Plastic Recycling Consulting Services

Exponent scientists and engineers help waste management companies test and evaluate the performance and safety of their pyrolysis processes and emissions control and treatment systems. Pyrolysis — an advanced, high-temperature, oxygen-free recycling process that breaks down hard-to-recycle plastics into raw materials that can be used to create new, high-quality plastics and other valuable commodity and energy chemicals — may produce toxic gases, create fire or explosion risks, and introduce chemical hazards to workers and surrounding environments.

Exponent's multidisciplinary teams help plastic recycling facility operators characterize volatile organic compounds (VOCs), polycyclic aromatic hydrocarbons (PAHs), and other gases produced through traditional and advanced recycling processes (including pyrolysis, hydrogenation, hydrotreating, stripping, water washing, polishing, and steam cracking) and mitigate potential risks to human health and the environment. We provide organizations with science-backed strategies to address process performance, risk, and safety through rigorous assessments of pollutant discharge and treatment systems; equipment design and robustness evaluations; identification of worker exposure pathways and determination of worker exposures and health risks; the testing and implementation of hazard controls such as personal protective equipment (PPE), local exhaust ventilation, and preventative maintenance protocols; and on-site monitoring and sampling studies for pyrolysis gases and other chemicals.

As the composition of plastic materials, including additives, fillers, and impurities, can significantly impact the recyclability of plastics and the quality of recycled products, Exponent helps plastic recycling organizations and plastic packaging manufacturers evaluate materials and mitigate issues with plastic performance and quality. Leveraging deep expertise in chemistry, materials science, and chemical and mechanical engineering, Exponent performs custom testing to identify the presence, type, and impact of impurities in plastic materials, which can degrade post-consumer recycled (PCR) resin, compromise mechanical properties, and affect processing efficiency. We provide robust support for product redesign to improve recyclability, reclaimed component performance, and sustainability.

Exponent's industrial hygienists assess recycling facilities for chemical hazards and provide occupational health and safety assessments for state and federal regulatory requirements. Our multidisciplinary teams of safety, compliance, industrial hygiene, human factors, and toxicological, medical, and environmental consultants go beyond standard safety evaluations to pinpoint vulnerabilities that may pose risks. We conduct custom, site-specific assessments to help organizations identify, quantify, and mitigate worker exposures to fugitive dusts, microplastics, nanomaterials, heavy metals, and volatile organic compounds (VOCs).

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Our chemical, environmental, and human health scientists and engineers help waste management and recycling facilities navigate challenging issues related to chemical release, pollutant discharge, and treatment or mitigation options, offering holistic risk assessments of emissions and wastewater. We conduct exposure and water quality assessments, fate and transport analyses, and human and ecological risk assessments to help clients assess how chemicals used or produced during operations might impact surrounding communities and the environment and how to mitigate potential impacts.

We offer extensive exposure assessments, such as bioavailability analysis for soils, sediments, and natural waters, and modeling of chemical uptake into organism tissues to better understand pathways and levels of potential exposure. Our risk assessors design studies and gather evidence to support more accurate predictions of chemical release and exposure that can be used to inform risk, helping clients protect the well-being of communities through retrospective and prospective studies.

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As global scrutiny over the impact of microplastics on human health and the environment increases, Exponent helps clients assess and manage risks associated with micro- and nanoplastic formation during plastics recycling. Our multidisciplinary teams conduct detailed assessments of plastic waste composition and recycling technologies to evaluate the likelihood of micro- and nanoplastic generation during the recycling process and throughout the lifecycle of a recycled product. We also characterize the rates of microplastic generation, analyze their chemical composition, and determine particle size distributions of microplastics at various processing stages.

These insights empower organizations to identify critical control points, implement targeted mitigation strategies, and ensure alignment with evolving regulatory, occupational, and environmental standards, ultimately supporting safer and more sustainable recycling operations. Exponent stays abreast of the evolving science and public scrutiny surrounding microplastics and the potential risk they may present to human and ecological receptors. We critically evaluate analytical methods and results, fate and transport models, and claims of exposure and risk to present our clients with valid data and appropriate risk management options.

Exponent's teams of thermal scientists and engineers specialize in fire and explosion risk assessment for plastics recycling facilities. We help clients interpret National Fire Protection Association (NFPA) standards and conduct thorough risk assessments for flammable pyrolysis products (gases and oil), combustible dust, and combustible bulk plastics in recycling facilities. Our engineers perform custom process and contaminant evaluations to mitigate unintended ignition of plastic materials and design combustible dust testing programs tailored to plastics recycling. We support dust hazard analyses (DHAs) and assist facilities in implementing targeted management strategies based on DHA recommendations.

Our teams offer custom technical and risk-based analyses where standards compliance may be challenging, helping clients address enforcement risks and enhance safety for workers and communities. Exponent identifies relevant documentation and determines additional data needs from field surveys, equipment records, sampling, and testing to support combustible dust management in plastics recycling environments. Our engineers also help facility operators prepare for potential worker exposure events, fires, and explosions with evaluations of emergency response procedures and emergency training for employees.

Additionally, if fire and explosion incidents do occur, Exponent's teams have industry-recognized training and expertise, including National Association of Fire Investigators (NAFI) Certified Fire and Explosion Investigator (CFEI) and International Association of Arson Investigators (IAAI) Certified Fire Investigator (CFI) credentials. Our engineers can help facility operators effectively evaluate incident origin and cause and apply the results of these investigations to help prevent future incidents.

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Exponent's multidisciplinary teams help consumer product manufacturers address complex factors of product stewardship and develop accurate and compliant labeling for products containing recycled plastic content. Our team offers technical and regulatory support to substantiate marketing claims regarding recyclability, recycled content, and environmental benefits. Additionally, we actively participate in the development and interpretation of standards for labeling plastics as "compostable," "biodegradable," or "recycled," supporting clients in maintaining transparency and compliance in their product communications.

Our regulatory experts offer specialized expertise in environmental compliance with Toxic Substances Control Act (TSCA) and Environmental Protection Agency requirements. Our experts also provide plastic recycling organizations with guidance on occupational exposure compliance, helping to ensure that plastics recycling operations adhere to relevant worker safety standards overseen by the Occupational Safety and Health Administration (OSHA), California's Division of Occupational Safety and Health (Cal/OSHA), and other agencies. We help consumer products companies navigate state and federal regulations designed to reduce single-use plastics and promote recyclability, as well as emerging extended producer responsibility (EPR) regulations in California, Colorado, Maine, Oregon, and elsewhere. 

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Our scientists and engineers provide objective, science-based assessments to support clients in high-profile disputes involving allegations of false marketing claims, occupational exposures, or environmental releases. Our independent, data-driven evaluations and investigations bridge complex science and diverse legal environments, providing clients, judges, and juries with technical clarity founded on rigorous, reproducible scientific methods.

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EPR regulations require manufacturers, importers, and retailers of plastic products and packaging to take greater responsibility for the lifecycle of their materials, including collection, recycling, and proper disposal. These laws aim to reduce single-use plastics, increase recycling rates, and shift the cost burden of waste management from municipalities to producers. EPR programs often mandate reporting, labeling, and the use of recycled content, as well as compliance with state and federal standards. To address these regulations effectively, consumer product manufacturers — including food and beverage, personal care, household cleaning, pharmaceutical, and electronics companies — and plastic packaging companies can substantiate environmental claims with scientific data and evidence-based findings and implement robust, data-driven risk management and product stewardship strategies.

Chemical recycling is a process that breaks down plastic waste into its chemical building blocks, which can be re-polymerized to generate new plastics. This process can significantly improve the quality of recycled plastics by removing contaminants and controlling polymer structure. By optimizing reactor designs, implementing precise temperature controls, characterizing and assessing impurities, thoroughly pre-sorting feedstock, and other measures, plastic recycling facility operators can improve the quality and purity of recycled plastics to meet regulatory requirements and market expectations.

Reclaimed components from pyrolysis can be used in a wide range of applications, including automotive components, electronics components, construction products, consumer goods, medical products, packaging materials, and textiles. Their improved purity and performance make them suitable for demanding uses where durability, safety, and aesthetic standards must be met, allowing manufacturers to substitute recycled content for virgin materials without compromising quality. Experienced engineers can help facility operators optimize process parameters and overcome technical challenges that limit process efficiency and the versatility of plastic waste, allowing plastic recyclers to reduce waste and improve reusability.