Green Current Solutions is using innovative recycling solutions to transform ocean-bound plastic waste into 100% recycled HDPE (High-Density Polyethylene) custom injection molded pallets.

The recycled material originates from Living Lands & Waters river cleanup operations, giving new life to plastics recovered from waterways.

To learn more about Living Lands & Waters, watch this video here

From Recycling to Scalable Manufacturing

As Green Current Solutions expanded from recycling into full-scale pallet manufacturing, they needed more than just equipment. They needed process expertise, scalable infrastructure, and a partner who understood material variability.

TSM delivered a turnkey blending and loading solution that enabled Green Current Solutions to launch efficiently, scale confidently, and manufacture consistently using recycled materials with varying densities.

Entering a New Industry with No Installed Infrastructure

Green Current Solutions was stepping into injection molding without prior experience in material handling or blending systems, this would cause them to face several challenges:

• Having no existing processing equipment
• Limited in-house technical knowledge of blending and loading systems
• Variable material densities due to use of recycled feedstock
• Unique unloading requirements based on how materials were delivered
• The need to scale production with future expansion in mind

Recycled HDPE taken from environmental cleanups presents variability in both bulk density and form. Green Current Solutions required a system capable of blending pelletized resin and regrind at rates of 1,400 lb/hr per blender while maintaining high accuracy and consistency.

A Turnkey System Designed for Recycled Materials

Recommended by an existing TSM customer, Green Current Solutions partnered with TSM to design and implement a fully integrated pneumatic loading and blending solution.

From unloading through to material delivery, TSM engineered the entire factory process with scalability and flexibility at its core.

The system was designed to process materials with densities ranging from 22 to 40 lb/ft³, accommodating both pelletized resin and regrind. Blender top plates were customized specifically to handle the density profile of the recycled materials. Two production lines were installed, with infrastructure sized for future expansion.

Complete Material Handling and Blending System

To support Green Current Solutions’ transition into injection molding, TSM delivered a fully integrated material handling and blending system designed specifically for recycled materials and scalable production.

The system manages the entire process from unloading incoming recyclables through to accurate blending at the press.

Unloading

Incoming recycled materials arrive in multiple formats, requiring a flexible unloading solution. TSM engineered a system capable of handling this variability efficiently.

• 1 Customized Hydraulic Container Dumper
  Designed specifically for Green Current Solutions’ unique recyclable material delivery method, allowing large containers of recovered plastic to be safely and efficiently emptied into the processing stream.

• 2 Gaylord Tilters with In-Line Check Valves
  Provide controlled unloading of boxed materials while preventing material backflow and maintaining consistent feed into the system.

Loading

Once unloaded, materials are conveyed through a centralized pneumatic loading system designed to reliably transport both pelletized resin and regrind.

• 3 Positive Displacement Vacuum Pump
  Provides the consistent conveying power needed to move materials across the facility. Two vacuum pumps are operational with the third as a backup to limit downtime.

• 3 Central Filter Assemblies
  Maintain system efficiency by removing fines and protecting downstream equipment.

• 1 24-Station Loading System Control Panel
  Centralizes system control and monitoring, enabling coordinated material delivery across multiple stations.

• 8 Vacuum Receivers
  Deliver material to processing points while maintaining controlled flow and system efficiency.

Blending

At the core of the system are TSM’s gravimetric blending technologies, designed to maintain precise ratios even when processing recycled materials with varying bulk densities.

• 2 OptiMix MK2 1000 Gravimetric Blenders
  Configured to process both pelletized resin and flake material, ensuring accurate material dosing and repeatable blend quality.

Together, this integrated system enables Green Current Solutions to blend recycled HDPE and regrind at rates of 1,400 lb/hr per blender, while maintaining the flexibility needed to manage variability commonly found in recycled material streams.

From Startup to Scalable Manufacturer

By partnering with TSM, Green Current Solutions was able to:

• Launch their injection molding operations with confidence.
• Accurately blend recycled HDPE and regrind at production scale.
• Manage material density variation without compromising performance.
• Implement a scalable infrastructure designed for future growth.
• Rely on expert process guidance throughout system design and commissioning.

Watch this video showing the process and the impact Green Current Solutions makes across the US.

TSM’s involvement went beyond just equipment supply, the team provided expert knowledge in process engineering, application support, and full-system integration, effectively guiding Green Current Solutions through their transition from recycler to manufacturer.

Recycled plastics, particularly those recovered from waterways, introduce variability that demands carefully engineered processing systems. Precision blending, flexible material handling, and scalable infrastructure are essential to producing consistent, high-performance products from recycled materials.

With two production lines installed and expansion capability built into the system design, Green Current Solutions is now well positioned to increase output as demand for sustainable pallet solutions continues to grow.