Optimum PCR processing and maximum material savings

Especially as production solution provider, we have to ask ourselves how we can contribute to a sustainable handling of plastics. A well functioning recycling economy is the decisive way to achieve this sustainability.
We see ourselves as part of this cycle by linking between the raw material manufacturers and the processors and producing recyclable products.

Our target:

  • 100 % sustainable use of raw materials
  • Maximum material savings without sacrificing the final plastic product quality


R-Cycle fulfills one of the most important prerequisites for the recycling of plastics as marking makes the packaging identifiable. The complete value chain can be traced right back to the raw materials used via a cloud-based database.

Our case study

One bottle, two approaches

Not comparing apples with oranges, but pointing out specific possibilities. We look at one bottle, but two production approaches.

Both bottles were produced in the ReCo3 process under the same conditions on a KBB60D. The sustainable bottle (green) consists of bio-based plastic and foamed PCR.

Our result:

  • 18% material savings
  • Greater stability thanks to embarrassed cell structure
  • High CO2 savings
  • Same manufacturing costs
  • 100% recyclable

Blue bottle

Green bottle

  • fossil HDPE
  • 3 identical layer
  • Cycle time 13 seconds
  • Weight 48 g

  • bio-based HPPE und PCR
  • Outer and inner layer made of bio-based HPPE; 
  • foamed middle layer made of PCR
  • Cycle time 13 seconds
  • Weight 39 g

Downloads on this topic

You can find brochures, pictures and videos in our media center.



Here you can find the current issue of our customer magazine

We explore the PCR production of tomorrow

Don’t talk about tomorrow – take action today! Based on this philosophy, PCR types from all manner of suppliers have been tested and evaluated at the Kautex Technology Center – not just on behalf of our customers, but for raw material suppliers too.

All benefit from our expertise on the various requirements, allowing us to implement future projects together. We are already working on PCR processing improvements and looking for partners to optimize this further.

Talk to us or learn more about our Technology Center.

Technology Center

From mold validation in one of our international technology laboratories via simulation and all the way to complete line-engineering, everything needed for your turnkey solution is available.

Energy efficiency

The outstanding efficiency of the all-electric extrusion blow molding machines is confirmed by the latest test based on the Euromap 46.1 standards. Several Kautex machines of the KBB series achieved the best energy efficiency classification 10.


Our aim at Kautex, is to join our customers and partners in assuming a pioneering role in transition and the creation of added value with smart production solutions for extrusion blow molding.


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You can reach us by telephone at

+49 228 929 390 14