Packaging waste innovator saveBOARD has opened its first beverage carton recycling facility in Australia, located in Warragamba, in Sydney’s southwest. It has the capacity to process up to 4000 tonnes of materials per year and employ up to 12 staff. PKN joined a crowd of local government dignitaries, heads of associations, brand owners and other stakeholders to attend the opening.
This project marks the first collaboration between carton manufacturers Tetra Pak and SIG Combibloc in Australia and falls under the umbrella of the Global Recycling Alliance for Beverage Cartons and the Environment (GRACE), as well as being a joint initiative with saveBOARD and its partner Freightways.
The $5.5m facility is the first of its kind in the country to manufacture construction products entirely out of used beverage cartons, which would have ended up in landfill. The facility's development was supported by the Australian government’s Recycling Modernisation Fund and the NSW government’s Waste Less, Recycle More initiative.
Delegates were given a tour of the facility and learned that the cartons are sourced largely from container deposit scheme feedstock, recycled and processed on site using high-tech equipment imported from Czech Republic and Germany. Recycled paper sheeting converted and supplied by Opal and 80% recycled plastic sheeting converted and supplied by Convex form part of the finished product.
The process is as follows: all collected materials (including cartons, caps and straws) are shredded in an industrial blender. The shredded material is then compressed using heat as the bonding agent, eliminating the need for glues or other chemical additives. The board is coated with a thin facing material, and cut to size.
The resulting product is a sturdy, lightweight alternative to conventional plasterboard, plywood or particle board, which itself is also 100 per cent recyclable.
CEO and co-founder of saveBOARD Paul Charteris said at the facility’s opening ceremony: “It’s exciting to finally be opening the first saveBOARD facility in Australia, supporting the circular economy to make a real impact to the environment and climate change. This facility will enhance the construction industry’s drive towards more sustainable construction practices, while also showing consumers the importance and value in recycling and opting for recyclable products in their day-to-day lives.”
Andrew Pooch, managing director of Tetra Pak Australia and New Zealand commented: “We’re incredibly proud to be part of this sustainability journey alongside saveBOARD, as we look at even more innovative ways we can convert carton packaging waste into useful applications, and contribute to a strong circular economy.
“This is part of our ongoing sustainability commitment, as we look to enable more packaging to become 100 per cent recyclable or reusable, in line with the 2025 National Packaging Targets. By partnering with saveBOARD, we’re showing that innovation in recycling comes in many forms, and consumers can see first-hand how they can contribute to a more sustainable future.”
Guest speaker at the event, CEO of Australian Packaging Covenant Organisation Chris Foley said, “There has been a lot of work by stakeholders across the system to develop this project and get this facility up and running. Credit is due to Tetra Pak who has had the vision as a global business to back projects like this one to bring it to life in the Australian market with a very Australian solution.”
The project collaborators and guests on the day concurred that the launch of this facility marks an important step in developing the infrastructure needed to support carton recycling and enable a circular economy in Australia. saveBOARD will open another recycling facility in Campbellfield, Victoria in late 2024 after receiving $1m in funding from the Victorian government.
