Carolina Color Corporation’s G2: Proven Success For Post Consumer Resin (PCR) Molding

Feb. 3, 2015 - PRLog -- Carolina Color Corporation’s G2: Proven Success For Post Consumer Resin (PCR) Molding

Today, in an effort to reduce the amount of waste going into landfills and the overall cost of part molding, most molders have been able to incorporate recycled resin into their products. Incorporating recycled material into new products offers economical and environmental benefits, as it conserves energy by replacing the need for manufacturing new plastics.

One recycled resin option for molders is Post Consumer Resin (PCR). PCR is often re-pelletized at a compounder and then sent to a molder, where it is blended with new material before being molded into a product. During the blending process, the PCR is let it down at a variety of percentages and blended with a natural material, enabling molders to use as much as 20-50% post-consumer regrind in the final product.

The challenge pigmenting PCR is that the source of the resin varies. Such inconsistency in the resin can produce shades in the new resin that range from yellow to whitish. The variation in pellet can cause color additives to disperse inconsistently, making it considerably more difficult to achieve a desired color in products.

Also, studies have shown that inconsistent dispersion of color additives can have an overall effect on the performance abilities of plastics.  Improper dispersion can damage molecular bonds, “resulting in pigment agglomerates acting as defects in the polymer matrix and impairing the mechanical properties of the finished product.”¹ Thus, consistency is crucial when pigmenting post-consumer pellet, and in order to maintain the physical integrity and strength of the material, color additives must be properly dispersed.

Studies and experiments have been conducted to find a way around the challenge of re-pigmenting recycled resin. One experiment tested the effects of blending white pellet into the resin before adding color concentrates to learn if the presence of the white would help colors disperse more consistently. Yet, there continued to be a problem with consistency.²

In some instances, additional machinery and techniques are required to help with dispersion, as “the use of plasticating screws with enhanced mixing capability or static mixers would be recommended.”¹ However, a more cost-effective and efficient option is now available --- Carolina Color’s G2 --- an advanced color concentrate.

Carolina Color G2 Proven Success With Post Consumer Resin (PCR)

G2 pellets, patented by Carolina Color in 2008, are exceptionally well-dispersed and effectively distribute in both large and small parts, enabling consistent pigmentation of recycled resin for a number of applications.

Molders using PCR that have made the switch to G2 have been able to overcome challenges of molding with other color options in the market. G2 has proven to keep the critical molecules of the resin intact, thus reducing any risk of the plastic part failing to live up to the promised performance. The high color density in G2 pellets can eliminate common issues with “hue” of the recycled resin compared to conventional coloring methods. Plus, molders typically see let down ratios reduced from 6-8% down to 2- 4% with G2.

Carolina Color’s G2 product line has proven performance in diverse applications, including outdoor durables, packaging, industrial, non-automotive transportation, and much more. Convertors continue to be impressed by this game-changing technology.  Whether it is injection, extrusion or blow molding, G2 continues to hit the mark.

Carolina Color Corporation --- a successful, family-owned company since 1967 --- serves colorant needs from ISO 9001:2008 certified locations in North Carolina and Ohio. For more information about G2 visit: www.carolinacolor.com.

1 - http://www.materialstoday.com/polymers-soft-materials/journals/polymer-testing/

2 - http://www.chelseacenter.org/pdfs/TechReport1.pdf