From waste to recyclable material

Every year, 5.4 million tons of post-consumer plastic waste are generated in Germany alone. Most of it is incinerated—a technically convenient solution, but one that makes little sense from an ecological or economic standpoint. Valuable raw materials are lost, while at the same time political and social pressure to use plastics more sustainably is growing. Even more serious is the fact that some of this waste ends up in the environment and ultimately in our oceans.
This is where the SusPlasPro research project comes in. The aim is to use circular engineering to show that even heterogeneous recyclates (PCR) can be processed into high-quality, durable products – in a way that is economically competitive.

The reasons why post-consumer plastics have only been recycled to a limited extent to date are complex. Mixtures of different materials, residual materials, and additives make processing difficult. It is usually cheaper for manufacturers to use virgin materials: the material quality is stable, the processes are established, and the price is often unbeatable due to low crude oil costs.
The idea of “we're doing this for the climate” is not enough on its own to promote the use of recycled materials in industry. Ultimately, price and durability are the decisive factors: a product made from recycled material must be at least as robust and durable as its virgin material counterpart – and must not be more expensive. This is exactly where SusPlasPro comes in.

Instead of just tweaking individual aspects, the project takes a holistic approach. Materials research, process development, and digital simulation are all interlinked. The aim is not to replace new materials one-to-one with recycled materials, but to design products from the ground up so that they work with the properties of recycled materials.

The partners are combining their strengths to achieve this:

• As consortium leader, Gardena Manufacturing ensures practical relevance. The demonstrators developed there show how recycled materials can be used in everyday products.
• Merkle CAE Solutions contributes its expertise in digital simulation and component design. Virtual calculations can be used to optimize molded parts made from PCR before they go into production.
• Plexpert GmbH complements the consortium with its expertise in rheological simulation. It investigates how recycled materials can be processed in injection molding, thereby building a robust bridge between theory and production.
• Finally, Aalen University provides the scientific basis with its Institute of Polymer Science. New measurement methods and material testing ensure that the products developed are not only feasible but also durable.

This is the first time that an engineering guide has been created on how PCR can be used industrially—from material selection and simulation to the finished product.

Of course, it makes sense to reduce the amount of plastic ending up in the world's oceans. But the real driving force behind projects such as SusPlasPro is the conservation of resources and the economic use of waste. Every kilogram of plastic that is not incinerated but reused as a recyclable material not only saves crude oil but also opens up new business models.
If recycled materials can be used in such a way that they are competitively priced and achieve the required durability and quality, then recycling is no longer a green fig leaf, but a real locational advantage for industry.

To ensure that this does not remain mere theory, the results of SusPlasPro are being directly transferred to industry. A visible example of this is the 2025 Plastics Symposium at Merkle CAE Solutions in Heidenheim. Developers, designers, and companies can learn how to use recycled materials to design products that are economically viable and at the same time help keep plastic waste out of the environment.

Circular engineering shows that plastic recycling is not only beneficial for the environment, but also economically viable. Products made from recycled materials can be just as effective as those made from virgin materials—if they are designed accordingly from the outset. This transforms a waste problem into a new resource that reduces environmental impact while opening up new market opportunities.

👉 Register now HERE for the Plastics Symposium 2025 and experience how waste becomes a valuable resource – practical and economically sound.