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Circular Economy in injection moulding
Reduction of the CO2 footprint through efficient plastics recycling
ENGEL has been active in the area of the Circular Economy for years.
By processing recycled materials, it is possible to reduce CO2 emissions and produce more sustainably. Our services range from free material analyses to digital products and innovative plastic recycling processes.
Plastic is a valuable resource. Far too valuable to dispose of after a single use. Therefore, it is important to manage it in cycles.
 "Circular economy and sustainability in the plastics industry | ENGEL")
With ENGEL plastics recycling technologies, a new energy-saving plastics cycle can be closed. Direct processing of regrind on the injection moulding machine saves costs, energy and CO2.
"Design for recycling" is also made possible. At the end of their service life, our customers' products are returned to the cycle.
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Recycling package enables regrind processing
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Consistently high product quality despite recycled material
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Free material analysis and process-safe processing
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No odours, streaks or moisture residues in the component thanks to degassing
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More safety thanks to filtration of the melt
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Digitalisation to increase energy efficiency
Our recycling package enables trouble-free feeding, even of poorly flowing materials such as regrind, by means of modified plasticisation. The wear-resistant material design guarantees extended service life. Thanks to the feed grooves, optimised conveying and melting behaviour is achieved.
The processing of plastic waste usually requires less energy than that from fossil sources. The use of recycled material therefore has a direct positive effect on the CO2 balance. This is why ENGEL's in-house development focuses on solutions for recycling and upcycling. ENGEL offers the plastic recycling processes skinmelt, co-injection and the two-step process. In the first two processes, the recyclate is coated with virgin material. In the latter, the regrind is processed directly and degassed and filtered in the injection moulding process. This means that up to 100% recycled material can be used as feedstock.
As part of a free material analysis of the recyclate, we check the process-safe processability on our machines for you in the laboratory. Later, our assistance systems ensure the greatest possible process stability. Together with R-Cycle, we enable the traceability of the materials used in a digital product passport.
Volatile components in the material such as gases or moisture are eliminated with our integrated degassing. Degassing enables a wider range of recyclates to be used, component quality without streaks and less tool build-up. Odour pollution is reduced enormously. Especially with lacquered components, you achieve beautiful surfaces thanks to degassing.
Filter systems reliably remove contaminants from the recyclate. Depending on the design, they protect plasticising, hot runner and mould. Suitable filter systems are offered for different degrees of contamination. This prevents clogging of the mould, hot runner and sprue channels by foreign parts.
The self-optimising injection moulding machine is a key driver of Circular Economy. It is about avoiding rejects and increasing energy efficiency. Our digital solutions from the inject 4.0 programme help to automatically reduce influences on the process. Recyclates can thus be used for a wider range of applications than before.
Our recycling package enables trouble-free feeding, even of poorly flowing materials such as regrind, by means of modified plasticisation. The wear-resistant material design guarantees extended service life. Thanks to the feed grooves, optimised conveying and melting behaviour is achieved.
The processing of plastic waste usually requires less energy than that from fossil sources. The use of recycled material therefore has a direct positive effect on the CO2 balance. This is why ENGEL's in-house development focuses on solutions for recycling and upcycling. ENGEL offers the plastic recycling processes skinmelt, co-injection and the two-step process. In the first two processes, the recyclate is coated with virgin material. In the latter, the regrind is processed directly and degassed and filtered in the injection moulding process. This means that up to 100% recycled material can be used as feedstock.
As part of a free material analysis of the recyclate, we check the process-safe processability on our machines for you in the laboratory. Later, our assistance systems ensure the greatest possible process stability. Together with R-Cycle, we enable the traceability of the materials used in a digital product passport.
Volatile components in the material such as gases or moisture are eliminated with our integrated degassing. Degassing enables a wider range of recyclates to be used, component quality without streaks and less tool build-up. Odour pollution is reduced enormously. Especially with lacquered components, you achieve beautiful surfaces thanks to degassing.
Filter systems reliably remove contaminants from the recyclate. Depending on the design, they protect plasticising, hot runner and mould. Suitable filter systems are offered for different degrees of contamination. This prevents clogging of the mould, hot runner and sprue channels by foreign parts.
The self-optimising injection moulding machine is a key driver of Circular Economy. It is about avoiding rejects and increasing energy efficiency. Our digital solutions from the inject 4.0 programme help to automatically reduce influences on the process. Recyclates can thus be used for a wider range of applications than before.
 "Circular Economy Portfolio | ENGEL")
For more success of your circular business model
With our broad portfolio, we close material cycles together: ENGEL supports you with production cells to process recycled materials. Our offer ranges from free material analyses and digital products to innovative plastic recycling processes. With the recycling package or the two-stage process, regrind can be processed more easily, safely and consistently. Our processes support the required recycling rates and design for recycling.
 "Gerhard Dimmler | ENGEL")
Circular Economy is based on the interplay of all market participants. In order for the process chain to function seamlessly, it is important that each individual step within the overall process is economical. At this point the circle closes to the optimisation of energy consumption, CO2 balance and thus the cost structure. The plastics industry must act quickly and take advantage of the opportunities opened up by innovative technologies.
Direct processing of regrind using a two-step process, 100% recyclable e-bike frames, Frisbees made from old collected caps and transport boxes that consist of over 50% recycled material inside: We develop Circular Economy solutions for and with our customers that also prove themselves in practice.
 "Klaus Fellner | ENGEL")
Our experts will be happy to provide you with comprehensive know-how on the topic of Circular Economy and plastics recycling.
ENGEL's two-stage process means that a complete process step can be saved when processing plastic flakes, because the recyclate is processed in the injection moulding process without granulation. The company AVK Plastics BV uses this technology to produce new pallets from recycled material. This technical innovation increases efficiency in production and saves valuable energy.
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![Picture shows injection moulding machine for recyclate processing]( "Injection moulding machine for recyclate processing | ENGEL")
High recycling quality directly from plastic flakesJune 22, 2022With a new process, ENGEL makes it possible to process plastic waste as flakes in injection moulding directly after grinding.
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![Picture shows component made from recyclate]( "Component made from recycled material | ENGEL")
Processing rPET in thin-wall injection mouldingJune 17, 2022At K 2022, ENGEL and its partners ALPLA Group, Brink and IPB Printing will present a quantum leap for the packaging industry.
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![Picture shows CTO of ENGEL]( "CTO Gerhard Dimmler | ENGEL")
CO2 footprint: an opportunity for the plastics industryJune 15, 2022Rising energy and raw material prices pose new challenges for plastics processors.
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![Picture shows regrind of the two-stage process from ENGEL]( "Plastics recycling process in two stages | ENGEL")
CO2 savings through plastics recycling processMay 10, 2022New two-stage plastics recycling process reduces the CO2 footprint by eliminating the regranulation step.
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![Picture shows the removal of a transport box injection moulded in the skinmelt process for the logistics industry, consisting of recyclate and virgin material.]( "Processing of plastic recyclates in the logistics industry | ENGEL")
Processing of recyclate by sandwich injection moulding processApril 7, 2021With skinmelt, it is possible to produce a component with up to 50% recycled core and very good surface quality.
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![Picture shows transport box with a core made of recyclate, manufactured by ENGEL]( "Box made with sandwich process | ENGEL")
Increasing the recyclate content in the component through sandwich injection mouldingMarch 24, 2021What are the types, functions and applications of sandwich injection moulding? Find out the answers in the blog post.
 "Injection moulding machine for recyclate processing | ENGEL")
 "Component made from recycled material | ENGEL")
 "CTO Gerhard Dimmler | ENGEL")
 "Plastics recycling process in two stages | ENGEL")
 "Processing of plastic recyclates in the logistics industry | ENGEL")
 "Box made with sandwich process | ENGEL")
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