In a significant advancement for sustainable manufacturing and plastic recycling, STEER World, a global leader in materials transformation technologies, has introduced a pioneering method to reclaim crosslinked polyethylene (XLPE) waste—a material previously deemed non-recyclable. This breakthrough is made possible through STEER’s proprietary Omega Twin-Screw Extrusion Technology.

XLPE is widely used in high-performance applications such as cable insulation and piping systems due to its outstanding thermal and mechanical durability. These qualities are a result of its three-dimensional network of covalent bonds, which provide exceptional strength but also render the material nearly impossible to recycle using traditional methods. As a result, most XLPE waste ends up in landfills, raising long-term environmental concerns.

To combat this issue, STEER World has developed a solution utilizing its advanced Omega Twin-Screw Extruder, which incorporates the company’s patented Fractional Geometry Technology (FGT). This innovative process applies controlled mechanical shear and heat to selectively break down the crosslinked bonds within XLPE while preserving the polymer’s base structure. The resulting material, known as De-XLPE (Decrosslinked XLPE), can be reused in a variety of applications.

“This is not just an innovation in recycling—it’s a shift in how we look at thermoset waste,” said Dr. Prakash Hadimani, global head of the Application Development Center at STEER World. “With the Omega series of machines, we’ve made it possible to recover and reuse a material that was once considered unrecoverable. That’s a win for the industry and a big step forward for sustainability.”

The Omega extruder’s modular design allows for precise control of key processing parameters, including temperature zones, screw speed and configuration. These capabilities ensure consistent and scalable decrosslinking, making the technology viable for industrial use. Once converted to De-XLPE, the material can either be processed into new products or blended with virgin polymers, offering manufacturers a sustainable alternative to traditional plastics.

This innovation supports the global push toward a circular economy by reducing dependence on virgin materials and diverting plastic waste from landfills. It also opens up new opportunities for companies seeking to meet sustainability goals without compromising on performance or material integrity.

“With this process, we’re not just recycling—we’re redefining what’s recyclable,” added Hadimani. “The ability to reclaim and reintegrate thermoset materials like XLPE is a breakthrough the industry has been waiting for.”

STEER World’s technology represents a milestone in the evolution of recycling practices and underscores the company’s commitment to environmental responsibility and technological innovation.