Integrated Recycling Process for Transforming Post-Consumer Plastics into High-Value Construction Materials

Overview

Magma Group has developed an integral recycling process that converts post-consumer plastics, primarily PP and HDPE, into high-value construction materials. This approach addresses the inefficiencies of small-scale recycling operations in Colombia by introducing a complete, optimized workflow that transforms plastic waste into durable products including Lego-style interlocking blocks, square sheets, poles, and hexagonal pavers. The process reduces recycling costs while guaranteeing the quality and traceability of every output, enhancing both market potential and environmental impact.

The initiative is rooted in Magma Group's Technological Development Line in Circular Economy, which has previously executed open innovation projects focused on designing and validating plastic processing machinery. Past successes in continuous processing of PET and HDPE bottles laid the groundwork for this expanded effort. A current pilot project is underway to demonstrate the feasibility of these recycled materials in social housing construction.

Technical specifications

Recycling machinery suite:

• Shredders that triturate bottles, labels, and caps collectively, eliminating the need for pre-sorting
• Washers that exploit density differences to achieve effective separation of plastic types
• Dryers that prepare material for extrusion with consistent moisture control
• Extruders that process cleaned plastic into uniform feedstock
• Hot presses that form finished construction products

Validated processing capacity:

• Productivity of up to 100 kg/h of post-consumer PET and HDPE bottles
• PP and HDPE bottle blocks weighing between 1.2 to 1.7 kg
• Output products meet requisite mechanical properties for construction applications

Future enhancements:

• Integration of state-of-the-art automation to reduce waste and increase processing speeds
• Rigorous mechanical and physicochemical testing of blocks, sheets, poles, and pavers to exceed industry benchmarks
• Construction of a 45m² prototype house to demonstrate real-world application

Technology readiness level

The technology has progressed beyond conceptualization. All five core machines (shredders, washers, dryers, extruders, and hot presses) have been designed, validated, and tested in real-world trials with Colombian recycling associations. The process has demonstrated successful continuous processing of PET and HDPE bottles with proven productivity rates. Current efforts focus on refining machinery systems, automating operations, and conducting comprehensive product testing. The concluding phase involves constructing a full prototype house to validate practical application and potentially reduce conventional construction timeframes. The technology is at a stage ready for pilot demonstration and partnership engagement to scale operations.