Reactive Recycling™ — the missing performance layer in mechanical recycling
Recycled plastics weren't supposed to perform. They weren't supposed to cost less either. Reactive Recycling™ changes both — on existing extrusion lines, with no additional capex.
The Inverse Green Premium™: going green doesn't have to cost more
Most sustainability solutions come at a premium. Reactive Recycling™ targets the opposite: lower-cost feedstock, higher recycled content and steadier processing together bring total production cost down. Nexam calls this principle The Inverse Green Premium™.
| Virgin resin — baseline | 100 |
|---|---|
| Conventional “green” route | +15% |
| Reactive Recycling™ | −15% |
Relative production cost, indexed to virgin resin at 100. These are the manufacturer's published illustrative figures, shown to explain how the technology works; actual results depend on your feedstock, your line and your target product.
The problem: why performance is lost in recycling
Mechanical recycling changes polymer structure. Over successive processing cycles, polymers lose molecular weight, melt strength and processing stability. For decades this was treated as an unavoidable consequence of mechanical recycling.
On the line it shows up as falling intrinsic viscosity and brittle sheet in PET; insufficient melt strength, sag and unstable film bubbles in PE; and a melt flow rate that doesn't match the target process in PP. The outcome is the same in each case — more scrap, lower line speed and a capped recycled-content ratio.
The mechanism: rebuilding performance during processing
Reactive Recycling™ does not replace existing recycling systems; it reinforces polymer performance during processing. The reactive additive rebuilds molecular architecture in the extrusion step, restoring the properties converters rely on for stable, efficient production.
Instead of accepting degradation, manufacturers can recover performance while increasing recycled content. It is dosed into the existing extrusion step as a NEXAMITE® or NexCircle® masterbatch or powder additive.
Designed for industrial reality, not the laboratory
- Works on existing extrusion equipment
- Runs on existing production lines
- Leaves existing recycling infrastructure in place
- Requires no additional capital investment
- Dosage and formulation are set per line through technical trial
Industrial proof: every application follows the same path
| 01 · Laboratory validation | The feedstock is analysed; the right grade and starting dosage window are identified. |
|---|---|
| 02 · Pilot trials | The formulation is confirmed at small scale; IV, melt strength and flow behaviour are measured. |
| 03 · Industrial trials | Run on your own line, with your own feedstock, under normal production conditions. |
| 04 · Commercial production | Regular supply, a fixed formulation and repeatable results. |
| 05 · Continuous optimisation | As feedstock sources change, dosage and formulation are re-tuned together. |
Feedstock flexibility: better feedstock isn't always better business
Manufacturers often buy expensive, high-quality recyclate purely to keep the process stable. Once the performance layer is in place, the range of usable feedstock widens.
| Traditional approach | With Reactive Recycling™ |
|---|---|
| Premium feedstock required | Mixed-quality recyclate and internal scrap become usable |
| Lower recycled content | A higher recycled-content ratio can be targeted |
| Higher material cost | Lower total material cost |
| Process variability and scrap | Steadier production, less scrap |
| Sustainability at a premium | Sustainability with economic upside |
Which product for which stream?
| rPET — IV recovery | NEXAMITE® M021200 |
|---|---|
| PET yarn, filament and strapping | NEXAMITE® M992000 |
| rPE — melt strength | NEXAMITE® R305 · NexCircle® R401 |
| rPP — MFR control | NexCircle® R403 |
| Virgin PE — melt strength and sag | NEXAMITE® A48 / M480502 |
| Pure PMDA crosslinker | B02 (PMDA) |
Application pages
What this means for producers exporting to the EU
For a producer placing packaging on the EU market, recycled content is no longer only a sustainability target — it is a market-access condition. Regulation (EU) 2025/40 sets differentiated recycled-content targets by packaging category from 2030. Meeting that condition without raising the cost base is a direct competitive advantage.
Supply from Türkiye. Priority grades are held in stock in Istanbul, so a trial doesn't wait on a European shipment. Trials are planned and run on your own line with a local technical team, and KKDIK registration status is confirmed in writing on request.
Source and reference
The technical and economic content on this page is adapted from Nexam Chemical AB's official Reactive Recycling™ platform. Trademarked names are kept in their original form and belong to Nexam Chemical AB.
Frequently asked questions
The technical statements on this page are based on the manufacturer's current public product information. Dosage, temperature and performance targets are defined per line through technical trial.
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