Nova Chemicals and Novolex Open Major PE Film Recycling Facility in Indiana

Nova Chemicals and Novolex have officially opened a large-scale mechanical recycling facility in Connersville, Indiana, designed to process up to 145,000 bales of postconsumer plastic film annually. The state-of-the-art plant will produce recycled linear low-density polyethylene (rLLDPE) for use in food-safe packaging and other applications.

The 450,000-square-foot facility, one of the largest of its kind globally, will help meet growing demand from major brands and converters for recycled polyethylene. It also supports industry efforts to increase recovery rates for flexible plastics, which remain challenging to collect through traditional curbside recycling.

“There continues to be high interest from converters, retailers, and brand owners for recycled polyethylene,” said Nova CEO Roger Kearns. “This facility accelerates our ability to meet that demand using the latest recycling technologies.”

Recycled pellets produced at the site—marketed as Nova Syndigo—are certified by GreenBlue’s Recycled Material Standard and approved by the FDA for food-contact use, marking a first for postconsumer rLLDPE. The feedstock is sourced mainly from “back-of-store” film collected at retailers and distribution centers across the U.S.

Nova said the facility will process around 400 bales daily and create about 125 new jobs. Indiana Gov. Mike Braun praised the project as a “world-class example” of the state’s leadership in materials innovation.

Partners expected to use the recycled PE include Charter Next Generation, Winpak, Pregis, Sigma Plastics Group, and others.

The opening comes amid mixed results across the sector. Myplas USA, a separate film recycling plant in Minnesota, idled shortly after launching in 2023 due to financial issues. It has since resumed partial operations under new ownership.