How is cardboard recycled? A step-by-step explanation

Even though you come into contact with it every day, the question of how cardboard is recycled is probably not something you consider often. Yet cardboard (and paper-based packaging) has one of the highest recycling rates in the UK.

So, how exactly is cardboard recycled?

Cardboard recycling involves a six-step process. These steps are collection, sorting, shredding, and pulping; filtering; finishing; and converting back into corrugated board. It is possible to recycle cardboard more than 20 times before the fibres become too weak.

Over 70% of the cardboard that is used in the UK is recycled.

In this guide, we’ll provide you with an overview of the complete cardboard recycling process. It also covers limitations, differences between virgin and recycled fibres, and the business advantages of using recyclable (and recycled) cardboard packaging.

You may also find our guide to the Packaging Waste Regulations helpful, as it covers government recycling targets and details whether your business has any legal obligations.

If your business uses cardboard packaging, or if you have ever wondered what happens to your cardboard after putting it into your recycling bin, it can be enlightening to understand how the recycling process works.

As a brief overview, the six steps in recycling cardboard are:

• Collection of cardboard from kerbside bins or businesses.
• The material is sorted into different types.
• The materials are then shredded and pulped.
• The pulp is filtered to remove contaminants.
• The pulp is dried and “finished” into sheets or paper again.
• Specialist equipment manufactures new cardboard material.

There are many reasons why recycling cardboard benefits the environment.

Firstly, estimates indicate that overall energy savings of between 35% and 50% can be achieved when using recycled cardboard rather than virgin material.

Secondly, recycled cardboard uses between 70% and 100% less virgin material (it is commonplace to add some virgin material to recycled products during manufacturing).

Thirdly, water consumption is reduced by up to 99%.

Finally, there are considerable emissions reductions in manufacturing recycled cardboard in the UK by avoiding the import of materials. The UK can’t sustainably produce enough wood to meet the amount of paper and cardboard produced each year, but recycling the material already within the economy helps circumvent this issue.

Virgin and recycled fibres are standard terms used to describe paper and corrugated cardboard recycling.

But, what do these mean?

Virgin fibres are effectively pulp obtained by a chemical process which removes lignin (a class of complex organic polymers that form necessary structural materials in the support tissues of vascular plants) from wood. Effectively, it is making paper from wood.

Recycled fibres refer to pulp from recycled material, essential cardboard packaging or papers previously used but recovered for recycling.

But which is better for the environment?

Many people believe virgin fibres have a greater environmental impact because they involve deforestation.

However, this is not strictly true. Careful management and replanting mean forests become a renewable source of materials and a net producer of oxygen. The only major drawback of virgin fibres is the requirement for more process water treatment.

Recycled fibres actually take more fossil energy to process. Virgin fibres are also typically added to recycled fibres; they can be reused around 20 times before becoming too weak. After this, the fibres are so small that they wash out during the process.

Using recycled fibres helps reduce landfill waste by using existing material to its full potential. It also allows the use of virgin fibres in applications where their properties are specifically required.

However, it is vital to provide a balanced argument. Specific scenarios exist where recyclable packaging, such as corrugated cardboard, is counterproductive and less sustainable than non-recyclable packaging.

For example, plastic totes, such as those manufactured from Correx®, are often better than a single-trip cardboard alternative if part of a closed-loop supply chain. Compared to expendable packaging, their longevity means considerably fewer containers are required.

Using a smaller number of containers reduces overall material use, minimises transit costs due to the required additional deliveries, and lowers energy consumption in manufacturing.

Another area where recyclable corrugated alone isn’t always suitable for exceptionally valuable or fragile items.

You must also consider the environmental (and monetary) costs of the damaged items. If a product breaks in transit, it is typically disposed of in a landfill. There is a requirement for additional energy and material in manufacturing replacements. Plus, the further transport to return and redeliver the item.

However, it also significantly impacts your business. Written-off stock, unhappy customers, and certain oily or moist products will degrade the corrugated materials, rendering them ineffective.

Food produce is likely to spoil quickly, leading to increased food waste in landfills. It can also make the material unsuitable for recycling (e.g., pizza boxes being too greasy).

How your business can benefit from recyclable packaging.

Although cardboard packaging is not suitable for every application, it has many advantages when used where possible.

As well as the environmental benefits, including the reduction in your organisation’s carbon footprint, using easily recyclable packaging often leads to better consumer perception of your brand and business.

Equally, it can allow you to position your brand in a specific market. Ultimately, there is potential to increase sales among particular demographics, and customers who can easily recycle your packaging typically report higher satisfaction levels.

Whether you are simply wondering how cardboard is recycled or a business using significant amounts of corrugated packaging (for eCommerce, transit, or retail applications), understanding the cardboard recycling process can be helpful and interesting.

Should you require recycled or other eco-friendly packaging or need assistance with recycling best practices, GWP can help. With over 30 years of experience in sustainable packaging, we can help your business on your sustainability journey. Please get in touch for further information.