In the film manufacturing industry, we often come across two important terms:

• PCR reagents
• PIR raw material

Both are made from recycled plastic, but their origin, purity, processability and potential uses may differ. A construction film, a bin bag, an industrial sack, a pallet cover or packaging for an odour-sensitive product may all require a completely different choice of raw material.

In this article, we explain what PCR and PIR raw materials are, what the difference is between them, and how to choose between them for the production of LDPE film. The article is based on a technical discussion with a client, during which the production, applications and limitations of recycled LDPE films were discussed in detail.

What does ‘recycled raw material’ mean in the context of film production?

Recycled raw material is made from plastic that has previously been in use in some form, was produced as a by-product of manufacturing, or was collected as waste. This material is processed, cleaned, ground, melted down and then transformed back into granule-form raw material.

This is what we call regranulate.

The regranulate can then be reused in the manufacture of various plastic products, such as LDPE films.

Items that can be made from recycled materials include, amongst others:

• construction films,
• covering films,
• bin bags,
• industrial sacks,
• flat films,
• pallet caps,
• certain types of cling film,
• plastic sheeting for agricultural or industrial use.

The key point, however, is that the quality of the recycled raw material depends heavily on where the original plastic came from, how clean it was, how it was sorted, and the technology used to process it.

It is therefore important to distinguish between PCR and PIR raw materials.

What is PCR reagent?

PCR is the Post-consumer recycled abbreviation.

In Hungarian, this roughly means: plastic raw material recovered and recycled after consumer use.

It is made from plastic waste that has already been used once, and was then collected and recycled after use.

Examples of this might include:

• used cling film,
• consumer or commercial plastic packaging,
• collected plastic film waste,
• bags, pouches, packaging materials,
• various types of plastic waste generated by consumers.

The key point about PCR raw materials is that plastic which would otherwise have ended up as waste is returned to the material cycle.

This is an important benefit from a sustainability perspective, as it can reduce the demand for new, virgin raw materials and help ensure that plastic waste does not end up in landfill, incinerators or, worse still, in the environment.

The advantages of PCR reagents

One of the greatest advantages of PCR raw material is that it recycles genuine consumer waste back into the economy.

This is particularly important for companies that wish to use more sustainable packaging materials or make progress in the areas of ESG, the circular economy and waste reduction.

1. Reduces the use of virgin raw materials

Using PCR-based raw material may reduce the need for new, virgin plastic raw material. This is particularly important for products where recycled raw material is also capable of fulfilling the required function.

2. Supports the circular economy

The use of PCR raw materials helps to ensure that plastic waste is not treated as a single-use material stream, but is reused as a raw material for new products.

3. It may be a good choice for industrial and construction applications

There are numerous applications where LDPE film made from PCR-based raw materials can perform well. These include, for example, construction films, protective sheeting, bin liners, industrial sacks and pallet covers.

4. It could be a cost-effective alternative

In certain market situations, film made from PCR raw material may offer a more cost-effective solution than film made from virgin raw material, particularly for high-volume industrial applications.

The limitations of PCR reagents

When using PCR raw materials, it is important to bear in mind that, due to their consumer origin, the quality of the material may vary considerably.

This does not mean that the PCR reagent is poor. Rather, it means that it must be selected and tested appropriately, and used for the correct product type.

1. Greater variation in quality

The origin of PCR raw materials is often more varied than that of PIR raw materials. This means that the composition, purity and properties of the processed waste may vary.

This may affect the film:

• its tensile strength,
• its extension,
• its processability,
• colour,
• the smell of,
• its surface appearance.

2. Odour risk

One of the most common customer concerns regarding recycled films is the odour. This can be a particular issue with PCR-based materials.

The intensity of the smell depends on:

• depending on the type of original waste,
• the quality of the selection,
• depending on the washing and processing technology,
• depending on the additives used,
• the intended use of the finished product.

With outdoor construction-grade film or industrial sacks, this is often not a problem. However, when it comes to packaging a mattress, textiles or odour-sensitive products, it can be a significant consideration.

3. Not suitable for all products

PCR material is not ideal for all applications. It must be handled with particular care in situations where:

• there is direct contact with food,
• complete odour neutrality is required,
• a very thin film needs to be produced,
• this concerns a critical application involving an automatic packaging machine,
• there are high optical or purity requirements.

What is a PIR raw material?

PIR is the Post-Industrial Recycled abbreviation.

This is a type of recycled plastic raw material produced from by-products, offcuts or reclaimed material derived from industrial manufacturing processes.

PIR therefore does not originate from household or consumer waste, but typically from industrial sources.

Examples of this might include:

• film waste generated during production,
• cutting waste,
• a pure industrial plastic by-product,
• uncontaminated production residues,
• recyclable waste derived from the same raw material.

In many cases, PIR template is purer, easier to control and of a more consistent quality than PCR template of mixed origin.

The benefits of PIR as a raw material

The greatest advantage of PIR as a raw material is its more predictable quality.

As it originates from an industrial manufacturing environment, in many cases it is known more precisely what type of plastic it is made of, the process by which it was produced, and the level of contamination involved.

1. A cleaner flow of raw materials

PIR raw material is often less contaminated than PCR derived from consumer waste. This can be particularly important for films where a better appearance, more consistent quality or a lower risk of odour is required.

2. Better odour profile

PIR material is generally a better choice for packaging that is more sensitive to odours.

For example, when it comes to packaging textiles, mattresses, furniture or higher-end products, odour neutrality may be far more important than it is for an outdoor tarpaulin or an industrial waste collection bag.

3. More consistent workability

As the composition of the PIR raw material can often be better controlled, it may also be more predictable during film production.

This could be an advantage:

• for films used in automatic packaging machines,
• for films that require precise dimensional stability,
• for bespoke packaging tasks,
• for products where consistent thickness and tensile strength are important.

4. It could be a good bridge between primer and PCR

For many companies, PIR raw material can be a good first step towards using recycled films.

If a company has previously used only film made from virgin raw materials but is looking for a more sustainable solution, PIR raw material can often offer a safer transition than a lower-quality PCR alternative.

The limitations of PIR as a raw material

Although PIR is often more stable and produces clearer results, it is not identical to PCR in every respect.

1. It recycles non-consumer waste

An important distinction from the perspective of sustainability communication is that PIR is derived from industrial by-products rather than consumer waste.

Therefore, if a company wishes to specifically report on post-consumer recycled content – that is, recycled material derived from consumer waste – then the PIR alone is not necessarily sufficient.

2. More limited availability

The availability of high-quality PIR raw material depends on industrial waste streams. It is not always available in every quantity or to every standard.

3. Pricing may differ from that of PCR

PIR raw material of a purer, higher quality may, in some cases, be more expensive than lower-quality PCR. However, if the product’s function is more sensitive, this additional cost may be justified.

PCR or PIR: which one should you choose?

The answer isn’t that one is good and the other is bad.

The real question is:

For which product, which function and in which environment should the film be used?

An experienced LDPE film manufacturer does not base their decisions solely on the raw material, but takes the intended use as their starting point.

When might PCR reagents be a good choice?

PCR material can be a good choice for products where:

• recycled content is important,
• complete odourlessness is not essential,
• the visual appearance is not the main consideration,
• the film mainly serves a protective, covering or collecting function,
• This is a thicker, industrial-grade product.

Typical areas of application:

• construction film,
• plastic sheeting,
• bin bag,
• industrial sack,
• pallet cap,
• certain flat films,
• non-sensitive industrial packaging.

When might PIR be the better choice?

PIR insulation may be the better choice in situations where:

• cleanliness is more important,
• a lower odour risk is required,
• a more consistent quality of raw materials is required,
• greater dimensional accuracy is required,
• a more delicate product is being packaged,
• The partner would like to make a gradual shift from primary raw materials towards recycled ones.

Typical areas of application:

• mattress packaging film,
• textile packaging,
• furniture packaging,
• some of the films used in automatic packaging machines,
• industrial flat films with higher quality requirements,
• packaging that is more sensitive to odours.

Comparison: PCR and PIR raw materials

Why isn’t it enough just to say “recycled plastic film”?

The term ‘recycled film’ is too general on its own.

A recycled LDPE film may be:

• 30%, containing recycled material,
• 50%, made from recycled materials,
• 100%, made from recycled materials,
• PCR-based,
• PIR-based,
• Manufactured from a blend of PCR and PIR,
• combined with a primer,
• with additives,
• UV-stabilised,
• anti-static,
• odour-reduced.

For this reason, it is always necessary to specify, at the time of procurement, what type of recycled content and what type of raw material is involved.

There can be a huge difference between two types of “recycled film” in terms of quality, price, odour, processability and potential uses.

What questions should you ask before placing an order?

If a company wishes to use recycled LDPE film, it is worth clarifying a few basic points.

1. What will the film be used for?

It does matter whether the film is intended for covering, packaging, waste collection, machine processing or outdoor protection.

2. Is it for indoor or outdoor use?

For outdoor use, UV resistance, weather resistance and the use of additives may be important.

3. Does it come into contact with any sensitive products?

In the case of textiles, mattresses, furniture, premium products or odour-sensitive goods, the odour profile of the raw material is particularly important.

4. Is visual appearance important?

If the film is used as a visible packaging element, then its colour, surface finish, clarity and printability may also be important considerations.

5. What thickness is required?

Film that is too thin may not fulfil its purpose, whilst film that is too thick may result in unnecessary use of raw materials and additional costs.

6. Will it run on an automatic packaging machine?

For mechanical applications, consistent dimensions, thickness, weldability and workability are of paramount importance.

7. Are there any requirements regarding recycled content?

Certain partners or ESG targets may determine the required proportion of recycled content.

Why is manufacturing experience important?

The production of LDPE film made from recycled raw materials requires a great deal of technical expertise.

The quality of virgin raw materials is generally more predictable. With recycled raw materials, however, the manufacturer must have a precise understanding of what a given regranulate is suitable for, what mixing ratios can be used, which products it is compatible with, and what adjustments are required during production.

Key considerations:

• knowledge of raw materials,
• laboratory test,
• experience in machine set-up,
• filter replacement and processing checks,
• pattern-making,
• understanding product features,
• clarification of the client’s requirements.

High-quality recycled film isn’t produced by chance. The right choice of raw materials, combined with the right technology and experience, is what produces the end result.

PCR, PIR and ESG: what should be communicated?

Accuracy is very important in ESG and sustainability communications.

It is not enough simply to say that a film is “green” or “environmentally friendly”. It is far more credible if the company can demonstrate exactly:

• what proportion of recycled raw material it contains,
• Is the raw material of PCR or PIR origin,
• what product feature it was designed for,
• how it reduces the use of primary raw materials,
• what documentation is associated with it,
• what quality certificates are available.

Accurate, professionally substantiated communication is not only important from an SEO perspective, but also helps to build trust with B2B partners.

When is it worth considering a combination of PCR and PIR?

It is not always necessary to consider exclusively PCR or exclusively PIR raw materials.

For certain products, combining different raw materials can also be a good solution. For example, a film can be produced using a combination of PCR, PIR and virgin raw materials.

The purpose of this may be:

• achieving the right price,
• better workability,
• reducing the risk of odours,
• more consistent quality,
• ensuring the desired recycled content,
• maintaining the technical function.

Determining the correct ratio always depends on the specific product and its intended use.

Practical examples

Construction film

In the construction industry, whether for covering, separating layers or providing vapour protection, PCR-based materials may often be suitable, provided that the thickness and mechanical properties of the membrane meet the required standards.

Rubbish bag

When it comes to bin liners, recycled materials are generally a good choice. For indoor use, however, odour is a factor to bear in mind, whilst for industrial waste collection, tensile strength and load-bearing capacity are likely to be the deciding factors.

Mattress or fabric packaging

In this context, odour neutrality and a cleaner raw material may be far more important. Therefore, in such cases, a PIR raw material – or an appropriate combination of virgin and recycled materials – may often be the better choice.

Pallet lid

In many cases, recycled raw materials from the 100% range can be used for pallet lids, particularly where the aim is to provide protection against dust, mist or rain.

Film for automatic packaging machines

Consistent quality and precise dimensional stability are particularly important here. The use of recycled raw materials may be possible, but only following testing and in accordance with the manufacturer’s recommendations.

Summary

Understanding the difference between PCR and PIR feedstock is crucial when selecting recycled LDPE films.

PCR raw material is made from waste collected after consumer use; it therefore has high sustainability value and can be a good choice for many industrial, construction or waste collection applications.

PIR is derived from an industrial by-product, and as such it can generally offer a cleaner, more stable alternative with a lower risk of odour. This can be particularly useful for more sensitive packaging applications.

The right decision is not whether to choose PCR or PIR, but rather what function the film in question is intended to fulfil. A construction film requires a different raw material to a bin liner, which in turn differs from that used in an automatic packaging machine, and yet another from that used for packaging odour-sensitive products.

With the right manufacturing expertise, choice of raw materials and testing, recycled LDPE film can be not only a more sustainable option, but also a technically reliable and cost-effective solution.

Frequently Asked Questions

What does ‘PCR reagent’ mean?

PCR stands for Post-Consumer Recycled. It refers to a type of recycled plastic raw material made from waste collected after consumer use.

What does the term ‘PIR raw material’ mean?

PIR stands for Post-Industrial Recycled. It is a recycled raw material produced from waste, offcuts or by-products resulting from industrial manufacturing processes.

Which is better: PCR or PIR?

It is not possible to say in general terms that one is better than the other. PCR has strong sustainability credentials because it recycles consumer waste. PIR is generally a cleaner and more stable raw material. The choice always depends on the intended use.

Is it possible to produce high-quality film from PCR-based raw material?

Yes, LDPE film suitable for many industrial and packaging applications can be produced from carefully selected and processed PCR feedstock.

When should you choose a PIR substrate?

PIR raw material may be the better choice if a purer raw material, a lower risk of odour, more consistent quality or the packaging of more sensitive products are important.

Does PCR film smell worse than PIR film?

In the case of PCR raw material, the risk of odour may be higher because it is derived from consumer waste. PIR is generally of a purer origin and therefore often has a more favourable odour profile.

Can PCR or PIR materials be used for food packaging?

In the case of direct food packaging, the use of recycled plastic is strictly regulated. In such cases, separate testing, suitable raw materials and compliance with regulations are always required.

Can recycled LDPE film be produced in 100%?

Yes, it is possible with certain products. For example, it is often feasible with construction films, bin liners, industrial sacks or pallet collars. The exact ratio always depends on the intended use and the required quality.

Why is it important to distinguish between PCR and PIR raw materials?

This is because they differ in terms of their origin, purity, odour risk, processability and potential applications. A poorly chosen raw material can cause quality issues, whilst the right raw material can provide a stable and cost-effective solution.