An automated system for producing a slug having a repeatable shape from a plastic bottle, the automated system comprising: a housing having an elongated shape, an axis in a direction of elongation, and an opening configured to receive the bottle in a generally coaxially orientation with the housing; a compacting subsystem adapted to compact the bottle substantially in a first direction within the housing; and a slug processing subsystem adapted to form a slug having an essentially predefined form from the compacted bottle, the slug processing subsystem adapted to form the slug by application of force in at least a second direction, substantially normal to the first direction; wherein the slug processing subsystem is adapted to form a slug from a single compacted bottle; wherein the slug processing subsystem is configured to form a slug having a flattened geometric shape; wherein the flattened geometric shape is a polygon having a characteristic dimension less than 90 millimeters.