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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.
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.
 "Circular economy and sustainability in the plastics industry | ENGEL")
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.
- Recycling package enables regrind processing
- Consistently high product quality despite recycled material
- Free material analysis and safe processing
- No odors, streaks or residual moisture in the component thanks to degassing
- More safety thanks to filtration of the melt
- Digitization for increased energy efficiency
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.
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.
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.
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.
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.
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 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.
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.
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.
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.
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.
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.
 "Circular Economy portfolio | ENGEL")
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.
 "Gerhard Dimmler | ENGEL")
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.
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.
 "Klaus Fellner | ENGEL")
Our experts are happy to share their expertise on Circular Economy and plastics recycling.
![Picture shows ENGEL's Ecovadis Platinum status]( "Ecovadis Platinum status I ENGEL")
Pioneer sustainable moldingMay 6, 2024Recycling is no longer an option but a necessity for plastics processors who want to thrive in the future. The plastics industry faces increasing pressure to provide sustainable solutions that are environmentally friendly and economically viable.
![Image shows injection molding system for two-stage process]( "Injection molding system for two-stage process and recyclate processing | ENGEL")
Customer AVK uses two-stage process by ENGEL to increase efficiencyENGEL's two-stage process means that a complete process step can be saved when processing plastic flakes, because the recyclate is molded without granulation.
![Picture shows injection molding machine for recyclate processing]( "Injection molding machine for recyclate processing | ENGEL")
High recycling quality processing plastic flakesJune 22, 2022With a new process, ENGEL makes it possible to injection mold plastic waste in the form of flakes directly after grinding.
![Picture shows component made from recyclate]( "Component made of recyclate | ENGEL")
Processing rPET in thin-wall injection moldingJune 17, 2022At K 2022, ENGEL and partners ALPLA Group, Brink and IPB Printing will present a quantum leap for the packaging industry.
![Picture shows CTO of ENGEL]( "CTO Gerhard Dimmler | ENGEL")
CO2 footprint: an opportunity for the plastics industryJune 15, 2022Rising energy and raw material prices are presenting plastics processors with new challenges.
![Picture shows regrind of the two-stage process from ENGEL]( "Plastics recycling two-stage process | ENGEL")
CO2 savings through plastics recycling processMay 10, 2022New two-stage plastics recycling process reduces CO2 footprint by eliminating the regranulation step.
![Picture shows the removal of a transport box injection molded 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 molding processApril 7, 2021With skinmelt, it is possible to produce a component with up to 50% recycled core and high surface quality.
![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 moldingMarch 24, 2021What are the types, functionalities and applications of sandwich injection molding? Find out in the blog post.
 "Ecovadis Platinum status I ENGEL")
 "Injection molding system for two-stage process and recyclate processing | ENGEL")
 "Injection molding machine for recyclate processing | ENGEL")
 "Component made of recyclate | ENGEL")
 "CTO Gerhard Dimmler | ENGEL")
 "Plastics recycling two-stage process | ENGEL")
 "Processing of plastic recyclates in the logistics industry | ENGEL")
 "Box made with sandwich process | ENGEL")
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