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Regrind in circulation

How much of the plastic has been through more than three times when we run with 25% recycled material?

Answer: When inlet and scrap are painted and mixed back into new granulate, some of the plastic goes through the machine again and again. Each time it breaks down a bit: chains get shorter, melt flow index rises and colour can change. With a fixed fraction of regrind r, the fraction of material that has been processed at least n times is rⁿ. The calculator shows how much is old and how many times the plastic on average has been through so you can stay within the customer's or material supplier's limit.

Formula

In equilibrium, the proportion processed exactly k times is: (1 − r) × r^(k−1)

The share processed at least n times: rⁿ (the sum of the rest of the series)

Average number of passes: 1 / (1 − r)

Assumes that the regenerate is evenly mixed and that the share is the same every day

Symbols and units in the formula
SymbolMeaningUnit
rShare of recycled material in the mix%
nNumber of runs you want to check (at least n times)gange
=Share processed at least n times%
=Average number of passesgange
=Share that is completely new (first time)%
=Share processed exactly n times%

Validity and source

Source
Geometrisk række: andelen der er forarbejdet mindst n gange = rⁿ

Does not apply when

  • How much recycled material an item can tolerate is stated in the specification or material datasheet. Many technical items (e.g. food-contact, medical or safety parts) must not have any recycled material at all. Keep the recycled material dry and free from dust, and blend it with the same grain size as the granulate.

Worked example

The calculator's own default values inserted. The figures are calculated with exactly the formula the tool uses.

Substituted

  • Share of recycled material in the mix25 %
  • Number of runs you want to check (at least n times)3 gange

Giver

  • Share processed at least n times1.56 %
  • Average number of passes1.33 gange
  • Share that is completely new (first time)75.0 %
  • Share processed exactly n times4.69 %

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Sådan bruger du den

Når indløb og kassationer males og blandes tilbage i granulatet, kommer noget af plasten igennem maskinen mange gange og nedbrydes lidt for hver gang. Du regner, hvor meget der er gammelt, når I vil hæve andelen af regenerat for at spare materiale og CO₂, eller når en kunde spørger, hvor meget regenerat der er i deres emner.

Step by step

  1. Skriv andelen af regenerat i blandingen, fx 25 %.
  2. Skriv hvor mange gennemløb du vil tjekke, fx 3.
  3. Læs andelen, der har været igennem mindst så mange gange, og det gennemsnitlige antal gennemløb.
  4. Sammenlign med materialeleverandørens eller kundens grænse.

Typical errors

  • At tro at 25 % regenerat betyder, at 25 % er nedbrudt. Det meste af regeneratet har kun været igennem én gang før.
  • At bruge regenerat i emner, hvor kunden eller standarden forbyder det, fx fødevarekontakt eller medicinsk.
  • At blande fugtigt regenerat i hygroskopisk materiale uden tørring.

Examples from everyday life

25 % regenerat i PP-låg

I kører PP-låg med 25 % malet indløb blandet i ny granulat og vil vide, hvor meget der er kørt mere end to gange.

Share of recycled material in the mix
25 %
Number of runs you want to check (at least n times)
3 times

It means: Kun 1.56 % af plasten har været igennem mindst tre gange. I gennemsnit har plasten været igennem 1.33 times, og 75 % er helt ny.

Halvdelen regenerat

For at spare materiale foreslås 50 % regenerat. Leverandøren anbefaler højst 5 gennemløb.

Share of recycled material in the mix
50 %
Number of runs you want to check (at least n times)
5 times

It means: 3.13 % af materialet har været igennem fem gange eller mere. Det gennemsnitlige antal gennemløb er 2 times. Tjek smelteindeks og farve på emnerne, før I går over.

Rule of thumb

Med 25 % regenerat har under 2 % af plasten været igennem tre gange eller mere.

How to check the answer

Andelen helt nyt + andelen forarbejdet mindst 2 gange skal give 100 %.