Regrind Material in Injection Molding: A Smart Strategy for Cost-Effective Plastic Manufacturing
- AAIMS Molding
- Apr 16
- 3 min read
In the competitive world of plastic manufacturing, keeping production costs low without compromising quality is key. One proven way injection molding companies achieve this is by using regrind material—a sustainable and cost-effective solution that supports both environmental and economic goals. At AAIMS Molding, we understand the value of smart material usage, and regrind plays an important role in optimizing our injection molding process.
What Is Regrind Material?
Regrind refers to plastic scrap—usually sprues, runners, or rejected parts—that are ground up and reused in the manufacturing process. Unlike virgin plastic, which is new and unused, regrind is recycled in-house, helping injection molding companies maximize material efficiency.
How Is Regrind Material Processed?
At AAIMS Molding, regrind begins with an efficient and precise process using industrial-grade granulators—specialized regrinding machines designed to handle tough plastic scrap from injection molding operations.
Once parts like runners, sprues, or rejected components are collected, they are fed into the granulator. This machine features a series of sharp rotating blades that grind plastic into uniform granules, typically referred to as “regrind.” These granules are then screened to ensure consistent size and quality before being reintroduced into the molding process.
Our granulators are located directly on the production floor to streamline operations and reduce handling time. This not only improves efficiency but also ensures traceability and control over the regrind material.
Whether it's ABS, polypropylene, or other thermoplastics, our equipment is calibrated to maintain the integrity of the plastic throughout the grinding process—ensuring that our regrind is clean, homogeneous, and suitable for reuse in a wide range of applications.
Why Use Regrind in Injection Molding?
Lower Production Costs
One of the primary benefits of using regrind material is its ability to reduce raw material expenses. Virgin plastic resin is one of the highest costs in injection molding production. Regrind helps offset this by supplementing or replacing a percentage of virgin material, especially in non-cosmetic parts or internal components.
Less Waste, More Sustainability
Reusing plastic materials helps reduce the overall amount of waste generated during manufacturing. This aligns with the growing push toward sustainable plastic manufacturing and eco-conscious practices. At AAIMS Molding, our ability to recycle and reuse plastic aligns with our commitment to responsible manufacturing.
Supports Lean Manufacturing
By minimizing waste and maximizing material usage, regrind contributes to lean manufacturing practices—a key advantage in maintaining competitive pricing and operational efficiency.
How Regrind Is Used: Blending with Virgin Material
In most applications, regrind material is not used on its own. Instead, it is carefully blended with virgin resin in specific ratios to maintain part integrity and quality. This practice allows manufacturers to reduce costs while preserving the physical and aesthetic properties of the final product.
A typical blend ratio might be 10% to 30% regrind with 70% to 90% virgin plastic, depending on the application.
For non-critical parts, the regrind percentage may be higher.
For precision components or cosmetic parts, the blend is often limited or avoided altogether to ensure consistent appearance and performance.
At AAIMS Molding, we evaluate every project individually. Our engineers determine the appropriate regrind-to-virgin ratio based on part design, material type, performance requirements, and end-use conditions.
Things to Consider When Using Regrind
While the benefits are significant, it’s important to consider a few challenges:
Material Degradation
Each time plastic is re-melted, its properties can slightly degrade. Excessive use of regrind may affect the strength, color, or finish of the final part. That's why blending with virgin resin is crucial—it stabilizes the material and maintains consistency.
Consistency in Quality
Using regrind requires a controlled process. Poorly sorted or contaminated regrind can compromise product quality. At AAIMS Molding, we implement strict quality controls to ensure our regrind is clean, consistent, and suitable for reuse.
When Is Regrind the Right Choice?
Regrind material is ideal for:
Non-visible parts (internal components, structural elements)
Prototype parts or early production runs
High-volume runs where cost savings compound over time
Products that allow flexibility in color and material specifications
AAIMS Molding’s Commitment to Smart Manufacturing
As a leading injection molding company in Southern California, AAIMS Molding blends innovation with efficiency. We use high-quality plastic materials, including regrind, when appropriate, to offer clients the best balance between performance, sustainability, and cost. Our team ensures that every batch of regrind meets stringent quality standards, so your products perform flawlessly—every time.
Using regrind material in plastic injection molding is more than just a cost-saving measure—it's a smart step toward sustainable and efficient plastic manufacturing. Whether you’re launching a new product or looking for ways to cut production costs, AAIMS Molding is ready to help you make the most of your materials.
Need Help with Your Next Injection Molding Project?
Let’s talk about cost-effective solutions tailored to your needs. Contact AAIMS Molding today at www.aaimsmolding.com or call us at (951) 296-6200 for a custom quote.
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