PE (polyethylene) in film form can be effectively recycled into second-grade production material once sorted. But sorting issues and the processing before pellet extrusion prevent much of this from being commercially viable. The film waste must be well sorted, to reduce the incidence of mixed material being reprocessed; otherwise, the properties of the resultant material are easily degraded. This sorting is not easy, as very low levels of colored films will significantly devalue a &#;clear&#; end product. The film materials also cause chronic tangling in the shredding process, requiring high labor costs to correct.
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The sorted film is shredded, washed, dried, and extruded to form &#;new&#; pellets which are of high quality. They are unlikely, however, in the second incarnation to be used in film manufacturing or in food-grade applications. Most are used for low-grade applications in building and agricultural materials.
Recycled material maintains a fairly high price, but the process is barely profitable because of the handling difficulties. Very little PE (polyethylene) is effectively recycled; instead, it ends up in incineration or landfill. Most kerbside recycling collection points do not accept PE (carrying any recycling mark or the &#; identifier) but treat that which is left by consumers as waste material to be removed and disposed of.
HDPE (high-density polyethylene) film materials are generally used in heavier (or thicker) sections and colored, and are relatively easy to sort for high purity. The process does not require the separation of colored, natural, and clear materials at the sorting stage&#;all colors are processed together.
Like PE, sorted plastic is first washed, then dried, and shredded to produce greater uniformity and easier processing. The shredded material is then heated to a melting point and extruded to form a standard molding-pellet feedstock. The equipment to perform this process is low cost, but there is considerable labor in the sorting stage&#;where much of the market value is added&#;as multi-polymer blend material has virtually zero value.
The end result is high-quality, second-grade material that generally has a dark color and can be used for a range of otherwise normal applications, substituting for virgin material, or more often as a second-grade minority component with otherwise new material.
All PE (polyethylene) materials are commercially produced from hydrocarbon source materials and represent a significant environmental burden. Very little HDPE (high-density polyethylene) is recycled, though claims of 28% recycling of milk containers are made in some markets. Despite this, overall estimates of recycling volume are unreliable and very low.
Overall, PE materials are highly recyclable and can produce good resultant products for 10 or more cycles (potentially many more, if perfectly sorted and treated gently). However, real recycling rates worldwide are minimal as a percentage of the total made. Most are lost to the environment, put in landfills, or burned for disposal or power generation.
Like all of the PE family, HDPE is a low-price material that is manufactured in huge quantities and is generally considered a commodity material. The price for virgin material is around $8.50 per kg, reduced to $2.50 for recycled material.
Polyethylene (PE) has a considerably lower cost than HDPE, generally selling as granules in the $0.90&#;$1.10 price range. Recycled clear PE is available at a similar or slightly lower price, and it is generally used as a 10&#;20% addition to virgin material, saving a few cents per kg.
Polyethylene (PE) has a wide range of applications and these suit different alternative materials. For films, some available options are: BOPP (biaxially oriented polypropylene), PVC (polyvinyl chloride), polycaprolactone, PET, and PLA (polylactic acid). For pipes and fittings, the alternative materials are: UPVC (unplasticized polyvinyl chloride), HDPE, PEX (radiation cross-linked PE), metal&#;copper, iron, plated and stainless steel, etc. For homewares, some alternative materials are: ABS (acrylonitrile butadiene styrene), PET, HIPS (high impact polystyrene), and PP (polypropylene).
HDPE (high-density polyethylene) has a wide range of applications, but they are narrower in scope, and alternatives are more straightforward. For most applications, alternatives are PE, PET, PEX, ABS, PP, and rubber-modified PP.
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Previously published on fastradius.com on May 27,
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Polyethylene (PE) was discovered just before the turn of the 20th century and instantly became an industry favorite. Thanks to its affordability, machinability, and compatibility with other materials, polyethylene is still a staple in the manufacturing industry. PE is widely used across consumer goods, medical devices, and industrial applications such as tanks and pipes.
There are many forms of polyethylene, broken down by three main chemical structures &#; branched versions, linear versions, and cross-linked polyethylenes. High-density polyethylene (HDPE) and low-density polyethylene (LDPE) are the two most common kinds of PE. This low-density polyethylene vs. high-density polyethylene &#;Know Your Materials&#; guide provides everything you need to know about these two materials, so you can decide which type of polyethylene is best for your next project.
HDPE is a type of polyethylene with a linear structure. Since its molecules are packed together tightly, HDPE is an incredibly strong polyethylene with high tensile strength, rigidity, and impact resistance. HDPE is also resistant to chemicals and can be UV-resistant. Along with its durability, HDPE is quite a versatile material and easy to fabricate.
Due to its malleability and dimensional stability, HDPE is often used in outdoor furniture and equipment, including structures like playgrounds. HDPE is also used in industrial applications, such as pipe flanges and chemical tanks, as well as consumer goods like food and beverage bottles, cutting boards, and even toys.
Here are a few key mechanical and chemical properties of high-density polyethylene:
Some disadvantages of HDPE include a susceptibility to stress cracking under intense pressure and low-to-moderate heat resistance. There is also a risk of shrinkage while molding HDPE and for this reason, HDPE is best suited for CNC machining and additive manufacturing. Processing HDPE with CNC machining is especially popular, as this manufacturing method can yield tight tolerances.
One massive benefit to HDPE is its recyclability and reusability. Recycled HDPE is often just as versatile and weldable as new or &#;virgin&#; HDPE, making recycled HDPE an excellent material choice for reducing your ecological footprint.
LDPE is a branched version of polyethylene, meaning its molecules are more loosely packed. As a result, LDPE is less dense than other linear polyethylenes like HDPE. This doesn&#;t mean LDPE isn&#;t strong, though.
Along with boasting impact resistance, LDPE is also stain-resistant, electrically insulating, and waterproof. LDPE is also naturally transparent and reflects light well. Some other mechanical low-density LDPE properties include:
Common LDPE consumer components include grocery bags, plastic film or wrap, flexible packaging material, and food and beverage containers. LDPE is also used in medical device manufacturing for orthotics and prosthetics.
Design teams should be mindful of some of LDPE&#;s limitations &#; LDPE is more prone to stress cracking than HDPE, less heat resistant than HDPE, and highly permeable to gases like carbon dioxide. LDPE is also highly flammable, which greatly limits its use in high-temperature applications.
One upside to LDPE&#;s lessened heat resistance is its low melting point, which improves heat sealing. This makes LDPE easy to process using injection molding, which opens up many manufacturing possibilities in this realm.
High-density polyethylene and low-density polyethylene are two common polyethylenes with differing structures but similar properties. HDPE has a linear structure and is opaque, while LDPE is a transparent branched version of PE. Both materials have excellent strength and weldability, boasting impact and chemical resistance alongside malleability and manufacturability.
While LDPE and HDPE can both be processed using injection molding and additive manufacturing, LDPE is best suited for injection molding whereas CNC machining HDPE can help achieve tight tolerances. It&#;s up to product teams to do their research and determine which material is best suited for their upcoming project. A trusted manufacturing partner can help you make these decisions confidently.
SyBridge can help you understand the key differences between HDPE and LDPE, as well as choose between many other manufacturing materials. Our team of manufacturing experts dedicate themselves to helping you create the best part possible, guiding you through each step of the process. With SyBridge, gain insight into choosing the right material and optimizing product design at every turn. Contact us today to get started.
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