Dear Joslyn: Virgin vs. Regrind

Dear Joslyn,

My company is launching a new product line and, while researching material options, the terms “virgin” and “regrind” keep popping up. What’s the difference and how do I decide what’s best for my application?

-Cpt. P. Lanet

Dear Captain,

Let’s begin with a quick lesson on the differences between regrind and virgin materials. Regrind, also referred to as reprocessed or utility, is any recaptured scrap resin resulting from the manufacturing process. For example, rejected parts and production scrap are two of the main sources of regrind. These leftovers are ground down to pellet size, mixed with virgin resin and extruded to make new material, or a layer of regrind material may have a virgin cap applied to it. Virgin material is made from resin that has never been processed before, meaning it has never been through the extrusion or molding process. The tables below compare some of the pros and cons of each material type, but the end use of your parts should determine your material selection.

 

Regrind Material

Pros

  • Costs less than virgin material
  • Optimizes material usage
  • Reduced demand on natural resources

Cons

  • Lower cosmetic quality (i.e., color and thickness variations) and lower part strength
  • Material shrink may vary slightly more than virgin material
  • Higher % of regrind usually results in a higher material scrap rate

 

Virgin Material

Pros

  • Higher part quality and aesthetics
  • Improved repeatability in the production process
  • Higher stability and strength of part

Cons

  • Higher cost than regrind material
  • Sheet formulations may vary between extruders, resulting in the use of one supplier and their material cost
  • Specific resin availability may fluctuate

-Joslyn Manufacturing

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