Video: Nova Chemicals Unveils Flexible Film Recycling Facility

Transcript:

Hi, I am Alan Schrob. I’m the director of Mechanical Recycling at Nova Circular Solutions, and we're here at our recycling facility in Connersville, Indiana. At this facility, we’re going to recycle film into finished products that can be used into a whole variety of high performing applications all the way up to and including food packaging. We'll process about 140 million pounds of film that will ultimately be producing 110 million pounds of high performing recycled polyethylene. This facility is very unique. We’ve designed it specifically to be able to produce very high-performing, finished products that can be used in a whole variety of applications. So, as such, the technology we’ve employed and the scale that we're using is very technologically advanced and large. That way we can provide all the right products that we need to our customers in the way in which they like to receive it. We use film that’s used in many different forms, so the source of these are from distribution centers, back-of-store retail outlets for which we collect, bring to this facility. And then we use a whole variety of steps to process the material by sorting it and then cleaning it, and then palletizing it into products that can be used. And a number of different products like broad use food packaging, pet food applications, heavy duty shipping, sacks, e-commerce products.

Background:

It’s been just over a month since Nova Chemicals started the first line at its new flexible film recycling facility, Syndigo One, in Connersville, Ind.—marking a major milestone for the company. Syndigo One is the inaugural project of Nova’s Circular Solutions business unit, launched in 2023 and is designed to meet the rising demand for high-quality post-consumer recycled polyethylene (rPE). In late February, the company’s executive team offered select media a first look at the facility, underscoring its commitment to advancing circular plastics solutions.

“This facility is one of the largest and most sophisticated film recycling plants in the world,” said Greg DeKunder, VP of Nova’s Circular Solutions. “Syndigo One is our first big step toward becoming the leading polyethylene recycler in North America.”

The facility, operated in partnership with Novolex, is currently running one line, with three more expected to be up and running by the beginning 2026. The plant will mechanically recycle post-consumer polyethylene film waste—e.g., shrink wrap, stretch film, pallet wrap, plastic mailers, etc.—into high-quality Syndigo recycled polyethylene (rPE) resin. At full capacity, the plant will process 145,000 bales of plastic per year—about 400 per day. That’s enough film to fill four football fields to the top of the goalposts.

Recycling with purpose—and precision

What sets this facility apart isn’t just its scale (it spans more than 500,000 sq ft) or its eventual 110 million pounds of annual output by 2026—it’s the rigor behind the process. With 13 silos and a state-of-the-art sortation system, Connersville is designed to meet demanding specifications, including those for food-contact applications.

“Yes, food-grade is a substantial part of what we’ll be producing,” confirmed Alan Schrob, director of mechanical recycling at Nova. “We designed at least two of our lines for broad-use food packaging applications, and we’ve already received a Letter of Non-Objection from the FDA.”

That means Syndigo rPE can be used in food-contact applications where safety and purity are paramount. To make that possible, Nova and Novolex developed a meticulous auditing process to verify the origin and composition of incoming film. “Before the material even enters our plant, we ensure it’s eligible for food-contact use,” said Schrob. “Then we remove all surface contamination—glue, labels, anything that might interfere.”

To ensure the safety of the film, Nova is leveraging a its expertise and experience with virgin materials. “We have very core competencies in things like product safety and product stewardship,” Schrob continued. “The same people who are ensuring that our virgin products are safe to be used in food packaging applications are the same people who are working with us to ensure that we’ve got the right processes, procedures, and processes outside on the floor here to ensure we can meet those stiff requirements.”

A closed-loop system for flexible film

Part of Nova Circular Solutions’ strategy is to set up closed-loop systems with brand owners and retailers. “We can take PE film streams and recycle them to their highest and best use through mechanical recycling,” said the company. “Participating in our program will enable brand owners and retailers to support the circular economy and promote sustainability. The plastic film that accumulates from products packaged in plastic can be collected, processed at our Connorsville facility, and turned into Syndigo rPE. The used film that distribution and retailers acquire from multiple sources can then reenter the market as recycled content.” 

“The goal is to collect film waste from retail and distribution centers, recycle it into rPE, and then return it to the market as packaging material—sometimes for the same companies that generated it,” explained DeKunder. “That’s a powerful sustainability story.”

For participating retailers and distribution centers, the benefits go beyond environmental impact. “They get paid for the film,” said Schrob. “And more importantly, they get to say, ‘This package used to be our waste.’ That’s compelling.”

A good portion of the Syndigo material to be produced at the Connersville plant has already been contracted, with offtake agreements with packaging suppliers that include Amcor and Winpak. Additional capacity has been reserved for short-term buyers. 

Community impact and future growth

Beyond circularity, Nova’s investment is making a tangible difference for the Connersville community. With 125 employees, the facility is breathing new life into a former automotive plant and contributing to regional economic revitalization. 

Stan Bikulege, CEO of Novolex, reflected on the human side of the equation: “To have a facility like this with 125 families making a difference—it’s tremendous. We should all be proud of what this represents.”

While Connersville is the company’s first major recycling facility, it won’t be the last. “We’re already designing the next one,” DeKunder revealed. “And depending on the market need, it could be smaller. We don’t always need 500,000 square feet—we can scale as needed.”  PW