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Image shows Circular Economy at ENGEL

Circular Economy in injection molding

Reduction of the CO2 footprint through efficient plastics recycling

ENGEL has been active in the area of Circular Economy for years. By processing recyclates, it is possible to reduce CO2 emissions and produce more sustainably. Our services range from free material analyses and digital products to innovative plastic recycling processes.

30% savings of CO2, energy and costs of plastics recycling

Plastic is a valuable resource. Far too valuable to dispose of it after a single use. That's why it is essential to keep it in the cycle.

A new energy-saving plastics cycle can be closed with ENGEL plastics recycling technologies.
Direct processing of regrind on the injection molding machine saves costs, energy and CO2. "Design for recycling" is also made possible. Our customers' products are returned to the cycle at the end of their service life.

Advantages of working together with us towards a Circular Economy
Recycling package enables regrind processing
Picture shows wear-resistant plasticising unit from ENGEL

Our recycling package enables trouble-free feeding with a modified plasticizing unit, even of poorly flowing materials such as regrind. The wear-resistant material design guarantees extended service lives. Thanks to the screw flights, optimized conveying and melting behavior is achieved.

Consistently high product quality despite recycled material
Picture shows cross-section of a box made of plastic recyclate

The processing of plastic waste usually requires less energy than that from fossil sources. The use of recyclate therefore has a direct positive effect on the CO2 balance sheet. This is why ENGEL's in-house development focuses on solutions for recycling and upcycling. ENGEL offers plastic recycling processes like skinmelt, co-injection and the two-stage process. In the first two processes, the recyclate is coated with virgin material. In the two-stage process, the regrind is processed directly and degassed and filtered in the injection molding process. As a result, up to 100% recycled material can be used as raw material.

Free material analysis and safe processing
Picture shows regrind for plastics recycling

As part of a free material analysis of the recyclate, we check the material’s processing capability on our machines in the laboratory. Later, our assistance systems ensure optimum process stability. Together with R-Cycle, we enable the traceability of the used materials in a digital product passport.

No odors, streaks or residual moisture in the component thanks to degassing
Picture shows bumper of a car

Volatile components of the material, such as gases or moisture, are eliminated with our integrated degassing process. Degassing enables a wider range of recyclate applications, delivers component quality without streaks, and decreases residue buildup in the mold. Odor is reduced enormously. Especially with painted components, beautiful surfaces are achieved thanks to degassing.

More safety thanks to filtration of the melt
Image shows possible contamination such as paper, metal or wood

Filter systems reliably remove contaminations of the recyclate. Depending on the design, they protect the plasticizing unit, hot runner and mold. Suitable filter systems are offered for different degrees of contamination. This prevents clogging of the mold, hot runner and sprue channels by unwanted particles.

Digitization for increased energy efficiency
Image shows digital solutions by ENGEL

The self-optimizing injection molding machine is a key driver of Circular Economy. The aim is to avoid scrap and increase energy efficiency. Digital solutions from our inject 4.0 program help compensate for changes in material quality or other factors that influence the process. This also means that recyclates can be used for a broader range of applications than before.

Our solutions for recyclates processing

For more success of your circular business model

Let’s close material cycles together. ENGEL’s broad portfolio includes 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 solutions help fulfill required recycling rates and design for recycling.

Picture shows CTO at ENGEL Austria

Circular Economy involves all market participants. 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 optimization of energy consumption, CO2 balance and costs. The plastics industry must act quickly and take advantage of the opportunities opened up by innovative technologies.

Gerhard Dimmler, CTO at ENGEL Austria
Innovative projects in the area of Circular Economy

Direct processing of regrind using a two-stage process. 100% recyclable e-bike frames, Frisbees made from old collected caps, and transport boxes that are made of over 50% recycled material inside: We develop Circular Economy solutions for and together with our customers that also prove themselves in practice.

    • technical molding
    Closed recycling cycle in injection molding

    In the two-stage plastic recycling process, dolly pallets are produced from recycled plastic flakes. Plastic waste is processed as flakes directly after grinding.

    • technical molding
    100% recyclable e-bike frame

    The first completely injection-molded bicycle frame with advanced thermoplastic composites is 100% recyclable.

    • technical molding
    Transport boxes with recycled core material

    With ENGEL skinmelt technology, up to 50% recycled material can be used in the core of this transport box.

    • technical molding
    Frisbees from recycled beverage caps

    Beverage caps collected at the JKU Linz campus were recycled and processed into Frisbees to demonstrate Circular Economy with a simple example.

Picture shows team leader Circular Economy at ENGEL Austria
How can we help you?

Our experts are happy to share their expertise on Circular Economy and plastics recycling.

Image shows injection molding system for two-stage process
Customer AVK uses two-stage process by ENGEL to increase efficiency

ENGEL's two-stage process means that a complete process step can be saved when processing plastic flakes, because the recyclate is molded without granulation. The company AVK Plastics BV uses this technology to produce new pallets from recycled material. This technical innovation increases production efficiency and saves valuable energy.

More about Circular Economy at ENGEL
Solutions for circular economy

Image shows energy efficiency subject from ENGEL

Reduced CO2 footprint

Fully utilize energy-saving potential: reduce your energy consumption by up to 67% with an efficient production system.

Picture shows recycled material

Injection molding process for recycled materials

More safety and consistently high product quality despite recycled material.

Image shows recycling package from ENGEL

Recycling package

Consistent direct processing and optimized conveying and melting behavior of recyclates thanks to modified plasticizing unit.

Markus Lettau

Molding Industry Business Advisor

+1 (717) 767 2016

Write us

The ENGEL team is happy to support you with extensive knowledge in the field of injection molding.

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