Recycled plastics once had a reputation problem. Inconsistent batches, contamination, parts that warped or cracked because the feedstock couldn’t maintain the same properties as virgin material throughout moulding.

That reputation generally no longer reflects reality. Advances in sorting, cleaning, and compounding have brought post-consumer recycled (PCR) polymers to a level where they perform on par with virgin plastics in a growing number of applications.

Read on to find out where they work in the plastic injection moulding process, where they don’t, and what to consider before committing.

How Recycled Polymers Have Improved

A huge range of post-consumer and posit-industrial recycled plastics now arrive in pellet form, processed to tight specifications and ready for standard moulding equipment. Four developments have driven this:

  • Sorting technology now separates polymer types with far greater accuracy
  • Washing and decontamination strips out the residues that used to cause surface defects
  • Compounding with targeted additives restores or enhances mechanical performance
  • Suppliers have tightened their quality control to meet what moulders need

Many manufacturers run 25–50% recycled content with minimal modifications to their tooling or process settings.

Applications Suited to Recycled Content

The bottom line is that if the recycled grade meets the specifications for melt flow, impact resistance, and shrinkage, the machine produces broadly the same part regardless of where the pellets originated.

Products running successfully on recycled polymers include:

  • Housings and enclosures
  • Packaging components and closures
  • Non-structural automotive parts – clips, trims, covers
  • Storage containers and industrial components
  • Garden products and general consumer goods

Of course, a case-by-case evaluation is required to ensure performance, longevity, strength, and compliance.

Applications That Still Demand Virgin Material

Recycled content doesn’t suit every use case. Medical devices, some food-contact parts, safety-critical automotive components, and parts that require tight colour consistency all demand attention.

Here are some key risks:

  • Batch-to-batch variation in mechanical properties
  • Contamination affecting surface finish or structural integrity
  • Weaker UV resistance compared to virgin equivalents
  • Narrower colour range, particularly for lighter shades

None of those simply removes recycled plastics from consideration, but they do mean material selection needs proper technical input.

If a recycled grade meets spec, it runs. If it doesn’t, we recommend an alternative that does.

How BEC Group Can Help

We run plastic injection moulding across a broad range of materials. Our in-house toolroom and engineering team enable us to test, adjust, and validate recycled plastics as you require.

If you’re weighing up recycled content for an existing product or a new project, we can advise on suitable grades and run trials before you commit.

Contact our team to discuss your project.

Frequently Asked Questions

Does recycled plastic affect part quality?

Not if the grade meets your specification. Recycled polymers now deliver mechanical properties close to those of virgin polymers across many applications. Selecting the correct grade and testing it before production is the critical step.

What percentage of recycled content can I use?

It depends on the part. Many manufacturers run 25–50% PCR as standard. In some cases, 100% recycled feedstock works perfectly well. The upper limit depends on performance requirements.

Can recycled plastics be used in food-contact products?

Some recycled grades carry food-contact certification, particularly recycled PET. Regulatory requirements are strict, and not all recycled materials qualify. We can advise on compliant options.

Is recycled plastic cheaper?

Often, though not always. Pricing depends on polymer type, processing level, and market conditions. The cost advantage tends to be greatest with commodity polymers such as polypropylene and polyethene.

Do I need different tooling?

Typically not. Recycled polymers with melt flow and shrinkage comparable to those of their virgin equivalents can run in existing tools without modification.