Get answers to common questions about our technology, circular recycling process and how hard-to-recycle plastics can be transformed into new materials.
Nexus Circular uses a patented pyrolysis-based process to recover hard-to-recycle plastics used in everyday products and packaging, including films, foams and flexible packaging materials made from high-density polyethylene (HDPE #2), low-density polyethylene (LDPE #4) and polypropylene (PP #5).
Applying only heat in an enclosed reactor without oxygen, plastic molecules are converted into their original hydrocarbon building blocks, creating a liquid product known as circular oil. These hydrocarbon building blocks are then used as a replacement for fossil-based resources to produce virgin-quality plastics and materials that meet stringent quality standards for sensitive and regulated food, pharmaceutical and medical packaging applications.
Advanced recycling complements established mechanical recycling systems. Mechanical recycling systems are designed to process selected rigid plastic containers, such as water bottles made from polyethylene terephthalate (PET #1) and milk jugs and laundry detergent bottles made from high-density polyethylene (HDPE #2). The used plastic is collected and sorted by plastic type, then ground into smaller pieces, washed, dried and melted into recycled plastic pellets. These pellets can then be used to manufacture new plastic products. With repeated mechanical reprocessing, the quality of the plastic molecule degrades, which can result in the downcycling of plastic into building and construction applications.
Advanced recycling, sometimes also called chemical recycling or molecular recycling, represents a range of technologies and processes that recover additional types of plastic that can be challenging to process mechanically, including films, foams and flexible packaging. By converting these plastics back into their original hydrocarbon building blocks, advanced recycling creates feedstocks used to offset fossil-based resources in the production of new virgin-quality plastics and materials.
Together, these approaches create a more comprehensive recycling ecosystem that can effectively address and recycle a broader range of used plastics.
Established recycling systems work well for many rigid plastic containers, but materials such as films, flexible packaging, foams, mixed plastics and small-format items can be challenging to sort, separate, clean and process. Their size, shape and composition can make them difficult to efficiently and economically recover through established mechanical recycling infrastructure while also making it challenging to produce high-quality recycled plastic for a broad range of packaging applications.
Nexus Circular’s recycling process complements established recycling systems by converting these hard-to-recycle plastics back into their hydrocarbon building blocks for reuse.
No. Established recycling systems remain an essential part of the plastic circular economy. Nexus Circular’s recycling technology complements current recycling methods by processing hard-to-recycle plastics, like films, flexible packaging and foams, that cannot be efficiently or economically managed by current mechanical recycling processes.
Pyrolysis is one type of advanced recycling that conserves the plastic resource and returns it to the supply chain for reuse. Pyrolysis heats plastic in an enclosed system without oxygen to convert used plastic back into its original hydrocarbon building blocks, creating a liquid product known as circular oil that can be used as a feedstock for making new plastics and materials.
No. Nexus Circular does not burn or incinerate plastic. Our patented pyrolysis-based process heats plastic in the absence of oxygen, conserving the plastic resource rather than burning or consuming it through incineration. Instead, pyrolysis heats plastic in an enclosed system without oxygen to convert used plastic back into its original hydrocarbon building blocks, creating a liquid product known as circular pyrolysis oil. This circular oil is returned to the supply chain and used to manufacture new plastic products.
Nexus Circular’s patented recycling process produces a high-quality circular oil that is used as a direct replacement for fossil-based feedstocks traditionally used to manufacture plastics.
Petrochemical partners use this circular oil to produce virgin-quality materials and plastic resin. Plastic packaging producers then use that plastic resin to create new plastic products, including packaging that meets stringent standards for sensitive and regulated food, pharmaceutical and medical packaging applications. By incorporating circular materials into their supply chains, these companies can reduce reliance on fossil-based resources and support a more circular plastics economy.
Nexus Circular has historically worked across the plastic value chain to recover resources and sell circular oil to customers such as Braskem, Chevron Phillips Chemical, LyondellBasell and Shell Polymers. Moving forward, Nexus Circular is partnering with plastic producers to help them meet sustainability goals around recycled plastic content.
Circular oil is the primary product created through Nexus Circular’s pyrolysis-based recycling process. Unlike mechanical recycling, which degrades the quality of the plastic resource, pyrolysis-based recycling creates a virgin-quality circular oil that is used as a feedstock to replace virgin fossil-based resources in the production of new plastics. By converting hard-to-recycle plastics into circular oil, Nexus helps keep valuable plastic resources in circulation and accelerates the circular plastic economy.
Yes. Plastics made using Nexus’ circular oil are the same virgin quality as those made from virgin fossil-based feedstocks. Nexus Circular’s process converts used plastics back into their original hydrocarbon building blocks that are then used to produce identical virgin-quality plastics in the same petrochemical assets.
Nexus Circular partners with sustainability-minded companies and recycling organizations across the plastics supply chain to secure streams of used plastic, which are the feedstocks for our recycling process. Potential partners can contact Nexus to discuss their available materials, volumes and feedstock specifications. Nexus works collaboratively with supply partners to create a reliable outlet for hard-to-recycle plastics while supporting their waste reduction and circularity goals.
No. Nexus Circular’s facilities are not set up as public recycling drop-off locations. Companies interested in becoming a feedstock supply partner can contact the Nexus team to discuss their materials and volumes.
Individuals looking for recycling options for hard-to-recycle plastics can find nationwide drop-off directories through Earth911-How to Recycle and Plastic Film Recycling or visit CHaRM (Center for Hard to Recycle Materials) in the Atlanta metro area.
Nexus Circular’s products are ISCC PLUS certified. ISCC PLUS is a voluntary, third-party certification system that verifies sustainability characteristics and enables traceability of circular and recycled materials throughout the supply chain. It can also support verified claims through chain-of-custody methods.
Cox Enterprises is a long-term investor and partner of Nexus Circular, supporting the company’s mission to expand recycling solutions for hard-to-recycle plastics and advance a more circular economy.
Cox and Nexus share a commitment to addressing environmental challenges through innovation. In 2015, Cox made its initial strategic investment in Nexus Circular to support the development of the company’s commercial facility in Fulton County, GA. Since then, Cox has continued to invest in Nexus, including a $150 million investment to support its next phase of growth and expansion.
Nexus Circular’s facilities in Georgia are permitted and regulated by federal and state environmental agencies as a Synthetic Minor under Section 112 of the Clean Air Act, which sets enforceable limits on emissions.
Each facility operates responsibly to ensure full compliance with its permits by monitoring and controlling emissions and regularly reporting environmental performance through established regulatory programs.
The Clean Air Act, established by the U.S. federal government in 1970, is the primary federal law governing air emissions from stationary and mobile sources. It authorizes the U.S. Environmental Protection Agency (EPA) to establish national air quality standards and regulate emissions of pollutants that can affect human health and the environment. Facilities are required to obtain permits, monitor emissions and comply with enforceable limits established by environmental regulators to help protect air quality.
An air quality permit establishes the requirements and enforceable limits a facility must follow for its air emissions. Depending on the facility and applicable regulations, a permit may specify allowable emission levels, operating conditions, monitoring, recordkeeping and reporting requirements.
A Synthetic Minor facility operates within permit limits, utilizing emissions control devices when applicable to ensure its emissions remain below permitted thresholds.
Nexus Circular’s facilities in Georgia are permitted and regulated by federal and state environmental agencies as Synthetic Minor facilities under Section 112 of the Clean Air Act, which establishes enforceable emissions limits.
Emissions controls are equipment and systems designed to capture, reduce or otherwise control pollutants released during manufacturing processes. Nexus Circular incorporates emissions controls into its facility design to ensure compliance with applicable air quality permit requirements.
The Good Company reports that emissions from an advanced recycling facility are similar to those from common industrial facilities and institutions found in communities across the country, including hospitals, universities, food packaging facilities, automotive assembly plants and other manufacturing operations.
Safety is a core part of how Nexus Circular operates. We follow all applicable federal, state and local regulations, including requirements established by the Occupational Safety and Health Administration (OSHA), while building a culture where safety guides every decision.
Our safety program focuses on protecting our employees, partners and the communities where we operate. Through training, operational standards and continuous improvement, we empower our teams to identify risks, make informed decisions and carry a culture of safety beyond the workplace.
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