Bakcycle Recycling, a pioneer in Türkiye’s packaging sector, has partnered with Tomra Recycling Sorting to revolutionize the processing of low-density polyethylene (LDPE) waste. Using cutting-edge sensor-based sorting systems, the Izmir-based facility is now producing high-quality recycled LDPE (rLDPE) pellets, setting new benchmarks in sustainable packaging production.
Breaking New Ground in Flexible Packaging Recycling
Launched by Bakioğlu Holding in late 2023, Bakcycle Recycling is Türkiye’s first facility dedicated to recovering LDPE from discarded flexible packaging. The plant’s 20,000-square-meter operation processes approximately 8,000 tons of LDPE annually, converting municipal and industrial packaging waste into rLDPE pellets. These pellets serve as a substitute for virgin materials in flexible packaging manufacturing.
Tomra Recycling Sorting, a division of Norway-based Tomra Systems, supplied five advanced AutoSort machines for the facility. “This project demonstrates the potential of technology in advancing sustainable practices,” says Oral Çimsöken, emerging markets sales manager at Tomra.
Advanced Sorting for Superior Quality
Bakcycle’s recycling process leverages Tomra’s sensor-based sorting solutions to achieve unparalleled purity. The workflow begins with three AutoSort SpeedAir systems that focus on color and polymer separation. The first two units isolate transparent LDPE, while the third distinguishes between transparent LDPE and linear low-density polyethylene (LLDPE).
Two additional AutoSort machines then refine the output, separating mixed-color LDPE from white LDPE. Together, these five systems achieve a purity rate exceeding 98 percent, ensuring the rLDPE pellets meet the high-quality standards required for flexible packaging.
“Using recycled material in LDPE film production is highly sensitive work,” explains Bakcycle Recycling’s General Manager, Övünç Dirik. “Tomra’s advanced technology ensures the precision we need to meet these exacting requirements while enhancing operational efficiency.”
Pioneering Sustainability in Türkiye
The facility also incorporates hot washing, laser filtering, extrusion, and odor removal to further refine the recycled material. “Flexible packaging recovery rates have historically lagged behind other packaging types like PET and HDPE,” notes Dirik. “We aimed to address this gap, and this facility is a significant step forward.”
Looking ahead, Bakcycle plans to double its production capacity within two years, paving the way for greater adoption of recycled content in Türkiye’s growing flexible packaging market.
A Model for the Future
As sustainability takes center stage in the global packaging industry, the collaboration between Bakcycle Recycling and Tomra highlights how innovation can drive meaningful change. By showcasing the potential of sensor-based sorting systems, this initiative sets a powerful example for advancing circular economy goals in packaging.
With its advanced technology and ambitious vision, Bakcycle Recycling is not just transforming flexible packaging waste into valuable materials—it’s redefining what’s possible in sustainable manufacturing.
