Easing logistical challenges to recycling

The intent to recycle is beset by logistical challenges, says Andrew Nasarczyk, global director, innovation and sustainability, for Gale Pacific Ltd. However, through a strategic approach, his company is having good luck with agricultural grain covers, water containment liners, structural fabric and billboard fabric. Nasarczyk presented a session at Advanced Textiles Expo 2025 in Indianapolis, Ind. 

“You need a good recycling partner to be involved,” Nasarczyk says. “You need to have the will to do it and a lot of partners to do it. … It requires a network of collaborators.” 

It’s difficult to do economically and at scale, he says. After their first use, materials need collection and transport for shredding, washing and pelletizing before they can be repurposed for a new application or be fed back into a circular process. 

Designing products that are not composites is one key, because traditional coated PVC fabrics are difficult to get back into their individual components. He says Gale has found that coated polypropylene (PP) and polyethylene can be repurposed, such as into another plastic product, or made into a recyclable resin for coating fabric, enabling circularity. PP is lighter weight than PVC, doesn’t need plasticizers for flexibility and still has comparable performance qualities while being recyclable. 

“We’re finding that it still has good mechanical properties after four times in that [circular] loop,” he says. “How many times this circular loop can be repeated is yet to be fully determined; however, our initial observations are very encouraging.”