Advanced Technology to Transform Recycled Cartons into Eco-Friendly Construction Solutions

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The Carton Council, Elof Hansson, and Upcycling Group have announced a partnership to establish a state-of-the-art recycling facility, set to open in the second half of 2025. This facility will convert post-consumer food and beverage cartons into durable and sustainable building materials. The initiative is poised to create a new domestic market for recycled cartons, offering significant environmental and economic benefits.

Innovative Technology Leading the Way

At the heart of this initiative lies an innovative technology that combines environmental sustainability with economic viability. The facility will use a zero-waste process that eliminates the need for water, formaldehyde glues, and hazardous chemicals. This process involves shredding the cartons and bonding them into large, durable sheets using high-pressure and heat treatment.

“The innovative technology at this future facility comes at a critical time when the building industry is actively seeking methods to decarbonize processes and enhance the circular economy," said Jan Rayman, co-founder and CEO of Upcycling Group. “Our zero-waste process significantly reduces carbon emissions by utilizing whole food and beverage cartons to produce boards for various construction applications."

Facility Details and Impact

Though the precise location of the facility has yet to be announced, it is expected to be revealed later this summer. Upon completion, the facility is projected to process 750 tons (1,500,000 pounds) of recycled cartons per month.

“This new facility not only validates the value of carton recycling but will also provide a significant boost to recycling efforts across the West Coast, offering local materials recovery facilities a new viable domestic option for their recycled cartons,” said Jason Pelz, vice president of recycling for the Carton Council.

Partners’ Commitment to Sustainability

The Carton Council, Elof Hansson, and Upcycling Group partnership brings together organizations with a strong commitment to sustainability and innovation.

  • Carton Council: Formed in 2009, the Carton Council includes leading carton manufacturers like Elopak, Pactiv Evergreen, SIG, and Tetra Pak. The organization aims to build a sustainable infrastructure for carton recycling in the U.S. and works to increase recycling rates nationwide.
  • Elof Hansson: Known for its expertise in pulp and paper trading, commercial real estate development, and sustainable projects, Elof Hansson is driven by a passion for trade and entrepreneurship. “This partnership is a testament to the vision and mission of our founder’s commitment to pursuing innovative solutions to expand sustainable markets,” said Staffan Nordin, managing director of Elof Hansson USA.
  • Upcycling Group: With a mission to develop a global network of Circular Economy facilities, Upcycling Group focuses on increasing local recycling rates while creating new green manufacturing jobs. The company leverages its extensive network and expertise to convert waste materials into products and materials for the construction industry.

Environmental and Economic Benefits

The facility’s impact extends beyond recycling, offering numerous environmental and economic benefits. By keeping 750 tons of cartons out of landfills each month, the facility significantly contributes to waste reduction efforts. Additionally, the durable sheets from recycled cartons can be used in various construction applications, promoting sustainable building practices. Moreover, establishing the facility is expected to create green manufacturing jobs, support local economies, and foster community development.

The new recycling facility will profoundly impact the local community. The initiative aligns with broader efforts to enhance community well-being and support economic growth by creating jobs and providing a cleaner, more sustainable environment. By leveraging innovative technology and a zero-waste process, the new facility will transform post-consumer cartons into valuable building materials, reducing carbon emissions and promoting the circular economy.

Environment + Energy Leader