The hidden weak point in plastic recycling
Plastic recycling depends on powerful machines. These machines shred, cut, and grind plastic waste into smaller pieces so it can be processed again. At the heart of this process are industrial knives installed in shredders and granulators.
These knives work under extreme conditions. They are exposed to high mechanical stress, abrasion, and contamination from mixed plastic waste streams. Over time, they wear out quickly.
When knives wear out, recycling plants face downtime, high maintenance costs, and reduced efficiency. Replacing knives is expensive. Stopping machines interrupts operations. Worn knives also consume more energy and reduce the quality of processed material.
For recycling operators, this is not a small issue. It directly affects profitability and sustainability.
The MOIK project set out to address exactly this challenge.
From by-product to high-value material
MOIK stands for Metalization of Industrial Knives. The project was developed by Ekstera d.o.o. and Additio d.o.o., two Slovenian SMEs (small and medium-sized enterprises), with support from the European INCIRCULAR cascade funding programme.
The idea behind MOIK was simple but powerful:
Can we make industrial knives last longer by applying a high-performance metal coating and, at the same time, use a recycled industrial material?
Ekstera produces Inconel powder as a by-product of its primary industrial processes. Inconel is a nickel-based superalloy known for its excellent resistance to wear, heat, and corrosion. Instead of treating this powder as waste or low-value material, we saw an opportunity.
We used 100% recycled Inconel powder to create a protective coating for industrial knives made from D2 tool steel. D2 is already a strong and widely used material in cutting applications. The added coating significantly improves its resistance to wear and corrosion.
This approach combines performance improvement with circular economy principles.
From prototype to real industrial testing
In the first phase of the project, we developed 50 prototype knives. Each knife had a D2 steel base and an Inconel coating produced from Ekstera’s internal by-product powder.
We carried out laboratory validation, including:
- Dimensional verification
- Hardness testing
- Adhesion testing
- Microstructural analysis
These tests confirmed that the coating was stable, properly bonded, and technically reliable.
The next step was crucial. Laboratory testing is important, but real performance must be proven in real conditions.
In the second phase, the knives were installed at the Gorenje facility and tested on an AMIS industrial shredder under real operating conditions. We monitored wear behaviour, coating stability, and operational performance.
The results were clear. The coated knives demonstrated approximately 30% better performance compared to standard solutions.
For recycling operators, this means longer service life, fewer replacements, and lower maintenance frequency.
Why European funding mattered
For an SME, developing and testing a new industrial solution always carries financial risk. Prototyping, laboratory analysis, and real industrial trials require significant resources.
The support from INCIRCULAR allowed us to accelerate development while reducing risk.
It enabled us to move from concept to validated industrial application faster than we could have through internal funding alone. It also gave us access to mentoring and a European innovation network focused on circular economy solutions.
What changes for our business
The MOIK project has strengthened our position in several ways.
First, we now have a validated product with a clear route to market. This reduces uncertainty and allows us to move toward commercial rollout with confidence.
Second, we have created a higher-value product line focused on performance-enhanced, circular solutions for the recycling industry.
Third, we demonstrated that industrial by-products can become strategic assets when combined with the right technology.
Instead of competing only on price, we now compete on performance, durability, and sustainability.
But the benefits extend beyond our company. More durable knives mean:
- Reduced downtime in recycling plants
- Lower maintenance costs
- Less frequent material replacement
- Reduced resource consumption
- Better overall efficiency
Using 100% recycled Inconel powder also strengthens circular material flows. A by-product becomes a high-value input for another industrial application.
This is exactly the type of innovation the European circular economy aims to promote: practical, scalable, and economically viable.
The MOIK project shows that meaningful innovation does not always require completely new materials or complex technologies. Sometimes it means rethinking what already exists. By combining recycled high-performance powder with advanced metallization, we improved durability by around 30%, reduced waste, and created a scalable market opportunity.
For SMEs, targeted European funding can make the difference between a promising idea and a validated industrial solution. And for the recycling sector, even small improvements in core components can have a large impact on efficiency, cost, and sustainability.
MOIK is a practical example of the circular economy in action, turning an internal by-product into a stronger, longer-lasting solution for plastic recycling.