ReVentas is an innovative recycling technology company focused on unlocking more value from mixed waste polymers. Instead of treating mixed plastics as a problem stream, ReVentas set out to prove a scalable, commercially viable way to recycle them into new products.
To do that, they needed more than a good idea on paper. They needed an operating pilot plant that could turn their concept into real data, real product and real investor confidence.
From the outset, ReVentas had three clear goals:
In short, ReVentas wanted a pilot plant that not only worked, but could also act as a credible blueprint for future commercial facilities.
IDEA joined the project as ReVentas’ end-to-end engineering partner. Our remit covered:
Rather than handing over drawings and stepping back, we stayed involved from first concept discussions through to initial plant start-up. This continuity helped preserve the design intent and reduce delivery risk.
The project was delivered by a multidisciplinary IDEA team, including:
We worked closely with ReVentas’ own process experts, combining their technology know-how with our experience in designing and delivering complex process plants. Regular working sessions, design reviews and joint decision-making kept everyone aligned on priorities, constraints and commercial drivers.
The first step in FEED was simple to describe but critical to get right: understand the entire recycling route from end to end.
We worked with ReVentas to:
This deep process understanding formed the foundation for every later design decision, from equipment selection to control strategy.
Next, we mapped the plant as a complete system. That included:
By treating the pilot plant like a mini full-scale facility, we ensured that the data generated would translate directly into future scale-up decisions.
All of this information was captured in a formal Basis of Design. This document:
The Basis of Design became the reference point for the whole project, helping to prevent scope drift and misaligned expectations as work progressed.
With the high-level route defined, we developed the process architecture in more detail. This involved:
Clarity at this stage avoided confusion later when vendor packages, utilities and control strategies were being designed.
A pilot plant is rarely run in perfectly steady-state. Start-ups, shutdowns and planned changes in operating conditions are part of daily life.
To support this, we developed a comprehensive operating and control philosophy that described:
By thinking through these scenarios early, we helped ReVentas and their operators avoid trial-and-error approaches later on.
The control philosophy also specified:
In effect, this philosophy became a playbook for operators long before the first trial run – improving safety, consistency and confidence.
A robust mass and energy balance underpinned the whole design. IDEA’s process team:
These calculations allowed us to size vessels, heat exchangers, pumps, utilities and control valves with confidence, reducing the risk of under- or over-design.
Because energy use is a major cost and sustainability driver in recycling plants, the mass and energy balance was also used to:
This helped ReVentas align the pilot plant with their wider sustainability goals from day one.
The final balance also provided a data-rich foundation for scale-up:
In other words, the pilot plant wasn’t just a test rig – it became a source of credible engineering data for the business.
Once FEED was complete, IDEA moved into detailed design. Our process and mechanical deliverables included:
These documents ensured that every item of equipment and every line in the P&IDs had a clear design basis and purpose.
In parallel, our EC&I and CAD teams delivered:
The 3D model allowed ReVentas and contractors to visualise the plant before anything was installed, helping to spot clashes, access issues and maintenance constraints early.
All of these deliverables were tightly integrated. The P&IDs, 3D model, datasheets and control documents referenced the same tag numbers, line numbers and design data.
For suppliers and installers, this meant working from a single source of truth, reducing the risk of conflicting information, rework and delays.
IDEA also defined the complete installation scope of work for mechanical and EC&I elements, covering:
This clarity helped ReVentas procure installation services with a clear view of what was in (and out) of scope.
By setting out responsibilities clearly in the design and scope documents, we helped:
The result was smoother procurement and construction phases, with fewer surprises on site.
Polymer recycling can involve flammable and potentially hazardous materials. Process safety therefore sat at the heart of the project.
IDEA led structured HAZOP (Hazard and Operability) and LOPA (Layer of Protection Analysis) workshops, involving:
These reviews identified potential hazards, existing safeguards and any gaps where additional protection layers were needed. All agreed actions were tracked and fed directly back into the design.
In addition, our process safety team delivered:
This ensured that equipment selection, installation and inspection regimes were aligned with UK regulations and best practice. Safety was therefore embedded into the design, not bolted on at the end.
IDEA remained actively involved as ReVentas moved into procurement. Our team:
This technical support ensured that purchased equipment would integrate smoothly into the wider plant and control architecture.
During installation and commissioning, we continued to support ReVentas by:
This continuity from FEED to commissioning reduced project risk and helped protect the original design intent.
The completed pilot plant provides ReVentas with a robust platform to:
Because flexibility was built in from the start, the plant can evolve as ReVentas develops and refines their recycling technology.
Beyond the physical plant, the project delivered:
This combination of real-world operating experience and robust engineering documentation gives ReVentas and their stakeholders confidence as they move towards larger-scale deployment.
Circular economy and recycling projects sit at the intersection of innovation, safety and commercial reality. They demand:
IDEA brings all of these together. Our teams can support you from early concept and FEED right through to commissioning and optimisation, ensuring that your pilot or full-scale plant is safe, buildable and future-ready.
On the ReVentas project, our focus was always to:
If you’re developing a new recycling, circular economy or low-carbon process, you don’t just need drawings – you need a partner who understands the bigger picture.
The ReVentas polymer recycling pilot plant case study shows what can be achieved when innovative technology is paired with disciplined engineering and process safety.
By working closely with ReVentas from concept through to commissioning, IDEA helped turn a promising idea into an operating pilot plant that:
If you’re planning a new pilot plant or looking to scale a circular economy concept, IDEA can help you move from idea to operating asset with clarity, confidence and control.
FEED (Front-End Engineering Design) is the phase where the overall process route, mass and energy balance, equipment lists, control philosophy and plant layout are defined in enough detail to create a reliable cost estimate and design basis. In polymer recycling, FEED is essential to de-risk new technologies before committing to full detailed design and construction.
A pilot plant turns theoretical performance into measured results. It provides real operating data, demonstrates that safety and compliance requirements can be met, and shows that the process can be controlled in practice. All of this builds confidence for investors, regulators and internal decision-makers when considering commercial scale-up.
Polymer recycling plants can be challenging because they often handle variable feedstocks, involve flammable or hazardous materials, and must balance quality, cost and sustainability. Designing for flexibility, safety and future scale-up requires robust process design, strong process safety practice and close collaboration with technology owners.
Yes. While this project was aligned with UK regulations such as DSEAR, IDEA’s engineering and process safety approaches are applicable to projects internationally. We can work with local partners and adapt designs to meet regional codes, standards and regulatory requirements.
The best first step is usually a conversation. We can review your current concept, discuss your objectives and constraints, and outline a sensible roadmap from concept and FEED through to pilot plant or full-scale delivery. Get in touch with IDEA to explore how we can support your next recycling, circular economy or low-carbon project.