Film
Overview
The Challenge
Turmec to delivered a major upgrade of an existing recycling facility in the UK. Originally designed to process and clean paper and mixed fibres, the plant required a complete transformation to handle mixed post-consumer and commercial plastic films.
The project represented a significant engineering and operational challenge, requiring the adaptation of existing infrastructure while integrating advanced film sorting technology capable of meeting growing market demand for flexible plastic recycling.
At the time of completion, the facility became the largest film sorting plant in the UK.
The original facility had been engineered specifically for paper and fibre recovery operations. Processing lightweight mixed films presented an entirely different material profile and operational dynamic, including:
- Highly variable feedstock composition
- Lightweight and difficult-to-handle materials
- Increased risk of wrapping and contamination
- The need for high volume throughput separation
- Maximising recovery efficiency while maintaining product quality
They required a future-focused solution that could convert the plant into a high-capacity film sorting operation without the cost and disruption of building a completely new facility.
The Solution
Turmec designed and delivered a comprehensive retrofit and upgrade programme that transformed the existing plant into a specialist mixed film sorting facility.
The upgraded system was engineered to process both post-consumer and commercial films at industrial scale, incorporating advanced mechanical separation and material handling technologies tailored specifically for lightweight flexible plastics.
Key elements of the project included:
- Reconfiguration of the existing plant layout
- Integration of specialist film processing equipment
- Enhanced separation and sorting capabilities
- Upgraded conveying and handling systems
- Optimised throughput and operational efficiency
- Improved contamination removal processes
The retrofit approach enabled them to maximise the value of existing infrastructure while significantly expanding operational capability.
Results
The completed facility established a new benchmark for film recycling capacity in the UK market.
Project Outcomes
- Largest film sorting plant in the UK
- Successful conversion from paper and fibre processing to flexible plastics recycling
- Increased recovery efficiency and throughput
- Enhanced capability to process mixed post-consumer and commercial film streams
- The project demonstrated Turmec’s ability to successfully repurpose and modernise existing recycling infrastructure for emerging waste streams and evolving market requirements.
- By transforming the facility into a high-capacity film sorting plant, they strengthened their position within the UK recycling sector while contributing to increased recovery and recycling of flexible plastics — a critical area of focus for the industry.
- The project also reinforced Turmec’s expertise in delivering complex retrofit solutions that combine engineering innovation, operational efficiency, and scalable recycling performance.
