Whether aluminum-plastic composite panel (ACP) scrap can be mechanically recycled depends mainly on its core material, panel structure, size, and contamination. Standard aluminum–PE–aluminum panels are generally well suited to dry crushing and separation, while panels with mineral-filled or fire-retardant cores may require a different process.

PE-core ACP is the most straightforward material for mechanical recycling. The panels are shredded and crushed to release the aluminum skins from the PE core, followed by fine grinding, screening, air separation, and, when required, electrostatic separation. This produces separate aluminum and plastic fractions without chemical treatment or thermal processing.

Coated ACP with PE, PVDF, or paint can also be processed if the underlying structure remains suitable. However, coatings may affect the purity of the recovered aluminum and can require additional separation. Advertising panels and construction offcuts are also suitable in many cases, but attached steel, wood, acrylic, PVC, rubber, or other contaminants should be removed during pre-sorting. Magnetic separation can be used to remove ferrous components.

Fire-retardant and mineral-filled panels require more attention. Their cores may contain inorganic fillers or flame-retardant materials that remain mixed with the polymer after grinding, reducing the quality of the recovered plastic. These materials should be tested before selecting a standard mechanical recycling process.

The most reliable way to determine whether a specific ACP waste stream is suitable is to test a representative sample. Testing can identify the core composition, contamination level, required size-reduction process, and achievable separation performance before equipment is selected. In general, clean PE-core ACP is the preferred feedstock for mechanical recycling, while mixed, heavily contaminated, fire-retardant, or mineral-filled panels may require a customized process.

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