It May Be Recycled, But Not What You Think

ABOVE PHOTO: Inspection checks are essential to confirm the right amount of high-quality scrap is incorporated in the manufacturing process and the acrylic meets clarity and sheet specifications.

THE FIRST THING any sign maker should know about wanting to use acrylic or polycarbonate that contains recycled content in their signs is that they’re probably already doing it. A best guess is that most reputable plastics suppliers include anywhere from 5-15% scrap material in their standard acrylic sheet and polycarbonate products.

These products aren’t marketed as recycled or green solutions, and the manufacturers of the plastics didn’t start doing it as part of any sustainability initiative. With these standard sheet products, the presence of non-prime material is all about reducing waste and cost for manufacturers focused on getting everything they can out of the raw materials that go into those plastics.

While there are many definitions to the word “recycled,” the recycled material in these products almost is exclusively post-industrial scrap, captured during the making and cutting of acrylic and thermoplastic sheet then reintroduced earlier in the process. This happens in-house, creating a closed loop that limits the opportunity for contaminants to enter the mix. At Plaskolite, 99% of all scrap produced in manufacturing our thermoplastics is reintroduced into a subsequent process. The only waste product we can’t recycle is sawdust, and even that we sell to extruders who use it on products with no concern for optical properties.

Post-consumer recycling is less common among plastics manufacturers due to the complications involved in accurately sorting scrap and controlling its storage and transportation to prevent contamination. It happens, but the conditions required to make it worthwhile are rare. Still, thermoplastics offer far more end-of-life recycling options than the disposable plastics used in water bottles and the like that end up in landfills. In fact, acrylic and polycarbonate can be recycled several times over as long as the material remains free of impurities or contaminants, and some applications expand on the recyclability and reusability because they don’t require extreme levels of purity.

All of this is happening across the industry and likely without the knowledge of most sign makers. Recycling in these small quantities doesn’t impact the cost or the properties of the products produced, so it’s common practice.

Fabrication cut-offs and sign-making scrap is reduced by ordering a run-to-size production batch, where specific lengths and widths are custom extruded rather than cut down from standard sheets.

Real Talk About Recycled Sheets

Of course, there are other products containing up to 95% recycled material and actively marketed as such. These products typically match the performance of the standard versions made predominantly with non-recycled raw materials. In fact, unless the application calls for extreme optical clarity, there is no discernible difference between the two.

This is relevant for sign makers, who frequently paint, back spray, or cover the acrylic or polycarbonate to create the color or effect they desire. In most sign applications, the fully recycled thermoplastic performs just as well as its standard counterpart. These recycled products are used when project specifications call for it or if local standards or regulations require it. But without those external pressures, most sign makers still opt for the standard product with minimal recycled material. The reason? Price.

Recycled thermoplastics slightly are more expensive than standard products, a fact that often comes as a surprise to our customers in the sign industry and elsewhere. There is a perception — mostly unfounded as we’ve discussed — that the recycled product measurably is inferior to standard alternatives. Again, other than optical qualities relevant only in specific applications, that is not the case.

The difference in cost isn’t related to performance or the qualities of the thermoplastic. Rather, it’s simple economics. Scrap materials used in recycled sheet must be collected, transported, sorted, re-ground, pelletized, and tested before they can be reintroduced into the manufacturing process. There is real cost involved in all of that and while all parties are making strides toward streamlining the process and reducing that cost, a gap persists.

Another consideration: The availability of thermoplastic scrap suitable for recycling is limited, making producing it in bulk a challenge. In fact, the ability to limit scrap in manufacturing and fabricating is a valuable tool in pursuing more sustainable manufacturing practices.

Clear polycarbonate or acrylic signage material can be manufactured with up to 95% recycled content, without compromising clarity or fabrication performance.

Sustainability Through Waste Reduction

One simple but underutilized way to reduce waste in sign manufacturing is with run-to-size sheet cutting. Acrylic and polycarbonate sheets come in standard sizes. When the fabricator cuts that sheet to meet the specifications for a sign, 10-15% of that sheet ends up as scrap.

It’s possible for manufacturers to provide sign makers a run tof heir sheet to the size needed, which saves the customer money on the cost of the material (10-15%, on average) and significantly reduces scrap. The only thing better than recycling scrap materials is to not generate scrap in the first place.

This isn’t common practice in the industry, but it should be. There are real cost savings available and the reduction in waste materials is a measurable sustainability strategy. Our hope is additional outreach leads to increased awareness and activity among environmentally responsible sign manufacturers.

Recycling and the use of recycled materials is a complicated issue without clear-cut answers. But products and practices are available that can help printers achieve their sustainability goals and become responsible environmental stewards.