Find out when recycled LDPE film can be used safely, what industrial and packaging applications it is recommended for, and when it is best to opt for virgin material.
Recycled LDPE film: when is it a good choice, and when is it not recommended?
Industrial and packaging companies are increasingly finding it necessary to replace films previously made from top-grade, virgin raw materials with films made partly or entirely from recycled LDPE.
There may be several reasons for this. Some companies are looking for a more cost-effective solution, whilst others wish to use packaging containing recycled materials because of their sustainability goals, ESG requirements or the environmental standards set by their partners.
Recycled LDPE film can indeed be a good choice in many cases. However, it is important to recognise that the same raw material does not work for every product or in every area of application. A construction site cover, a bin bag, film used on an automatic packaging machine, or the packaging of an odour-sensitive product may all have completely different technical requirements.
In this article, we explain when it is advisable to choose recycled LDPE film, when a separate assessment is required, and in which cases it may be a better decision to use first-class, virgin raw materials. The article is based on a technical interview conducted with the client.
What is LDPE film?
LDPE is the English term for Low-Density Polyethylene An abbreviation for low-density polyethylene. It is one of the most commonly used plastic raw materials in the manufacture of plastic film.
LDPE film is flexible and easy to process, and can be manufactured in a variety of thicknesses and sizes; it is therefore widely used in the industrial, packaging, construction, agricultural and commercial sectors.
It can be made from LDPE, for example:
- flat film,
- hose or half-hose,
- bin bag,
- industrial sack,
- pallet cap,
- shrink wrap,
- plastic sheeting,
- construction film,
- air-cushioned film,
- agricultural film,
- film used in various automatic packaging machines.
One of the major advantages of LDPE film is that it can be tailored to the intended use. A construction film used outdoors requires different properties to those of an indoor packaging film or an industrial bag.
What does ‘recycled LDPE film’ mean?
We refer to recycled LDPE film when the film is manufactured using plastic raw materials that have been partially or entirely reprocessed, known as regranulate are used.
Regranulate is a plastic raw material that was previously generated as waste or as a by-product of manufacturing, and which, following sorting, cleaning, grinding, melting and pelletising, has been transformed back into a raw material suitable for further processing.
The proportion of recycled raw materials may vary depending on the product and its intended use. Certain products may be made from up to 100% recycled raw materials, whilst in other cases a combination of virgin and recycled raw materials may be the better option.
PCR and PIR raw materials: what’s the difference?
When it comes to recycled films, there are two main types of raw material: PCR and PIR.
PCR reagents
PCR is the Post-consumer recycled Abbreviation. This refers to a recycled raw material made from plastic waste that has been collected after consumer use.
Examples of this might include packaging materials, cling film or other plastic waste collected after use.
The advantage of PCR raw material is that genuine consumer waste is returned to the circular economy. At the same time, its quality depends heavily on how clean, well-sorted and properly processed the original waste was.
The following may occur with the PCR sample:
- greater variation in quality,
- a milder or stronger smell,
- greater risk of foreign matter,
- processing that requires greater attention.
This does not mean that the PCR raw material is poor. Rather, it means that it must be used with the right product and by a manufacturer with the appropriate experience.
PIR raw material
PIR is the Post-Industrial Recycled Abbreviation. This refers to recycled raw materials derived from industrial manufacturing processes.
PIR typically comes from a cleaner and more controllable source than PCR, which is made from mixed consumer waste. For this reason, it may in many cases be more suitable for packaging applications where a cleaner appearance, more consistent quality or a lower risk of odour are more important.
For example, when packaging textiles, mattresses or higher-end industrial products, it is often better to consider PIR as the raw material rather than lower-quality PCR.
When is recycled LDPE film a good choice?
Recycled LDPE film is a good choice if the product’s function, the environment in which it will be used and the required technical properties allow for the use of recycled raw materials.
The most important question is always this:
What do you need to know about foil in practice?
What matters is not simply whether the film is made from recycled or virgin raw materials, but whether it performs as required for its intended purpose.
For construction films
Construction films may represent one of the best applications for recycled LDPE.
Examples of such films include:
- for covering,
- for layer selection,
- built into the floor,
- for temporary protection,
- to protect against condensation,
- for the protection of building materials.
With these products, in many cases it is not optical perfection or odourlessness that is the most important factor, but rather that the film is of the correct thickness, sufficiently durable and functionally reliable.
For this reason, in the case of construction films, recycled raw materials can often be a good, cost-effective and more sustainable alternative.
For bin liners
Rubbish bags are also a typical application for recycled LDPE.
The primary function of a bin bag is to store and transport waste. In most cases, it is not necessary to use virgin, first-grade raw materials, provided that the recycled film has the appropriate tensile strength, elongation and thickness.
It is important, however, that the bin bag does not give off an unpleasantly strong odour, particularly if it is intended for use in offices, institutions or indoors.
That is why it is also important to choose the right material for bin liners. A different standard of quality may be acceptable for an outdoor or industrial waste collection bag than for one used in an office environment.
For industrial sacks
Recycled LDPE film can also be a good choice for industrial bags.
Examples of bags that can be used include:
- for the collection of production waste,
- for the packaging of industrial components,
- in-house logistics,
- for warehouse processes,
- for the protection of semi-finished or finished products.
When it comes to industrial sacks, the most important factors are generally load-bearing capacity, size, thickness and the sack’s ability to perform reliably in the specific operating environment.
With the right regranulate and production settings, recycled LDPE can be suitable for many such applications.
For pallet lids
The purpose of pallet covers is generally to protect palletised goods from dust, moisture, rain or other external factors.
In many cases, recycled raw materials are a particularly good choice for these products, as the film primarily serves a protective function and does not necessarily come into contact with sensitive products.
In the case of pallet caps, various additives may also be used, such as:
- UV stabiliser,
- anti-static additive,
- anti-corrosion additive.
This ensures that the film not only provides basic protection, but is also tailored to the specific industrial application.
For flat films and covering films
Recycled LDPE is often suitable for use in flat films and covering films, particularly where the film is intended to provide temporary protection for products or surfaces.
An example of such a function might be:
- protection against dust,
- protection against moisture,
- surface covering,
- temporary packaging,
- warehouse security.
When selecting raw materials for these products, it is necessary to consider the environment in which the film will be used, how long it needs to fulfil its function, and what mechanical stresses it will be subjected to.
When does the use of recycled film require a separate assessment?
There are certain areas of application where the use of recycled LDPE film cannot be ruled out, but it certainly requires a more careful selection of raw materials, design and testing.
Shrink wrap
Shrink film is a particularly sensitive product because it shrinks when exposed to heat, whilst still having to retain its packaging function.
If the recycled raw material contains too many foreign substances or impurities of an unsuitable particle size, the film may develop holes, become weakened or fail to provide adequate protection during the shrinking process.
This is why it is particularly important in the case of shrink film:
- the pure raw material,
- the selection of the appropriate regranulate,
- precise production settings,
- testing,
- a thorough understanding of the product’s functionality.
In some cases, recycled raw materials may be suitable; in others, however, using virgin or partially virgin raw materials may be the safer option.
For films used in automatic packaging machines
For films used in automatic packaging machines, dimensional stability, thickness, weldability and machine runnability are critical.
Film of this kind is not merely “packaging material”, but an integral part of the manufacturing process. If it does not run properly on the machine, it can cause machine downtime, rejects, packaging faults and a loss of output.
It is therefore important for film intended for use in vending machines that:
- knowledge of the specific machine type,
- the exact size,
- the correct thickness,
- the consistent quality of raw materials,
- pilot production,
- consultation between the manufacturer and the user.
Recycled film may also be an option here, but only if its function and suitability for mechanical processing allow it.
For odour-sensitive products
One of the most common concerns about recycled plastic film is the smell.
This fear is not entirely unfounded. Certain PCR raw materials can indeed have a distinctive odour, particularly if the source waste has not been properly sorted or cleaned.
However, this does not mean that all recycled plastic film smells.
The risk of odours can be reduced:
- using higher-quality regranulate,
- Using PIR as a raw material,
- by blending the right ingredients,
- with odour-neutralising additives,
- specifying the intended use in detail.
If, for example, the film is used to wrap mattresses, textiles or other odour-sensitive products, it is particularly important that the manufacturer does not automatically opt for the cheapest recycled raw material, but instead recommends a solution suited to the intended use.
For thin films
It is a common misconception that only thick, coarse films can be produced from recycled raw materials.
The reality is more nuanced than that. Thinner films can also be produced from recycled raw materials, but this requires higher-quality regranulate, more stable production settings and greater technical expertise.
The thinner the film, the lower the tolerance. Even a minor impurity or variation in quality can cause a bigger problem than with a thicker product.
For this reason, individual inspection and testing are always required for thin films.
When is recycled LDPE film not recommended?
Although recycled LDPE is suitable for use in many areas, there are situations where it is not the best choice.
For direct food packaging
In the case of packaging that comes into direct contact with food, the use of recycled plastic is strictly regulated and, in many cases, not permitted.
In this field, it is not enough for the film to appear technically suitable. It must also comply with food safety and regulatory requirements.
For this reason, direct food packaging generally requires specifically authorised, audited raw materials that are suitable for this purpose.
In the case of packaging that is largely odourless
If the packaged product readily absorbs odours from its surroundings, the use of recycled raw materials must be handled with great care.
Examples of this might include:
- mattress,
- textile,
- clothing item,
- premium consumer goods,
- a product stored in an enclosed space for a prolonged period.
In such cases, recycled raw materials need not necessarily be ruled out, but it is worth opting for a higher-quality, cleaner solution – perhaps even one based on PIR.
In the case of mulch films, made from poor-quality raw materials
Agricultural mulch films are subjected to heavy loads.
They are affected by:
- solar radiation,
- temperature fluctuations,
- moisture,
- soil,
- chemicals,
- mechanical stress.
If film made from recycled raw materials of inadequate quality is used in such an environment, it may deteriorate prematurely, tear, and even cause environmental problems.
It is therefore particularly important to use the right raw materials and additives for mulch films. In certain cases, the primer-based raw material may be a safer and, in the long term, more cost-effective choice.
The most common misconceptions about recycled LDPE film
There are several misconceptions on the market regarding recycled films, which are deterring many buyers from making the switch.
That is not true in this form.
The quality of recycled film depends primarily on the raw material, the sorting process, the quality of the regranulate and the manufacturer’s experience.
It is indeed impossible to produce high-quality film from poor-quality, contaminated regranulate. However, film that is perfectly suitable for many industrial applications can be produced from properly sorted, well-processed raw materials.
Many people believe that it is not possible to guarantee consistent dimensions, thickness and quality when using recycled raw materials.
In practice, however, with the right machine settings, experienced machine operators and good raw materials, recycled film is also capable of maintaining precise dimensions.
This is particularly important for industrial partners, where the film is not just a packaging material but an integral part of the production process.
Certain recycled raw materials may have an odour, particularly in the case of PCR. However, this does not mean that all recycled film has an unpleasant odour.
The intensity of the smell depends on:
- from the origin of the raw material,
- from waste sorting,
- depending on the washing and processing technology,
- depending on the mixing ratio,
- depending on the additives used.
Good advice from the manufacturer is crucial here. Not every product requires the use of the same recycled raw material.
It is true that thicker, industrial-grade films are more commonly made from recycled raw materials, but this does not mean that thinner products are automatically ruled out.
The production of thinner films requires greater care, but with the right raw materials and settings, it can be achieved in certain cases.
The question is always what function the film in question is intended to fulfil.
How should a purchaser make the right choice?
To make the right decision, it is not enough simply to say, “We need LDPE film”. Knowing the exact intended use is just as important.
A procurement officer should consider the following questions:
- What will the film be used for?
- Is it designed for indoor or outdoor use?
- Is UV resistance required?
- Does it come into contact with any sensitive products?
- Is odour neutrality important?
- What thickness is required?
- What width and packaging do you need?
- Will it run on a slot machine?
- Are anti-static, anti-corrosion or other additives required?
- Are there any requirements regarding recycled content?
- Is a quality certificate or documentation suitable for an ESG report required?
The more accurate this information is, the better the recommendations for raw materials and products can be.
Why is consultation with the manufacturer important?
Choosing recycled plastic film is not simply a question of price.
In many cases, the greatest savings do not come from choosing the cheapest raw material, but from ensuring that the film is specifically designed for the task at hand.
An experienced manufacturer can help:
- in determining the correct thickness,
- in optimising the size of the film,
- in selecting the appropriate regranulate,
- in determining the proportion of virgin and recycled raw materials,
- in the sampling process,
- in automated testing,
- in compiling the documentation.
Many companies have been using oversized packaging materials for years simply because that is how the manufacturing process was originally set up. A more precise size or a thinner material could result in material savings of even a few per cent, which, when dealing with large volumes, can lead to significant cost reductions.
Sustainability: it’s not just the raw materials that matter
When we talk about more sustainable packaging, many people automatically think of recycled materials. This is certainly an important consideration, but it is not the only one.
You can improve the sustainability of the packaging by:
- increasing the proportion of recycled content,
- optimising the thickness of the film,
- reducing the size,
- avoiding unnecessary over-packaging,
- a longer service life,
- the recycling of waste,
- reducing energy consumption in manufacturing.
A well-designed film that uses fewer materials but still fulfils its function reliably is often a better solution than a poorly chosen “green-looking” alternative.
Recycled film and ESG requirements
Due to ESG and sustainability requirements, an increasing number of companies are looking into ways of reducing their environmental impact.
Recycled LDPE film can help in several ways:
- may reduce the use of primary raw materials,
- may contribute to the recycling of plastic waste,
- may support the objectives of a circular economy,
- can help in developing more sustainable packaging alternatives,
- It can make the development of packaging materials more easily documented.
It is important, however, that ESG communication is accurate and based on sound professional knowledge. It is not advisable to make exaggerated claims. The environmental benefits of the film should always be presented on the basis of the specific raw materials, manufacturing process, end use and supporting documentation.
When should you choose a primer?
Top-quality raw materials are not at odds with recycled film. There are simply situations where their use is justified.
Choosing a primer may be the better option if:
- this concerns direct food packaging,
- there are very high purity requirements,
- complete odour neutrality is required,
- a particularly thin film must be produced,
- if exposure to strong UV radiation or chemicals is expected,
- the film runs through a critical packaging machine process,
- The partner specifies audited primary raw materials.
The best approach for manufacturers is not to use recycled raw materials at all costs, but to find the best technical and economic solution for the function in question.
Summary
Recycled LDPE film can be an excellent alternative in many industrial and packaging applications. It is particularly well suited for use in construction films, bin liners, industrial sacks, pallet covers, flat films and various covering applications.
However, it is not always an automatic solution. In the case of shrink films, films used on automatic packaging machines, odour-sensitive packaging or direct use in the food industry, a more thorough assessment is required.
The basis of a good decision is always a precise definition of the intended function. The question is not whether recycled film is generally good or bad, but whether it is suitable for the specific product, in the specific environment, and given the specific technical requirements.
With the right choice of raw materials, backed by experienced manufacturers and thorough testing, recycled LDPE film can be not only a more sustainable option, but also a cost-effective and reliable solution.
Frequently Asked Questions
Recycled LDPE film is a low-density polyethylene film made partly or entirely from reprocessed plastic raw material, i.e. regranulate.
No. Recycled materials can be used effectively in many products, but specific testing is required for food-grade, odour-sensitive or critical machine-packaging applications.
PCR is made from plastic waste collected after consumer use, whilst PIR is derived from industrial manufacturing waste. PIR is generally a purer and more controllable raw material.
Certain recycled raw materials may have an odour, particularly in the case of PCR. However, with the right choice of raw materials, blending and additives, the odour problem can often be managed.
In many applications, yes – provided it is produced from regranulate of the appropriate quality, with the correct machine settings and backed by an experienced manufacturer. Performance must always be assessed on the basis of the specific application.
It can be a good choice for construction films, tarpaulins, bin liners, industrial sacks, pallet covers, flat films and certain types of packaging film.
It is not recommended – unless specifically tested – for direct food packaging, odour-sensitive products, very thin films, critical automated packaging machinery, or agricultural applications involving high levels of UV exposure and chemical exposure.
Yes, this is possible with certain products. These might include, for example, certain types of construction film, bin liners, industrial sacks or pallet collars. The exact proportion always depends on the intended use and the required quality.
Yes, with the right documentation and genuine recycled content, you can help to establish more sustainable packaging practices. However, it is important that your communication is accurate and backed up by expert evidence.
Are you unsure whether recycled LDPE film can be used for your product?
Please get in touch with us and we will help you choose the right material, thickness, size and film type for your specific application. A well-chosen film can provide not only a more sustainable but also a more cost-effective and reliable packaging solution.