Can Carton Waste Revolutionise Sustainable Manufacturing?
Tetra Pak and Yellow Dreams are making waves in the European recycling sector by announcing a new €3.1m (US$3.2m) recycling facility in Ittervoort, The Netherlands.
The cutting-edge plant will significantly increase the recycling of drinks cartons by processing the non-fibre component, known as polyAl, into reusable materials.
With an annual capacity of 20,000 tonnes, this initiative is a significant step forward in creating a circular economy for beverage packaging.
The new plant builds on the existing infrastructure in the European Union, where 20 specialised mills already recycle beverage cartons. These facilities primarily extract paper fibres, which are reused in products such as e-commerce packaging and shopping bags.
The non-fibre layers, made of polymers and aluminium (polyAl), are currently processed by just 10 facilities.
This expansion in Ittervoort complements an earlier project at Recon Polymers in Roosendaal, The Netherlands, which increased its capacity to 8,000 tonnes in 2023.
Combined, these facilities represent a major leap in polyAl recycling capacity, enabling the Netherlands to surpass its official recycling targets.
Kinga Sieradzon, Tetra Pak’s Vice President of Collection and Recycling, comments: “We are pleased to announce this new plant, which significantly enhances the recycling capacities of used beverage cartons in the region.
"By collaborating with Yellow Dreams, we have the opportunity to exceed the Netherlands’ official recycling targets.”
This collaboration highlights the commitment of Tetra Pak and Yellow Dreams to sustainable practices and their role in building a circular system.
Turning waste into everyday products
Recycling polyAl is a game changer for the packaging industry.
When processed, the material can replace virgin plastics in applications such as injection moulding, extrusion and thermo-forming. The result is an array of durable goods, from pallets and crates to outdoor furniture and flower pots.
Even large-scale items, such as 3D-printed objects, are now possible thanks to advancements in polyAl recycling technology.
Since 2019, Tetra Pak has partnered with Recon Polymers to refine this technology, culminating in the successful launch of the Roosendaal plant in 2021. The Ittervoort facility builds on this success, employing the same innovative processes to transform waste into value-added products.
“The joint endeavour of Yellow Dreams and Tetra Pak not only showcases the potential of polyAl recycling but also sets a remarkable example of the value of collaboration towards building a circular system," adds Bas Gehlen, Managing Director at Yellow Dreams.
Investing in a sustainable future
The opening of this new plant is part of a larger strategy by Tetra Pak to drive innovation in recycling. The company invests up to €40m (US$42m) annually in projects aimed at advancing beverage carton recycling. These efforts align with the EU’s push for sustainable practices and stricter recycling targets.
A Tetra Pak spokesperson explained: “Expanding this infrastructure is a priority for Tetra Pak.” The company’s focus on collaboration, investment and technology is paving the way for a more sustainable future.
For manufacturers, the ability to repurpose polyAl into new products demonstrates the viability of recycling as a solution to material scarcity and waste management.
By working closely with partners like Yellow Dreams, Tetra Pak is showing that recycling is not just an environmental necessity but also a sound business opportunity.
Leading the way in recycling
The new facility in Ittervoort exemplifies the progress that can be achieved when innovation meets collaboration.
Tetra Pak’s partnership with Yellow Dreams illustrates how manufacturing firms can lead the way in transforming waste into a valuable resource. As recycling capacity expands, so does the potential for more industries to adopt circular economy principles.
Reflecting on the partnership, Bas concludes: “Through this project, we are continuing to spearhead the transformation of carton recycling, leaving a lasting impact on the environment and inspiring further the adoption of circular economy practices.”
This latest milestone is not just about achieving targets—it’s about redefining what’s possible for the manufacturing and recycling sectors.
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