Plastics processing - guide 2025

Introduction to plastics processing

Plastics processing is one of the most dynamically developing sectors of industry worldwide. Thanks to versatility, durability and relatively low production costs, plastics have found application in almost every field of life - from packaging, through automotive, electronics, construction, to medicine and aviation.

The Polish plastics processing industry is among the largest in Central and Eastern Europe. This sector employs tens of thousands of workers in thousands of plastics processing plants, which supply products to domestic and export markets.

In this comprehensive guide, we will present everything you need to know about plastics processing - from chemical basics, through production technologies, to trends and challenges facing the industry.

What are plastics?

Plastics are polymeric materials obtained synthetically from monomers derived most often from crude oil or natural gas. They consist of long molecular chains (polymers) that give them unique properties.

Basic characteristics of plastics:

• Versatility - possibility of giving any shape in the processing process
• Lightness - much lower density than metals or ceramics
• Resistance - to corrosion, moisture, many chemical substances
• Insulation - electrical and thermal
• Economy - relatively low production costs
• Possibility of modification - through additives, fillers, reinforcement

Depending on chemical structure and properties, plastics are divided into several main groups that differ in behavior under temperature influence and processing possibilities.

History of plastics development

The history of plastics dates back to the 19th century. The first semi-synthetic plastic was celluloid invented in 1869 by John Wesley Hyatt. The real breakthrough came in the 20th century.

Key milestones:

• 1907 - Leo Baekeland invented bakelite, the first fully synthetic polymeric material
• 1920s - development of PVC (polyvinyl chloride)
• 1935 - DuPont introduced nylon, the first fully synthetic fiber
• 1939 - start of mass production of polyethylene (PE)
• 1950s - development of polypropylene (PP) and high-density polyethylene (HDPE)
• 1960s-70s - dynamic development of engineering plastics (PC, PA, POM)
• 21st century - development of biopolymers and biodegradable plastics

Currently, global production of plastics exceeds 400 million tons annually, and plastics processing is an industry worth hundreds of billions of dollars.

Types of plastics

Plastics are divided into three main groups according to their behavior under temperature influence and chemical structure:

Thermoplastic materials

Thermoplastic materials (thermoplastics) are the most numerous and important group of plastics in plastics processing. They are characterized by the fact that under heat influence they soften and can be processed multiple times without loss of properties.

Thermoplastic processing includes a range of technologies:

• Injection molding (most common method)
• Extrusion
• Blow molding
• Thermoforming
• Rotational molding

Most popular thermoplastic materials:

Polyethylene (PE)

• PE-LD (low pressure) - films, packaging, bags
• PE-HD (high pressure) - containers, pipes, tanks
• PE-LLD (linear) - stretch films, flexible packaging

Polypropylene (PP)

• Food packaging
• Automotive elements
• Garden furniture
• Fibers and fabrics

Polyvinyl chloride (PVC)

• PVC-U (unplasticized) - pipes, window profiles
• PVC-P (plasticized) - film, flooring, upholstery

Polystyrene (PS)

• Crystal PS - disposable packaging, cutlery
• EPS (styrofoam) - insulation, protective packaging

Engineering plastics:

• ABS - device housings, toys (LEGO)
• PC (polycarbonate) - sheets, lenses, structural elements
• PA (polyamide, nylon) - gears, bearings, fibers
• POM (polyoxymethylene) - precision elements, bearings
• PMMA (plexiglass) - transparent elements, light fixtures

Thermosetting materials (duroplasts)

Thermosetting materials once heated and cured form a three-dimensional spatial network that cannot be reprocessed. Under high temperature influence they do not soften but decompose.

Main thermosetting materials:

• Epoxy resins - laminates, structural adhesives, coatings
• Polyester resins - composites, laminates, boats, pools
• Phenolic resins - electrical insulators, laminates
• Urea resins - adhesives, varnishes

Elastomers

Elastomers are rubber-like plastics characterized by high elasticity and ability to return to original shape after deformation.

Examples of elastomers:

• Natural rubber - tires, seals
• Synthetic rubber (SBR, NBR) - tires, hoses
• Silicone - high-temperature seals, medical implants
• Polyurethane (PU) - foams, seals, linings

Plastics processing technologies

Plastics processing includes a range of advanced production technologies. Choice of appropriate method depends on plastic type, product shape, series size and quality requirements.

Injection molding

Injection molding is the most popular technology in thermoplastic processing. The process involves melting plastic granulate and injecting it under pressure into an injection mold.

Injection molding applications:

• Automotive elements (dashboards, bumpers)
• Electronic housings
• Packaging (lids, closures, containers)
• Household articles
• Disposable medical tools
• Toys

More about injection molding can be found in our comprehensive guide to injection molding machines.

Extrusion

Extrusion is a continuous process of producing profiles with constant cross-section. Molten plastic is pushed through an extrusion die, giving it appropriate shape.

Products from extrusion:

• Pipes and profiles (PE, PVC, PP)
• Films (stretch, heat-shrink, construction)
• Sheets (cellular, solid)
• Window and door profiles
• Cables and wires (insulation)

Blow molding

Technology for producing hollow products. Heated plastic preform is blown with compressed air in a mold, taking its shape.

Products from blow molding:

• PET bottles
• Containers and canisters
• Fuel tanks
• Toys

Thermoforming

Process of forming products from thermoplastic sheets. Heated sheet is formed by vacuum or pressure on a mold.

Products from thermoforming:

• Vacuum packaging (blisters)
• Refrigerator liners
• Bathtubs and shower trays
• Decorative elements

Plastics processing plants

A plastics processing plant is an industrial facility specialized in production of plastic products. Several thousand such plants currently operate in Poland - from small family businesses to large international corporations.

Types of processing plants:

1. Injection molding plants

• Specialize in plastic injection molding
• Have machine park of injection molding machines of various tonnages
• Often offer mold design and production services
• Work on order or produce own products

2. Extrusion plants

• Production of pipes, profiles, films
• High-performance extrusion lines
• Often vertical integration (from granulate to finished product)

3. Blow molding plants

• Production of packaging (bottles, canisters)
• Single- or multi-station blow molding machines
• Often cooperation with food and chemical industries

4. Multi-profile plants

• Combine different processing technologies
• Complete offer from injection to extrusion
• Greater flexibility in customer service

Key elements of processing plant:

• Machines - injection molding machines, extruders, others
• Molds and tools - injection molds, extrusion dies
• Peripheral equipment - dryers, mills, chillers, robots
• Warehouses - raw material and finished products
• Quality control laboratory
• Technical department - production preparation, optimization

Choosing processing technology

Choosing the appropriate plastics processing technology requires analysis of a range of factors:

1. Product shape and geometry

• Complex, solid elements → injection
• Continuous profiles, pipes → extrusion
• Hollow products (bottles) → blow molding
• Flat, shell → thermoforming

2. Production series size

• Mass production → injection (multi-cavity molds)
• Continuous production → extrusion
• Small series → injection (single-cavity molds), 3D printing

3. Quality requirements

• High precision → injection on electric injection molding machines
• Strength → selection of appropriate plastic and technology
• Surface aesthetics → injection, rotomolding

4. Investment costs

• Injection molds - from several to several hundred thousand zlotys
• Extrusion dies - significantly cheaper
• Blow molds - medium cost

Quality control and standards

In plastics processing quality control plays a key role. Particularly important in regulated industries like automotive, medical or food.

Quality systems in processing:

• ISO 9001 - basic quality management system
• IATF 16949 - for automotive industry suppliers
• ISO 13485 - for medical devices
• ISO 14001 - environmental management system
• BRC/IFS - for packaging in contact with food

Quality control methods:

• Dimensional control - calipers, micrometers, CMM
• Mechanical testing - strength, hardness, impact resistance
• Thermal analysis - DSC, TGA, HDT
• Visual inspection - microscopes, vision systems
• Chemical analysis - FTIR, GC-MS

Recycling and sustainable development

Sustainable development is one of the biggest challenges of modern plastics processing. The industry undertakes a range of actions for circular economy.

Types of plastics recycling:

1. Mechanical recycling

• Shredding plastic waste
• Washing and separation
• Regranulation
• Reprocessing

2. Chemical recycling

• Pyrolysis - thermal decomposition to monomers
• Depolymerization
• Gasification

3. Energy recovery

• Incineration with energy recovery
• Alternative fuel production

Biopolymers and biodegradable plastics:

• PLA (polylactide) - from corn, biodegradable
• PHA (polyhydroxyalkanoates) - from bacteria
• Bio-PE, Bio-PP - from renewable sources, but not biodegradable
• Blends - mixtures of traditional and biodegradable plastics

Trends and future of the industry

The plastics processing industry is undergoing dynamic transformation. Key trends are:

1. Digitization and Industry 4.0

• IoT in injection molding machines
• Predictive maintenance
• Digital process twins
• AI in parameter optimization

2. Automation

• Robots at injection molding machines
• Automated production lines
• Vision quality control systems
• Autonomous warehouses

3. Sustainable development

• Circular economy
• Material consumption reduction (lightweight)
• Biopolymers
• Design for recycling

4. New materials

• Nanocomposites
• Fiber composites (carbon, glass fiber)
• Functional plastics (conductive, antibacterial)
• Smart materials (shape memory)

5. Production personalization

• 3D printing with plastics (FDM, SLS)
• Mass customization
• Rapid prototyping

Summary

Plastics processing is a key sector of modern economy. Plastics are ubiquitous and indispensable in almost every field of life.

Key conclusions from the guide:

• Plastics diversity - thermoplastics, duroplasts, elastomers have different properties and applications
• Thermoplastic processing - injection dominates, but also extrusion and blow molding
• Processing plants - from small companies to large corporations, various specializations
• Quality - ISO systems and advanced quality control are standard
• Sustainable development - recycling and biopolymers are the future of the industry
• Digitization - Industry 4.0 is revolutionizing processing

If you run a plastics processing plant or are planning investment in this industry, contact TEDESolutions. We offer comprehensive support - from technology selection, through delivery of Tederic machines, to training and service.

We also invite you to read our specialist articles about injection molding machines, injection molds and contract injection services.