IPRA™300

Hotline : +41 840 84 84 84

Transforming hard-to-recycle plastics into valuable, recyclable products

Each year, millions of tonnes of complex, multi-material plastics are incinerated or sent to landfill due to the absence of suitable recycling streams. These materials include multilayer packaging, composite products, and mixed plastic waste that conventional recycling processes cannot handle.

Developed by Aisa in partnership with the French sustainability pioneer REPLACE, the IPRA™300 offers a breakthrough response: a fully automated industrial recycling line capable of transforming hard-to-recycle plastic waste directly into durable, functional, and 100% recyclable products.

Built in France by Aisa, the IPRA™ 300 enables local, economically viable circular production, significantly reducing CO₂ emissions while creating long‑lasting value from waste.

One-step recycling process, without pre‑treatment

The IPRA™300 converts unprocessed plastic waste directly into finished products, without washing, drying, sorting, regranulation, or component separation.

Up to 75% of plastic types are compatible with the process, including:

ABL toothpaste tubes
Surgical masks
Flower pots
Champagne foils
Many other complex, multi‑component plastic wastes

This simplified process reduces operating costs, limits energy consumption, and enables stable, continuous industrial production.

Durable products designed to replace traditional materials

Products manufactured with IPRA™ technology are resistant to weather, impact, and intensive use, making them suitable for demanding applications.

Typical outputs include:

Vineyard stakes
Signalling and fencing poles
Pallets
Planks for urban furniture and infrastructure

These products can replace wood, concrete, or metal, while remaining 100% recyclable through the same IPRA™ process, enabling a true closed‑loop system

Proven environmental and economic performance

The IPRA™ solution has been optimised at every stage and validated through an independent Life Cycle Assessment (LCA).

CO₂ emissions up to 30 times lower than incineration
Energy consumption approximately 50% lower than conventional mechanical recycling processes
Economically viable with high output and low operating costs

A single IPRA™300 can produce over 3 million vineyard stakes per year using 100% recycled material, avoiding up to 3,000 tonnes of CO₂ annually compared to incineration

Line configuration

The complete line includes:

Material feeding system with weighing conveyor
Two-stage injection line composed of an extruder, a material filter and an injection machine

Process overview

Key benefits

A real solution for complex plastic waste

Recycles plastics with no existing recycling streams
Converts waste into long lasting, infinitely recyclable products

Low carbon, measurable impact

30× lower CO₂ emissions than incineration, confirmed by LCA
Clear, measurable results for ESG and CSR reporting

Economically viable industrial production

High throughput with low operational costs
Suitable for both large scale output and diversified local production

Flexible, localised manufacturing

Adaptable to agriculture, construction, logistics, urban and public spaces
Produces standardised or custom products depending on needs

Accessible, robust and easy to operate

Fully automated, continuous injection process
Requires only one operator with intuitive interface enabling operation by non-specialist and minimal training
Designed for easy cleaning and limiting dust generation
Quick changeover for product length adjustment, minimising line stops and maximising productivity
Compact footprint for easy installation, even in space constrained facilities

Technology

TECHNOLOGY FOR RECYCLING PLASTIC WASTE

Learn more

Machine specifications

MACHINE CAPABILITIES

Nominal throughput: 300 kg per hour
(based on a reference mix density of 0.3 kg/L. – approx. 2000 tonnes per year)

RAW MATERIALS

Ground mix of PE / PP / Aluminium / Fibreglass / EVOH
Compatible with inks and varnish residues