When analyzing the net cost of the semi-final product PET sheet, the result is a simple, but very clear picture. As shown in the chart, 80 % of the overall cost is material related, whereas only 20 % is associated with machinery, which includes all terms of costs regarding production like labor, electricity, investment, floor space, etc.

The market price development of the past years clearly shows a difference between PET flakes and PET virgin material, ranging from a 10 to 25 % lower price for an acceptable quality of PET flakes. In-house skeleton material as a cut-off from thermoforming is traded with major price variations, anywhere from 10 to 50 % less than virgin material. This mid-term trend of course shows slight variations through market fluctuations.


Depending on the thermoforming process, the in-house waste is around 20 to 40 % of the thermoformed sheet. Since approx. 10 % can be obtained from edge trims, just the remaining 50 % of PCR material have to be sourced on the market. To figure out this example and to show the potential in savings per year, see the following table.


The best strategy for a PET sheet producer
  • use as much PCR flakes as possible - the cheapest material with adequat
    iV for sheet extrusion available on the market
  • use the edge trims from sheet production +skeleton waste from
    thermo-forming and
  • as a non-integrated sheet producer, buy back the in-house
    waste from your thermoforming customers




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