinclair & Rush, sustainability is not just a goal—it’s how we do business. As plastic manufacturers, we continuously develop processes to minimise waste, reuse materials, and operate as efficiently as possible. Our commitment is demonstrated through strategic partnerships with companies like Best Energy and Horizon Polymers, our pursuit of B Corp certification, and the innovative systems we’ve implemented in our factories.
This article highlights the sustainability measures we’ve adopted at our Rochester and Maidstone factories, focusing on plastic recycling and water conservation. These initiatives showcase our dedication to reducing environmental impact while maintaining high-quality manufacturing standards.
Recycling LDPE Waste for 100% Recycled Nut Caps and Inserts
When producing black nut caps and tube inserts using our injection moulding machine, waste is inevitably generated. This waste, often in the form of sprue-like material, is collected and processed in our LDPE grinding machine. The result? Recycled LDPE flakes that are reused to manufacture new inserts and caps—closing the loop on waste. Additionally, surplus material is supplied to Horizon Polymers, contributing to a wider circular economy.
PETG Recycling System
Our PETG recycling system ensures that production waste is efficiently repurposed. Waste materials are sorted into two categories: tough sprue-like waste from caps and more flexible tube waste. Each type has its own dedicated grinding machine to prevent contamination and maintain material quality.
Once ground into flakes, the material enters our pelletiser, where it is heated, extruded into string-like material, cooled, and cut into PETG pellets. These pellets are then blended—30% recycled PETG with 70% virgin PETG—and used in our extrusion machine to create our PETG Clear Visipak Tubes. Thanks to this process, our tubes are exempt from the Plastic Packaging Tax, reinforcing our commitment to sustainable packaging.
We take recycling even further by reusing the original virgin material bins to store our recycled flakes, reducing unnecessary waste at every step.
Sustainability in Action: Our Closed-Loop Water Recycling System
Sustainability extends beyond plastic at Sinclair & Rush. At our Maidstone factory, we have implemented a Closed-Loop Water Recycling System to enhance resource efficiency. This system is crucial for cooling parts quickly after production—essential for maintaining product integrity as they emerge from machines at temperatures of 250-350°C.
The Sustainability Benefits
Without a closed-loop system, we would need to use vast amounts of fresh water for cooling. Instead, our system recycles approximately 95% of the water used, with only 5% lost to evaporation.
To ensure system efficiency:
✅ The water tank is occasionally topped up to compensate for evaporated water.
✅ Every six months, the tank is drained and refreshed to prevent contamination from silicone build-up.
By investing in this sustainable solution, we significantly reduce water waste, lower environmental impact, and enhance responsible manufacturing.
Our Commitment to a Greener Future
As part of our B Corp journey, we continue to develop and share sustainable practices that benefit both our business and the environment. To provide further insight into our processes, we’ve created detailed vlogs explaining our PETG and LDPE Recycling Systems at Rochester and our Closed-Loop Water Recycling System at Maidstone.
♻️ Watch our explainer videos to see sustainability in action. You can also see some supporting images of this process by scrolling through the image carousel!
