Abstract: A method of processing PCR plastic is disclosed, the method including a step of providing a bulk quantity of flakes of PCR plastic having a particle size of about 10 mm or larger separating ferrous and non-ferrous metals from the bulk of flakes of PCR plastic, comminuting the flake to a particle size less than 10 mm, such as about 4 mm, and thermally treating the flake to reduce a moisture content therein. The process may further including mixing the thermally treated flake with virgin plastic pellet and processing the mixture directly in an injection molding device.

Abstract: A method for treating extremely small particles of plastic comprises providing a quantity of plastic particles having an average mean particle size ranging from about 0.0005 inch to about 0.05 inch in diameter, heating the plastic particles to a temperature sufficient to cause at least a portion of the plastic particles to adhere to one another, and forming the adhered plastic particles into pellets, said pellets having substantially the same average surface-to-volume ratio as the bulk, un-adhered plastic particles.

Abstract: A method for treating extremely small particles of recycled polyethylene terephthalate comprises providing a quantity of RPET particles having an average mean particle size ranging from about 0.0005 inch to about 0.05 inch in diameter, heating the RPET particles to a temperature sufficient to cause at least a portion of the RPET particles to adhere to one another, and forming the adhered RPET particles into pellets, said pellets having substantially the same average surface-to-volume ratio as the bulk, un-adhered RPET particles.

Abstract: A process for preparing extremely small RPET particles comprises proving a quantity of RPET flakes, increasing the crystallinity of the RPET flakes, separating a portion of the RPET flakes having the lowest particle density from the remainder of the RPET flakes, and comminuting the remaining RPET flakes, to prepare RPET particles having an average mean particle size less than 500 microns.

Abstract: A method for treating extremely small particles of recycled polyethylene terephthalate comprises providing a quantity of RPET particles having an average mean particle size ranging from about 0.0005 inch to about 0.05 inch in diameter, heating the RPET particles to a temperature sufficient to cause at least a portion of the RPET particles to adhere to one another, and forming the adhered RPET particles into pellets, said pellets having substantially the same average surface-to-volume ratio as the bulk, un-adhered RPET particles.

Abstract: A process for preparing an RPET polymer blend component comprises providing a quantity of RPET flakes, comminuting the RPET flakes to prepare RPET particles having an average mean particle size from about 500 microns to about 5 microns, adding at least one specialty additive to the RPET particles, and mixing the RPET particles and specialty additive, to prepare a homogeneous blend of RPET carrier and specialty additive.