NOVA Chemicals Unveils its First Polyethylene Film Recycling Facility in Indiana

NOVA Chemicals has officially opened one of the most advanced polyethylene (PE) film recycling facilities globally, SYNDIGO1, located in Connersville, Indiana, USA. According to NOVA Chemicals, this facility will have the capacity to produce 100 million pounds of recycled polyethylene (rLLDPE) annually, a significant step towards a circular economy in the plastics industry.

Spanning 450,000 square feet, the plant is reported to process end-of-life plastic film waste, recycling up to 145,000 bales per year. Full-scale production is expected by early 2026, with the facility averaging 400 bales of plastic film per day (14,000 bales per month). Three of its four lines are already operational, and the final line will be launched by the end of 2025.

The facility’s operations aim to provide sustainable packaging solutions by turning waste plastic into valuable resources. The recycled rLLDPE will be used in a variety of packaging applications, including food-grade and non-food-grade options such as trash can liners and food packaging. A-grade SYNDIGO rLLDPE is FDA-compliant for all food types under Conditions of Use B through H, enabling its use in food packaging applications like refrigerator and freezer items.

NOVA Chemicals has partnered with Novolex, a leader in flexible packaging solutions, to operate the facility. This collaboration, first announced in 2023, is crucial to meeting the increasing demand for recycled content in packaging and supporting sustainability goals within the industry.

The launch of the SYNDIGO1 facility comes as part of a broader trend toward sustainable packaging innovations. Recently, Berry Global’s flexible films division unveiled Bontite Sustane Stretch Film, which incorporates 30% post-consumer recycled content and is recyclable where PE film collection programs exist. Additionally, Taghleef Industries introduced SHAPE360 TDSW, a polyolefin shrink sleeve film designed for clear PET bottles, offering high ink adhesion to ensure recyclate purity.

As the industry moves toward more sustainable practices, NOVA’s SYNDIGO1 facility represents a critical step forward in reducing plastic waste and promoting the reuse of materials in packaging, contributing to a circular economy.

Source: NOVA Chemicals