Vinyl records have made a remarkable comeback. Once considered obsolete, they are now cherished objects, valued for their sound quality, tactile experience and cultural meaning. But behind this revival lies a less romantic reality: vinyl records are traditionally produced from virgin PVC, a material with a significant environmental footprint. As demand grows, so does the urgency to rethink how vinyl is made.
At Beologic, in close collaboration with Dunk! Pressing and research partner Centexbel, we set out to explore a bold question: can old, discarded vinyl records become the raw material for new ones, without compromising sound quality, processability or regulatory compliance? This question formed the basis of the MuCiVil project (Music from Circular Vinyl), a feasibility study supported by VLAIO.
The challenge of post-consumer vinyl
Recycling vinyl records is far from straightforward. Unlike many plastic products, vinyl records contain a complex mix of additives, such as plasticizers, stabilisers, pigments, some of which date back decades. These so-called legacy additives, including banned phthalates (such as DEHP and DBP) and traces of lead, pose both technical and regulatory challenges.
In addition, a vinyl record is not a homogeneous object. Each disc consists of:
- an outer PVC body, which is the primary target for recycling;
- a center paper label, which must be removed or separated to avoid contamination;
- and a material history shaped by decades of evolving formulations.
The goal of MuCiVil was therefore not just to recycle vinyl, but to do so in a controlled, compliant and industrially viable way.
From collection to clean material streams
The first step was sourcing post-consumer vinyl. We set up a collection system through record labels and thrift stores, focusing specifically on records with no remaining resale value. This approach not only secures consistent material streams, but also creates a positive social impact by giving value to otherwise unsellable stock.
Once collected, the records undergo a series of processing steps:
- Punching out the center
The paper label is mechanically removed by punching out the centre of each record. This step intentionally sacrifices about 15% of the material but guarantees the effective removal of paper which is crucial for sound quality and customer acceptance. - Recycling the outer ring
The remaining PVC outer ring is retained as the primary recyclate stream. - Shredding and milling
The cleaned vinyl is shredded and milled into a controlled particle size suitable for compounding. 
To further eliminate residual contaminants, a dedicated PVC melt filter is introduced during processing. While fine filtration is common in PET recycling, applying it to plasticised PVC is technically challenging due to pressure and degradation risks. By closely working together with expert filter companies we were able to find a suitable solution.
Understanding legacy additives
A critical part of the feasibility study focused on material characterisation. We conducted extensive analyses to compare virgin vinyl compounds with recyclates from records of different ages.
Key findings included:
- The presence of legacy plasticisers (notably DEHP) and small amounts of lead in post-consumer vinyl.
- Concentrations remained well below regulatory limits for lead.
- Phthalate concentrations fluctuated around the REACH threshold, making controlled dilution essential.
Rather than attempting aggressive removal of these additives at this stage, the project adopted a pragmatic and scalable strategy: controlled blending. This approach also aligns naturally with how vinyl records are produced today. Every pressing generates unavoidable offcuts. The so‑called flashes result from trimming some excess material which ensures good quality records. This material is consistently available and of high quality, but often ends up downcycled or discarded. By incorporating this post‑industrial recyclate (PIR) into the blend, we prevent valuable material from becoming waste and create a genuine closed‑loop pathway for vinyl that ensures good quality and regulatory compliance.
From feasibility to formulation
We developed a series of vinyl compounds combining:
- Post-consumer recycled (PCR) vinyl,
- Post-industrial recycled (PIR) vinyl,
- And virgin material where needed.
These formulations were evaluated on both lab and industrial scale, with a strong focus on two decisive criteria:
- Processability (can the material run reliably on existing pressing equipment?),
- Sound quality (no audible noise, crackling, or degradation).
The outcome was clear:
- A compound containing up to 70% post-consumer recycled vinyl is technically and legally feasible.
- Sound quality and press performance remain within acceptable — and in many cases excellent — ranges. In a blind study, 700 participants even preferred the recycled version, noting that it sounded better.
- The process requires no fundamental changes to existing vinyl pressing technology.
In other words: recycled vinyl can function as a drop-in solution, not a compromise.
Why feasibility comes first
A key principle of the MuCiVil project was: first feasibility, then R&D.
Rather than jumping straight into large-scale investment, the study carefully mapped:
- Technical bottlenecks
- Regulatory constraints
- Material variability
- Economic viability
This step-by-step approach reduces risk and ensures that future development, whether in further additive optimisation, melt filtration or scaling up collection systems, is grounded in real industrial data.
Beologic has made the necessary investments to enable large-scale processing, with the equipment and infrastructure in place to scale up. The responsibility to adopt and commercialise these solutions now lies with labels, pressing plants and artists, who play a key role in bringing more sustainable vinyl to market.
Towards a circular vinyl ecosystem
The implications of this work go far beyond a single compound. MuCiVil demonstrates that vinyl records can become part of a closed-loop system, where music quite literally gives rise to new music.
The potential impact includes:
- 50–75% CO₂ reduction compared to virgin PVC,
- reduced dependence on fossil-based raw materials,
- new economic value for discarded records,
- and a scalable blueprint for circular plastics in niche, high-quality applications.
This project marks a crucial step towards sustainable innovation, without sacrificing performance, creativity or sound.
Vinyl has always been about more than music. With circular vinyl, it can now also be about responsibility.
Curious to explore circular vinyl in practice?
Discover our Beocycle PVC Rebound for vinyl pressing, Beologic’s circular PVC compound developed specifically for high-quality vinyl records. Designed to balance sound performance, processability and sustainability, it offers a concrete next step towards circular music production.
Importantly, this transition does not come with a financial penalty. The recycled solution is cost-neutral and in many cases even more affordable than virgin material, making sustainability not only an environmental choice, but also an economically sound one.
Send an email to sales@beologic.com if you’d like to learn more about the compound, its technical specifications or potential applications.
