Of course! It's a fascinating process that transforms everyday waste into durable, beautiful community assets. Here’s a step-by-step explanation of how we create our recycled plastic urban benches.
First, we collect post-consumer plastic waste—primarily bottles, containers, and packaging marked with recycling codes #1 (PET) and #2 (HDPE). This material comes from municipal recycling programs and commercial partners. The collected plastic is thoroughly sorted by type and color to ensure material purity. It's then cleaned to remove any labels, residues, or contaminants before being shredded into small, uniform flakes.
Next, these clean plastic flakes are fed into an industrial extruder. The flakes are heated until they melt into a viscous liquid. During this stage, we can add color pigments (often using more recycled plastic) and UV stabilizers to enhance the material's longevity and fade resistance against sunlight. The molten plastic is then forced through a mold, forming it into the specific profile needed for bench components, like seat slats, arms, or structural supports. This process is called profile extrusion.
Once extruded, the plastic is cooled and solidifies into its final shape. These long profiles are then cut to precise lengths. Using stainless steel or galvanized hardware, the components are assembled into the complete bench structure. The final product requires no painting or sealing—the color is embedded throughout the material, making it scratch-resistant and low-maintenance.
The result is a remarkably sturdy bench that withstands harsh weather, resists rot, insects, and graffiti, and lasts for decades. By closing the loop on plastic waste, we not only create functional urban furniture but also reduce landfill burden and promote a circular economy right in your local park or streetscape.