What is Recyclate? Options in Plastic Recycling and Distinction from Virgin Material
In an increasingly sustainability-oriented world, recycling and the reuse of materials play a key role. Plastic recyclates offer a sustainable alternative to virgin materials. But what exactly does the term mean, and how can recyclates be distinguished from virgin materials? Read more now.
Sarah Guaglianone
Updated on June 2, 2026
Contents
What are recycled materials? – The key points in brief
- The use of recycled plastic material, known as recyclates, reduces the environmental impact.
- There are two main types of recycled materials: post-industrial recycled materials (PIR) from production waste and post-consumer recycled materials (PCR) from end-consumer waste.
- The processing of recycled materials presents challenges for companies, as there are no uniform standards regarding colour standards, processing properties and surface quality.
→ Enquire now about thermoformed parts made from recycled material
The use of recycled materials: the current situation in Germany
The recycling of plastics is becoming increasingly important in Germany as a means of reducing the environmental impact of plastic waste. Currently, around 50% of plastic waste is recycled, whilst the remainder is used for energy recovery or sent to landfill.
Measures to increase the recycling rate
To increase the recycling rate, the Packaging Act was introduced in 2019, which requires companies to make their packaging more environmentally friendly and to ensure it is disposed of properly. The use of recycled plastics is also becoming increasingly popular. The circular economy is to be supported by optimal packaging design (Design for Recycling) in order to minimise environmental impact whilst ensuring optimal product packaging – ideally with the highest possible proportion of recycled material.
What is recycled material?
Recyclates are products created through the recycling process and are literally described as "reintroduced into the cycle". They are produced from various materials such as glass, paper or batteries. In the plastics sector, recycled materials refer to reused material such as PE (polyethylene), PP (polypropylene) or PET (polyethylene terephthalate), which has already been disposed of once by households or businesses and is now being used again to manufacture new products.
Types of recycled materials
Plastic recyclates are available in the form of granules, flakes or powder and are regarded as secondary raw materials.
There are two main types of recyclates:
- Post-industrial recyclates (PIR) or pre-consumer recyclates: these are created from excess plastic waste generated during the production of plastic packaging or other plastic products.
- Post-consumer recyclates (PCR): In contrast, PCR consists of recycled plastic waste that has been used in households, industry or commerce and subsequently disposed of via the yellow bag or yellow bin.
Recyclates: challenges in plastic thermoforming
The use of recyclates always makes sense from a recycling perspective. However, the processing of recyclates is also associated with challenges that need to be taken into account, especially in the case of visually or technically sophisticated thermoformed products:
No uniform colour standards
Plastics based on recyclates do not have uniform colour standards. Various regenerative components are mixed during the manufacturing process, which means that no RAL colour shade is possible.
For example, the colour palette for "PS Regenerat black" ranges from anthracite to black and for "PS Regenerat white" from a yellowish to a bright white. There is therefore no guarantee of colour accuracy.
Processing
Recycled materials can be less reliable to process than virgin materials. This is because recycled materials can come from a wide variety of sources and vary in composition from batch to batch. This can lead to variations in material properties, such as melting point, flow behaviour and mechanical properties.
Material degradation during recycling
During the recycling process, materials may undergo a certain degree of degradation, particularly if they have been recycled several times. This degradation can lead to a deterioration in the material’s properties. Typical consequences include:
- lower strength or impact resistance
- altered melting point
- poorer flow properties
This can mean that recycled materials no longer offer the same properties as the original virgin material.
Adjustment of processing parameters
Due to differences in material composition and quality, different processing parameters may be required to process recycled materials effectively. This includes changes to
- Application temperature
- Speed
- or compressed air.
Impact on production
Due to the varying parameters involved with recycled material, recycled products may, in some cases, result in a higher reject rate and longer cycle times compared to virgin material in order to achieve a similar level of quality. Furthermore, chipping of the milled edge is a problem that occurs to a greater or lesser extent with recycled material, depending on the quality of the material.
Surface quality
Due to the variety of raw materials used, there is no guarantee for the surface quality of the deep-drawn part.
Complex moulds with the use of recycled materials can be problematic. This is a particular problem with deep-drawn parts, such as plastic housings, where aesthetics play a role.
Problems that can occur on the surface are
- Air pockets
- Small bubbles
No material data sheet
It is important to note that the exact origin of the various recycled components is not always known. It is therefore not possible to guarantee the absence of silicone. Important: The mechanical properties of individual extrusion batches can usually be determined using laboratory samples. This no longer applies to the next series from a different material batch.
This means that there is no material data sheet available that can be used to trace the origin of the plastics.
Overview: Comparison of recycled plastic and virgin material
| Recycled plastic | Plastic virgin material |
|---|---|
| No RAL colour possible | RAL colour possible |
| No uniform colour standards | High colour accuracy |
| Potential bubbles and air pockets | Smooth surfaces |
| Exact origin of the recycled components not known | Origin known |
| No material data sheet available | Material data sheet available |
| Potential degradation | Consistent quality at all times |
How is recyclate produced?
The conversion of waste into recycled materials involves a multi-stage process.
- Collection: To produce recycled materials, recyclable plastic products such as packaging are first disposed of in the yellow bag or bin rather than in the general waste, ensuring that they enter the recycling cycle at least once.
- Sorting: The pre-sorted waste is taken to recycling centres, where it is separated by plastic type and colour using modern sorting equipment.
- Shredding and compaction: The waste plastic is compressed, shredded, or both processes are carried out in succession.
- Cleaning: A thorough cleaning is carried out to remove foreign plastics or other foreign materials.
- Further processing: The cleaned material is processed into flakes or granules . The resulting recycled plastic is then used as a raw material for new products or semi-finished goods.
What is the difference between recyclate, regranulate and reclaim?
Recyclate is the generic term for regranulate and reclaim.
- Regranulate: Depending on requirements and subsequent use, it may be necessary to produce regranulate from the used plastic. Recycled pellets are obtained from recyclable plastics without additives - from the ground, shredded plastics via a melting process.
- Regenerate: Regenerate is also produced by a melting process (compounding). By adding additives, various properties of the materials can be defined and customised according to requirements.
Recyclates in thermoforming
In the thermoforming sector, recycled plastic is used as a raw material for the production of plastic films and sheets by means of plastic extrusion, which can then be used for the thermoforming of plastic.
How is recycled material labelled?
To label plastics that have already undergone a recycling process and are therefore different from primary plastics, the letter "R" is often placed in front of the material name. For example, rPET, rPP, rHDPE, rLDPE and so on. In this context, the "R" stands for "recycled" and is often written in lower case.
Legal requirements for recyclates
- REACH Regulation (EC) No. 1907/2006 - REACH conformity
- RoHS Directives (EU) No. 2011/65 and Annex ⅠⅠ according to Directive (EU) No. 2015/863 - RoHS conformity
- All requirements of Annex XVII of the REACH Regulation regarding restrictions
- The Waste Framework Directive (EC) No. 2008/98:2018 on waste
- The GS specification AfPS GS 2019:01 PAH for category 2 - Other consumer products
Plastic recycling with formary
Recycling of production waste
All production waste, such as die-cutting and milling scraps, is collected and returned to the material cycle. These scraps are used to produce new granulate, which is then used to manufacture new films and sheets.
Post-Consumer-Recycling
The post-consumer cycle is beyond formary’s direct control, as end users are responsible for disposing of the products properly. If the end user is a business, all parts can be fully recycled at the end of their useful life. formary therefore takes back old thermoformed parts and reuses them.
The use of recycled plastics - a summary
The use of recyclates is widespread in the thermoforming industry and is seen as an important step towards a more sustainable use of plastics. Thermoformers generally utilise the leftover material from thermoforming and grind it up to produce the plastics as recyclates for the re-production of thermoformed parts.
However, there are still challenges in the production of high-quality plastic products, which can have sources of error, particularly in terms of aesthetics. It is therefore always worth consulting specialists if you want to use recyclates or bioplastics for your thermoforming project.
If you have any questions about the use of recyclates, please contact us! We will be happy to help you.
Frequently Asked Questions About Recycled Materials
Recycled materials are materials that have been recovered through recycling processes and reintroduced into the production cycle. In the case of plastics, they may consist of polyethylene (PE), polypropylene (PP), or polyethylene terephthalate (PET), for example.