Revinylize, a collaborative recycling initiative, expands post-consumer rigid PVC recycling across the United States.

Green Eagle, a PVC product manufacturer in South Carolina, used a VIABILITY grant to develop durable shipping pallets made from post-consumer PVC, expanding reuse of difficult-to-recycle vinyl and offering an alternative to traditional wood pallets.

Allied Industries, a South Carolina flooring manufacturer, used a VIABILITY grant to add automated equipment that increases recycling of post-consumer PVC into commercial products made with 100% recycled vinyl.

Exeon, a recycling company in Indiana, used a VIABILITY grant to purchase electrostatic separation equipment that improves recovery of post-consumer PVC from mixed plastics, significantly increasing their recycled PVC output and reducing landfill waste.

Avery Auto Mats, a Georgia-based manufacturer of automotive mats and accessories, used a VIABILITY grant to invest in new injection molding equipment and secure additional sources of post-consumer vinyl, boosting efficiency and diverting more PVC from landfills.

Every Shelter, a Houston-based nonprofit, repurposes used vinyl billboards into durable emergency tarps for disaster relief, diverting significant PVC from landfills while providing longer-lasting shelter solutions.

Lastique, a Louisville PVC recycler, used a VIABILITY grant to enhance its post-consumer PVC recycling capabilities and increase recovery of recycled vinyl materials for reuse.

CFFA, the Chemical Fabrics and Film Association’s roofing division, used a VIABILITY grant to build out PVC roof recycling infrastructure, expand recycling networks, and raise awareness among stakeholders to increase post-consumer PVC roofing recycling and keep material out of landfills.

FGIA, the Fenestration and Glazing Industry Alliance, used a VIABILITY grant to research and develop a pilot project to recycle vinyl windows at the end of their life.

North American PVC recycling prevents roughly 1 million tons of CO₂ emissions annually and continued advances in electrification and energy-efficient manufacturing could reduce emissions by 61% to 95% by 2050.²⁰

PVC recycling delivers significant conservation benefits, achieving 50–90% energy savings compared to virgin production while enabling recovery of valuable resources for reuse.²²

Recycled PVC can be processed into high-quality pellets and granules suitable for multiple reuse cycles with minimal quality loss.

The EPA’s 2020 Recycling Economic Information Report found that recycling and reuse activities generate 1.17 jobs for every 1,000 tons of materials recycled.²⁷

PVC recycling begins with collecting pre- and post-consumer waste, with careful separation of materials. Rigid and flexible PVC must be kept separate due to differences in composition and the use of plasticizers, making proper sourcing and procurement essential for effective recycling.

Primary shredding reduces PVC to roughly 20 mm particles using high-capacity equipment, typically processing 2–5 tons per hour. Careful temperature control during this step is essential to preserve polymer integrity and maintain final product quality.

PVC can be separated from other plastics through multiple processing stages, including density separation using water or brine solutions. More advanced electrostatic separation can further distinguish between rubber, flexible PVC, and rigid PVC, while additional steps such as magnetic separation and air classification remove metals and lightweight contaminants to improve material purity.

Advanced optical sorting uses near- and mid-infrared, X-ray, and camera-based technologies to identify and separate PVC by material type and color. These systems are critical for producing high-value, color-consistent PVC, while emerging AI-driven identification and robotic sorting are being developed to address more complex challenges such as tangled materials and black plastics.

Washing can be a critical step in PVC recycling, depending on the feedstock quality. Washing removes contaminants that can degrade material quality and performance. Cold washing removes lighter residues, while intensive hot washing at 60–90°C—sometimes using sodium hydroxide—eliminates oils, grease, and stubborn contaminants to ensure usable recycled PVC.

Granulation creates uniform PVC particles of 2–5 mm, which are then dried to very low moisture levels. The material is pelletized using extrusion at controlled temperatures, producing recycled PVC pellets with properties comparable to virgin material.

Quality control is maintained throughout the PVC recycling process through continuous monitoring of key parameters such as temperature, flow rates, and contamination. Statistical process controls and final performance testing ensure recycled PVC meets required mechanical and thermal standards.