Operational Ramp and Throughput Gains
Denver added a third shift and processed 44% more feed versus Q3, ramping to 14.0 million pounds (a 35% increase over the prior quarterly high). Ironton set a quarterly record with 7.5 million pounds produced and achieved higher daily records; successful rate tests were run at ~12,500 and 14,000 lbs/hour. Feed flexibility improved with purchases from >15 suppliers and procurement costs reduced by $0.06 per pound over the last 12 months.
Commercial Momentum and Pipeline Expansion
Booked $2.7 million of revenue in Q4 (fourth consecutive quarter of sequential revenue growth) and actively shipping to 11 customers. Pipeline expanded from ~100 projects a year ago to >170 today (>70% growth). Management cites 40–50 million pounds of run-rate demand they are actively shipping or expect to ship, plus an additional 20–25 million pounds at full ramp; one near-term opportunity represents ~10 million pounds annual demand.
On-Site Compounding and Application Qualifications
Phase I of on-site compounding started; Phase II mechanically complete in March with commissioning to follow. On-site compounding improves cost, carbon footprint and turnaround for high-value markets (BOPP film/stand-up pouches/thermoform). Materials qualified across flexible packaging, wrappers, pouches, closures, thermoform containers and multiple fiber applications — positioning PureCycle uniquely in food-grade recycled PP.
Regulatory Certifications and Market Position
Received APR post-consumer resin certification and has regulatory acceptance in Oregon, Colorado, California, Washington and Europe, positioning PureCycle as a scalable food-grade PP supplier under many mandates; management argues regulatory trends (EPR/PCR mandates) create hundreds of millions of mandated pounds over 5–7 years.
International Expansion and Feedstock Secured for Thailand
Rayong (Thailand) progress: 9 LOIs with feed suppliers (exceeding needs for first purification line), strong government and commercial engagement, BOI application submitted (potential ~ $100 million tax holiday benefit), expected groundbreaking H2 2026 and project completion in 2027. Antwerp project advancing (permits expected H2 2026; construction targeted 1Q 2027).
Gen 2 Engineering & Long-Term Cost Outlook
Initial Gen 2 engineering suggests no technological constraints to scale toward ~500 million pounds capacity. Preliminary economics indicate greenfield capacity cost ~ $1.50 per pound and brownfield expansion ~ $1.00 per pound, with a clear line of sight to Gen 2 cash costs potentially below virgin PP — implying materially improved future IRR and lower capital intensity.
Capital Structure Moves and Financing Paths
Repaid $20.3 million of high-cost equipment finance debt and retired $9.8 million principal on Ironton bonds. Extended warrants preserve ~ $273 million of potential proceeds (Series A ~$205M; public/private ~$68M). Secured EUR 40 million EIF grants for Antwerp and highlighted ~$75 million of revenue bonds as monetizable, giving multiple financing paths for the ramp.