In the latest step on its journey to make its products more sustainable, the Lego Group recently unveiled a prototype Lego brick made from recycled plastic.
Over the past three years, materials scientists and engineers tested over 250 variations of PET materials and hundreds of other plastic formulations.
The result is the new prototype, which uses PET plastic from discarded bottles, the first brick made from a recycled material to meet the company’s strict quality, safety and play requirements – including clutch power.
The prototype is made from recycled PET sourced from suppliers in the US that use Food & Drug Administration (FDA) and European Food Safety Authority (EFSA) approved processes to ensure quality.
The patent-pending material formulation process uses a bespoke compounding technology to combine the recycled PET with strengthening additives. On average, a one-litre plastic PET bottle provides enough raw materials for 10 2x4 Lego bricks.
“The biggest challenge on our sustainability journey is rethinking and innovating new materials that are as durable, strong and high-quality as our existing bricks – and fit with Lego elements made over the past 60 years,” explains Tim Brooks, vice-president of environmental responsibility at Lego.
Although it will still be some time before bricks made from recycled material appear in Lego's product boxes, Brooks says the team will continue test and developing the PET formulation and then assess whether to move to the pilot production phase.
This next phase of testing is expected to take at least a year.
“We know kids care about the environment and want us to make our products more sustainable,” says Brooks.
“Even though it will be a while before they will be able to play with bricks made from recycled plastic, we want to let kids know we’re working on it and bring them along on the journey with us.
“Experimentation and failing is an important part of learning and innovation. Just as kids build, unbuild and rebuild with Lego bricks at home, we’re doing the same in our lab.”
The recycled prototype brick is the latest development in making the Group’s products more sustainable.
In 2018, it began producing elements from bio-PE, made from sustainably sourced sugarcane. Although many Lego sets now contain elements made from bio-PE, especially smaller, softer pieces, the Group says bio-PE is currently still not suitable for making harder, stronger elements. In 2020, the company announced it will begin removing single-use plastic from its boxes.
“We’re committed to playing our part in building a sustainable future for generations of children,” comments Brooks.
“We want our products to have a positive impact on the planet, not just with the play they inspire, but also with the materials we use. We still have a long way to go on our journey, but are pleased with the progress we’re making.“
Lego’s focus on sustainable material innovation is just one of several different initiatives the company has in place to make a positive impact.
The Group is currently investing up to US$400 million over three years to 2022 to accelerate its sustainability ambitions.
