The waste LDPE film collected by Jayplas from Leadec’s operation at Halewood in Liverpool has been recycled and manufactured at Jayplas’ UK facilities to produce plastic sacks with 100% recycled content for internal use at the Leadec’s operations in Halewood.
12 months ago, the parties reached a decision on the specifications for the types of film to be recycled and the end product. This was followed by trials of the collection and recycling of the film waste and supply of finished plastic sack.
The Leadec team were responsible for completing a pre-sort by hand of the agreed film waste which was then transported to Japylas’ fully automated flexible plastic segregation facility in Smethwick in Birmingham.
The Smethwick facility used its Optical Near-Infrared (NIR) sorting system to sort the incoming bales for a second time by polymer type and colour. The bales were then transferred to the Jayplas washing and pelletising facility in Loughborough.
The PCR pellets produced in the Loughborough facility were then transferred to Jayplas’ Flexible Packaging Division at Worksop in Nottinghamshire, where the sacks were blown and converted to the agreed specification.
The 100% PCR finished sacks were then supplied back to Halewood which uses approximately 250,000 sacks annually. This equates to roughly 32.5 tonnes of film waste being kept in the supply chain.
A spokesperson for Jayplas said that the project was an “outstanding example of collaboration, which has showcased the benefits of creating synergies between the respective companies”.
They added: “It shows how it is possible to close the loop, keeping the cycle of material within the UK. We are delighted to supply Leadec’s Halewood operations with our service.”
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