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Substituting recycled HDPE flake (or regrind) for pellets, has cost and other environmental advantages. Flake does not require the additional processing steps to form the resin into pellets. Samples of an existing product were manufactured using different formulations ranging from 20% to 80% flake with the remainder of the formulation being pellet. Up to 25% flake (and 75% pellet feedstock) in the formulation provided an acceptable product, following physical property testing and visual inspection.
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