GCR Sustainable Plastic Solutions has officially begun operations at its new polyolefin recycling plant in Castellet i la Gornal, a municipality near Barcelona, Spain. With an annual recycling capacity exceeding 130,000 tonnes, this facility stands among the largest in Europe. By comparison, Sweden’s Site Zero can sort up to 200,000 tonnes of plastic packaging per year.

Announcing the launch on LinkedIn, the Spain-based material producer expressed pride in unveiling the plant after six years of planning and development. The facility is designed to recycle more than 100,000 tonnes of post-consumer polyolefins and 30,000 tonnes of post-industrial polyolefins annually, reinforcing GCR’s commitment to sustainability and circular economy initiatives.

The plant features state-of-the-art recycling technology, including Erema processing lines and Tomra optical sorting machinery, ensuring efficient material recovery. Additionally, it houses one of Europe’s largest hot-washing systems, enabling the production of high-purity recycled materials. To maintain strict quality standards, the facility integrates in-house laboratories for performance testing, specialised deodorisation for odour removal, and batch homogenisation to enhance material consistency. A closed-loop water system has also been implemented, significantly reducing water consumption during processing.

The recycled materials from this plant will contribute to GCR’s Ciclic portfolio of sustainable polyolefins and the Granic range of mineral-filled masterbatches and compounds. The Ciclic portfolio includes recycled HDPE, LDPE, LLDPE, and PP, offering a CO2 emissions reduction of up to 90% when incorporated into plastic formulations. Meanwhile, the Granic product line integrates ultrafine minerals such as calcium carbonate (CaCO3), talc, or silica with polyethylene (PE) and polypropylene (PP). This mineral addition can replace up to 70% of traditional polymer content, improving mechanical properties while lowering plastic consumption.

With a total production capacity of 500,000 tonnes per year, GCR plays a crucial role in advancing sustainable plastics solutions. The company exports 85% of its products to over 100 countries, underscoring its global reach.

By investing in advanced recycling infrastructure, GCR strengthens Europe’s circular plastics market, helping industries transition toward more sustainable material solutions. This new facility marks a significant step toward reducing plastic waste and carbon emissions, reinforcing the company’s leadership in the recycled polyolefins sector.

GCR specializes in developing and producing high-performance sustainable plastic solutions, catering to brand owners and plastic processors seeking recycled and recyclable plastics as well as mineral concentrates.

By prioritizing innovation and sustainability, GCR creates value for its partners, supporting their growth and strengthening their market position.

As a result, GCR’s materials offer a more eco-friendly alternative, reducing carbon footprint and dependence on virgin plastics—all while maintaining the quality and performance expected from traditional plastics.