Closed loop recycling: An award-winning recycling project.

Closed loop recycling: An award-winning recycling project.

Closing the loop.

When a long-standing, multi-national customer approached us, they wanted to explore how they could recycle the large volumes of polythene packaging coming into their sites from multiple suppliers. While they were already recycling cardboard, their polythene was going to landfill. Their ambition? A closed-loop recycling system that would capture both incoming supplier packaging and their own polythene waste.

We took a collaborative approach from the very beginning. Key stakeholders were invited to visit our extrusion site, where they could see firsthand how polythene is manufactured and watch a recycling machine in action. This helped to build a clear understanding of what was possible and to align all parties on the potential for a practical, cost-neutral solution.

From there, one of our Stevenage Packaging team members carried out a detailed review across every customer site, looking at all polythene products used or received. This allowed us to create a comprehensive list of items eligible for recycling, which was supported by a clear baler processing document issued to all locations.

A swift success.

To make the system as simple and effective as possible, we supplied a baler to each site, enabling them to collect, bale, and return their used polythene. The material is then reprocessed into polymer and used to manufacture new bags and film – transforming what was once waste into a valuable resource.

The results have been immediate and measurable. Since the initiative began, the customer has successfully collected, returned, and recycled 20,240 kilos of polythene. This is the equivalent of 40 pallets diverted from landfill. What was previously an environmental challenge is now a cost-neutral closed-loop system.

The next stage of the project is already in motion: incorporating the reprocessed waste directly into the manufacture of the customer’s own waste bags. This will create a truly closed-loop system, where polythene packaging waste is recycled and reintroduced back into their own operations. A perfect example of sustainable packaging in practice.

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