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We make it right

Some talk about sustainable plastic. Some spin it. We do it for real.

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Manufacturing Facilities

Manufacturing Facilities

We make it right

Some talk about sustainable plastic. Some spin it. We do it for real.

View manufacturing Video
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State-of-the-art manufacturing plants.

The plastic recycling process in Lavergne’s transforming facility is entirely automated.

When the feedstock enters the Lavergne facility, it follows a transformative process of turning old used plastics into new Post-Consumer Recycled (PCR) resins.

The process follows specific steps: shredding, separating, cleaning, mixing additives, and reactive compounding. We organize the steps in three separate centers called:

  • Plastic Care Center
  • Additive Mixing Center
  • Reactive Compounding Center
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Every manufacturing plant contains its own proprietary technologies, R&D team and moulding tech support.

01. Plastic Care Center

Shredding, Separation, Cleaning, Sorting

This center is where plastics, received from partner recyclers, are treated and restored rather than let go to landfills. They are shredded into smaller flakes, separated by type and color, cleaned to remove contaminants, and deep washed, and then sorted and homogenized in 16 mixing silos.

  • Proper segregation
  • Contaminants removed
  • Homogenization
01. Plastic Care Center

02. Mixing Additives Center

Mixing/formulation additives

In this center, in order to rebuild the molecular chain and create a resin tailored for specific client applications, our scientists develop an additive formulation, which includes a recycled base polymer and additives. These additives, the secrete sauce, ensure that the resin meets new resin specifications including color matching.

 

  • Tailor-made experience
  • Alloys formulation
  • Additives/color matching
02. Mixing Additives Center

03. Reactive Compounding Center

During the reactive compounding phase, the base polymers and additives are melted and blended. The resulting compound then undergoes extrusion and is cut into pellets. To ensure the high quality, every step is monitored, and every batch is tested in Lavergne’s certified quality testing laboratory.

  • Precision feeding system
  • Continuous process monitoring
  • Certified quality testing lab
03. Reactive Compounding Center
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