Plastic Regrind: Cutting Waste and Keeping Costs in Check

If you've spent any time around injection molding presses, you know that scrap resin is just an unavoidable reality of the process. But here at our Wisconsin facility, the team at Moraine Plastics has spent over 50 years actively turning that waste into a cost-saving advantage for our clients. Our primary method? Plastic regrind.

The concept itself sounds easy enough: we take all those leftover sprues, runners, and out-of-spec parts, grind them down, and blend them right back into the production cycle. But actually getting it right is a serious balancing act. Push the percentage of regrind too high, and you start to compromise the structural integrity and thermal properties of the final part. Ignore it entirely, and you are quite literally throwing away good money on virgin material. After decades of dialing in our material science, we’ve figured out exactly how to hit that sweet spot—giving you maximum cost efficiency without ever sacrificing part quality.

Image of discarded plastics for plastic regrind

Key Takeaways

• Reduce Waste and Costs: Plastic regrind allows Moraine Plastics to recycle scrap efficiently, cutting material expenses.

• Maintain Quality: Experience and careful blending of regrind with virgin resin ensure parts stay reliable and precise.

• Support Sustainability: Using regrind lowers the demand for new plastic, helping reduce energy use and carbon emissions.

• Balance is Crucial: Not every part can handle high regrind content — finding the right mix is essential for performance.

• Strict Quality Control: Thorough sorting and testing keep contamination and defects at bay, guaranteeing consistent results.

Why We Bother with Plastic Regrind

Look, tossing plastic scrap in the trash isn’t just wasteful — it’s expensive. And it piles up fast. At Moraine, every scrap counts. We grind it down, reuse it, and that’s a win for us, our customers, and the planet.

But it’s not a blind process. We’re picky about how much regrind goes back in and where. Some parts can take more recycled material, others — especially those with tight specs — need mostly virgin resin. It’s a balance, and it takes real know-how to get it right.

The Environmental Angle

Here’s the deal: less virgin plastic means less energy burned making new stuff. That means fewer greenhouse gases and a smaller carbon footprint. It’s not just good PR — it’s something we take seriously.

With customers pushing harder on sustainability these days, being able to mix in regrind keeps Moraine Plastics competitive — and proud.

Where You See It in Action

Regrind is all over the place if you know where to look: clips and brackets in cars, plastic housings for gadgets, packaging parts that don’t have to look perfect but have to hold up.

With decades in injection molding, we’ve got a feel for where regrind fits without causing headaches down the line.

The Catch

Nothing’s perfect, right? Heat from melting plastic can degrade it if you reuse the same material too many times. Dirt or bits of other plastics sneaking in can cause trouble. And sometimes the color or surface finish isn’t as sharp.

That’s why we take sorting seriously, control regrind ratios carefully, and run a ton of quality checks before parts leave our plant.

Using plastic regrind might sound small, but it’s a big part of how Moraine Plastics has kept its edge for more than half a century — cutting waste, saving money, and doing right by the environment without skimping on quality.

It’s just one more way we make sure every part that leaves our shop is built with precision and care.

FAQs (Frequently Asked Questions)

What is plastic regrind?

Plastic regrind refers to the process of recycling plastic materials by grinding them into small particles or pellets. This process allows for the reuse of plastic materials in the manufacturing of new products.

How is plastic regrind used?

Plastic regrind can be used in various manufacturing processes to create new plastic products. It is commonly used in the production of items such as containers, packaging materials, and automotive parts.

What are the benefits of using plastic regrind?

Using plastic regrind helps to reduce the amount of plastic waste that ends up in landfills. It also conserves natural resources by reusing existing plastic materials, and can be a cost-effective alternative to using virgin plastic materials.

What types of plastic can be regrind?

A wide range of plastic materials can be regrind, including polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polystyrene (PS), and more. The specific type of plastic regrind used depends on the intended application and manufacturing requirements.

Is plastic regrind safe for use in manufacturing?

When processed and used properly, plastic regrind is safe for use in manufacturing. However, it is important to ensure that the regrind material meets quality and safety standards to avoid any potential issues in the final products.