Image Credit: Borouge International

Introduction

NOVA Chemicals (now Borouge International) has taken a bold step toward redefining circularity in the plastics industry. Their newest facility, SYNDIGO1, in Connersville, Indiana is the world’s largest plastic film mechanical recycling facility, designed to process 400 bales of post-consumer plastic film per day.

An operation this size required a robust and highly engineered solution capable of delivering exceptional material quality, low waste, and reliable large-scale performance.

TSM Control Systems delivered a fully integrated equipment solution tailored for the facility’s precise project specifications while also aligning with circular economy principles. The system solution required detailed engineering, precision fabrication, mechanical and electrical installation, and full-system commissioning for the facility’s multiple processing lines.

In March 2026, NOVA Chemicals Corporation was acquired by Borouge Group International AG to establish Borouge International

The Goal

The company’s objective was clear: create a high-volume, high-efficiency system that allowed them to meet their customers’ demand for high quality recycled polyethylene that they can receive in railcars.

Project specifications required:

• Consistent and homogenized feedstock blends
• Control over material flow with low variability
• Reduction of dust, fines, and angel hair
• Energy-efficient and sustainable design parameters

To meet these challenges, our team engineered a fully integrated solution tailored for circular performance.

TSM’s Solution

TSM Control Systems delivered a comprehensive solution designed around these key outcomes: material consistency and sustainable, high-scale performance.

The equipment included:

• Pneumatic Conveying System: A tailored conveying system with vacuum and pressure pumps to efficiently move materials to various points within the facility; starting at the pelletizing extruder and ending at the railcar.
• External Mixing Silos: 240,000 lb. blending silos to blend and homogenize the material in addition to storage silos.
• External Storage Silos: 240,000 lb. capacity silos to store large volumes of PCR materials enabling them to meet their customer’s orders.
• Railcar Unloading: A customized railcar loading system with vacuum and pressure pumps to efficiently convey material from silos into railcars to be delivered to end users.

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Image Credit: Borouge International

These Solutions resulted in:

Consistent Material Homogenization

• The mixing silos support consistent blend quality throughout storage and transfer to railcar.

Minimized Dust, Fines & Angel Hair

• Controlled conveying velocities help minimize material degradation and improve material quality.

Enhanced Sustainability

• With the capacity to process over 100 million lbs per year of high performance recycled PE, Borouge International’s Circular Solutions – North America team dramatically increases the volume of material reintroduced into the circular economy.

Image Credit: Borouge International

Solutions Through Partnership

TSM supported NOVA Chemicals (now Borouge International) through a structured installation and commissioning process. During start-up, TSM worked directly with operations and maintenance to refine system settings, monitor performance, and ensure safe, reliable operation.

The partnership between the two companies exemplifies how technological innovation and strategic collaboration can drive sustainability in the plastics industry.

This case study highlights the impact TSM’s comprehensive solutions had in overcoming this facility’s specific challenges related to their plastics recycling application.

SYNDIGO1 demonstrates the application of mechanical engineering and system solution design at large industrial scale. The comprehensive solution supplied by TSM supports high-volume plastic film recycling with consistent material conveying and homogenized material.

The system’s early operational metrics confirm its suitability for continuous recycling environments and its capacity to support circular plastics manufacturing globally.

Image Credit: Borouge International

Image Credit: Borouge International

Visual Demonstration: Watch this YouTube video showcasing the installation of the silos provided to SYNDIGO1. This video highlights TSM’s solutions in a real-world setting, demonstrating its impact on this world-class facility’s operations.

Image Credit: Borouge International

Planning a large-scale material handling or recycling project? Connect with our team to discuss a solution tailored to your production requirements.