Resources » Case Studies » How RHINO and Vplas Turned a “Not a Good Idea” Into a Circular Manufacturing Success Story, EP2.

How RHINO and Vplas Turned a “Not a Good Idea” Into a Circular Manufacturing Success Story, EP2.

Fonterra asked if they could return their end-of-life RHINO mudguards for recycling. The easy answer was no — but we pushed on. Here’s how RHINO and Vplas built a verified circular manufacturing loop with a 76% lower carbon footprint.

Truck and trailer builders, fleet managers, and specifiers all face the same pressure: reduce waste, improve sustainability, and keep equipment performing safely on the road.

So, when Fonterra asked RHINO if they could return their end-of-life mudguards for recycling, the easy — and technically defensible — answer would’ve been no.
Existing recycling pathways didn’t support large-format plastic components, and earlier attempts in the transport sector had struggled with contamination, durability issues, and inconsistent feedstock.

But demand was real.
And innovation often starts with someone saying:

“That’s not a good idea.”

Instead of closing the door, we opened a new one.

EP2 of Behind the Scenes takes you through how RHINO and Vplas proved what many assumed was impossible — creating a circular manufacturing loop for heavy-transport components.

How It Started: Asking the Hard Question

When the RHINO team first approached Steve and the Vplas crew, we needed a straight answer:

👉 “Is this even possible?”

To find out, we worked through a full technical, compliance, and practical feasibility review.

The process included:

1. Returning RHINO manufacturing offcuts

These were our cleanest, most predictable test feedstock — helping establish baseline performance.

2. Fleets returning end-of-life mudguards

Real-world guards come back with everything from gravel and stickers to metal brackets. This required new sorting and QC systems.

3. Contamination management and material sorting

Removing non-plastic components remains one of the biggest practical challenges.
(Yes — we still remind people not to send metal brackets back with their guards. 😅)

4. Developing a recycled powder with UV stabilisers

UV additives were essential to maintain long-term road performance and reduce fading.

5. Performance testing and verification

Guards were tested for strength to ensure safety and compliance in NZ and AU operating conditions.

6. Full manufacturing trials

This confirmed the recycled material could run consistently through moulding equipment without quality issues.

The Result: A Circular Manufacturing Loop That Works

Once the recycled material and process were proven, the final step was finding a fleet willing to run the first full-scale real-world trial.

TR Group stepped up — and you’ll see that journey in the next instalment of Behind the Scenes.

Circular Recycling Process from Black Mudguards returned for recycling.

Doing the right thing matters. This collaboration shows how practical actions — returning guards, recycling Material, verifying results — add up to real progress.