Trex adds LLDPE pellet production

Trex Co., Winchester, Virginia, a leading manufacturer of composite decking and railing made in part from recycled linear low-density polyethylene (LLDPE), says it has found a viable way to close the recycling loop by using its excess raw material to produce recycled LLDPE pellets. Suitable for use in a variety of manufacturing applications, these pellets represent an entirely new business for Trex.

“As they say, necessity is the mother of invention,” says Jim Cline, president and CEO of Trex Co. “As one of the country’s largest recyclers of postconsumer and commercial polyethylene, we found ourselves with a surplus of material beyond what we could use in our core line of outdoor living products. We challenged our engineering team to come up with ways to use the excess material, and, as usual, they didn’t disappoint. In fact, what they developed has created a whole new business venture for us that not only benefits Trex but other manufacturers and the environment, as well.”

Leveraging its recycling and extrusion capabilities and using equipment downtime to experiment with and test different solutions, Trex says its engineering team ultimately delivered a LLDPE pellet suitable for use in a variety of products and industries.

“We envision numerous applications for our recycled pellets,” says Dave Heglas, senior director of material resources at Trex. “They are ideal for use in the production of bags, including trash bags, as well as molded products, such as bins, totes and even kayaks. We also see tremendous potential for these pellets in the manufacturing of both rigid and flexible tubing, such as agricultural drip tape.”

Heglas joined Trex in 1996 as an engineer responsible for the raw materials and plastic processing side of the business. After a few years working with recycled materials, he saw opportunities and potential value in using and repurposing recycled plastic, the company says. In 2004, Heglas formalized the Trex’s recycling operations, an initiative which has evolved into a company within the company.

“Turning Trex from a company using recycled plastic into a plastic recycler was something that made perfect strategic sense,” Heglas saya. “We were collecting way more than we needed or could ever use in our deck boards, so we began selling off some of our inventory to manufacturers in other industries.”

Among those manufacturers were small companies that Trex contracted to produce plastic pellets. Over time, it occurred to Heglas that Trex could be fabricating pellets in-house rather than outsourcing to third parties. After nearly a decade of experience producing pellets for Trex internal use, the next logical progression was to leverage the in-house expertise and expand capabilities to produce pellets for additional industries and markets, the company says.

“We quickly realized that we were the only company capable of producing LLDPE pellets in high volumes and with greater consistency,” Heglas says. “Previously, manufacturers had to rely on multiple sources for plastic pellets, which meant unpredictable quantities and widely varying product characteristics. With our extensive supply and equipment capacity, Trex is able to deliver the quantities and quality manufacturers’ need at a lower price and with the added convenience of a single-source provider.”

Currently, Trex says it has four lines dedicated to recycled pellet production, making it one of the largest producers of recycled LLDPE pellets in the country. The company says it has plans to add several more lines in the future. 

“Trex was literally built on sustainable principles, and these continue to be at the heart of everything we do,” Heglas says. “With this new business, we are looking to partner with manufacturers that recognize the many benefits of using recycled materials and share our commitment to protecting the environment.”

Trex says it is working with manufacturers across a wide range of industries, such as rotational molding, blown film, profile extrusion and material compounding, to explore additional uses for its LLDPE pellets. As the product innovator, the company says it has the flexibility to modify and reformulate pellet content as needed to better fit specific needs, processes and applications. 

More information about Trex’s new LLDPE pellets is available from Heglas at dheglas@trex.com or at 800-289-8739.