The science

Manufacturing high performance Zyplex is dependent on the excellence of our technical processes on site. Creating the different Zyplex blends involves rigorous testing and quality control checks.

Once it arrives on site, the plastic waste is shredded and granulated into small pieces before being sorted according to type and colour. It is then tested in our laboratory for filler content and viscosity to ensure it achieves the specific performance characteristics required by each Zyplex blend.

The individual Zyplex blends are created by mixing together different types of plastic, following specific formulations developed by our technical department. A wide range of different tests are used, including flexural strength, impact, weather resistance, fluid resistance and environmental stability, to establish the performance reliability of the blends.

Once the blend has been mixed correctly and has passed all the necessary quality controls for consistency, the compound is then melt processed under highly controlled conditions and converted into a range of plastic lumber or injection moulded into a variety of different shapes. Any offcuts of Zyplex created during the manufacturing process are fed back into the system, reshredded and turned into other recycled products. No plastic waste is created during the process.

A technician testing the shredded plastic in the laboratory

Our technical department (in alliance with the University of Sheffield and other independent test houses) is continually testing Zyplex to extend its use into new applications and to supply technical data for designers and engineers.

According to rigorous testing:

  • Zyplex does not contain any substances that are harmful to the environment 
  • Zyplex complies with European Union legislation to minimise the environmental effect of products
  • Zyplex meets the smoke toxicity requirements for London Underground
  • As ultraviolet light only penetrates a very thin top layer of Zyplex, the overall mechanical properties of the product are not significantly affected by UV degradation.
A technician measuring the plastic lumber in the laboratory

“Recycled plastics have the capability of being manufactured into a vast range of applications that can replace traditional materials like wood, concrete and steel. It is critical that the formulation of the plastics and the processing conditions are controlled carefully, but given the right process and thorough understanding of the constituent parts of the mix, incredible strength and versatility can be achieved in the final product.”

Dr Alma Hodzic, Reader in Aerospace and Mechanical Engineering, The University of Sheffield