From Production Scrap to New Raw Material: How Extrusion and Compounding Work at Skaza

At Skaza, sustainability is not just a commitment—it is an integral and measurable part of our manufacturing process. A key milestone in this journey is our new extrusion and compounding line, which enables us to convert clean production scrap into high-quality recycled material and reintegrate it into the production of new products.

This advanced technology allows us to make more efficient use of materials, reduce plastic waste, and develop proprietary material formulations tailored to the specific requirements of individual products and customers.

What Are Extrusion and Compounding?

Extrusion is a continuous process in which thermoplastic material is melted through the combined effects of heat and mechanical friction, thoroughly mixed, and conveyed through the production line.

Compounding takes this process a step further. During compounding, various additives are incorporated into the base polymer to modify and optimize its final properties. These additives may include stabilizers, pigments, fillers, reinforcing agents, flame retardants, and other performance-enhancing components.

This enables us to improve the material's mechanical, aesthetic, and functional properties while producing a raw material that meets the specific requirements of downstream manufacturing processes.

At the heart of the compounding line is a twin-screw extruder. The co-rotating screws melt the material, ensure uniform dispersion of all components, and transport the molten compound through a heated processing chamber.

As the process operates at elevated temperatures, precise temperature control and accurate dosing of each component are essential. These parameters are monitored and controlled using temperature sensors and a gravimetric dosing system.

The resulting homogeneous melt exits the extrusion line as continuous strands resembling spaghetti. These strands are subsequently cooled, dried, and pelletized into granules. The finished pellets are then ready for reuse in manufacturing processes such as injection moulding.

Which Materials Can Be Processed?

Our new line primarily processes clean technical production scrap generated during manufacturing. This includes start-up scrap, excess material, and parts that do not meet quality specifications due to minor deviations.

Before processing, the material is size-reduced into flakes using an industrial grinder. Since these materials are compositionally similar to the virgin raw materials used in regular production, they can be reintroduced into the manufacturing process after appropriate treatment.

However, the process involves far more than simply grinding and remelting plastic. Through compounding, the material is homogenized under controlled conditions, enhanced with carefully selected additives, and engineered to achieve the desired performance characteristics.

The result is a more stable, higher-quality, and more consistent recycled material suitable for manufacturing new products.

Up to 400 Tonnes of Recycled Plastic per Year

The new compounding line has a processing capacity of 100 to 200 kilograms of material per hour. At full utilization, this translates into the potential to recycle up to 400 tonnes of plastic annually.

A significant portion of production scrap that would otherwise become waste can therefore be transformed back into valuable raw material. This reduces the volume of material requiring disposal while decreasing the demand for virgin polymers.

Such an approach also contributes to lower greenhouse gas emissions and a reduced carbon footprint across the manufacturing process.

In addition to recycling production scrap, we have also developed our first proprietary material formulations. Rather than viewing materials solely as production inputs, we consider them a strategic development element that can be customized to suit a specific product, application, and customer requirement.

Greater Control over Development and Manufacturing

The new compounding line represents an important step in Skaza's vertical integration strategy. By developing and producing our own material formulations, we gain greater control over the entire manufacturing value chain—from raw material selection and formulation development to injection moulding, automation, and final product assembly.

Beyond its environmental benefits, the technology also significantly enhances our development capabilities. It enables us to create tailor-made materials for specific customer applications while responding more quickly to the requirements of individual projects.

This further strengthens Skaza's position as a development partner and provider of integrated manufacturing solutions. Our goal is to offer customers comprehensive support—from material and product development through production optimization and automation to final assembly—all under one roof.

Investing in the Circular Economy

The new extrusion and compounding line was established as part of the European PlasticLIFEcycle project, which received funding from the European Union's LIFE Programme.

The investment also included a broader reorganization of production, process centralization, logistics optimization, and more efficient utilization of available resources.

The introduction of the new line marks another important step in implementing circular economy principles. Material that would traditionally be treated as waste in a linear production model is instead transformed into a valuable raw material for a new manufacturing cycle.

Looking ahead, our objective is to maximize the line's capacity and further increase the volume of processed material. While a significant share of the required feedstock comes from our own production scrap, we also see substantial opportunities through collaboration with external partners and the development of new sources of suitable recyclable materials.

With our new compounding line, we are extending the life cycle of production materials, reducing waste, and creating new opportunities for material innovation. In doing so, we are translating the principles of the circular economy into everyday manufacturing practice and building a more efficient, responsible, and sustainable approach to resource management.