A step-by-step guide to recycling cardboard

Cardboard packaging is a staple in the supply chain, yet many are unaware of the journey it takes once it leaves your hands for recycling. The cardboard recycling process is essential to sustainability efforts across industries, and the UK has one of the highest cardboard recycling rates globally.

But how is cardboard recycled? Here’s a closer look at the step-by-step process and how businesses can benefit from using recycled packaging.

1. The six-step process
2. Environmental benefits
3. Virgin vs recycled
4. Choosing the right packaging
5. Business advantages
6. Summary

Recycling cardboard involves several steps, which we’ll explain below. At Suttons Performance Packaging, we help businesses understand the full recycling lifecycle and how this impacts the environment and their operations.

Step 1: Collection

The recycling process begins when the cardboard is collected. Whether from your business premises, kerbside bins, or bulk collection points, this waste is transported to recycling facilities, including paper mills.

Step 2: Sorting

After collection, the material is sorted into various categories. Coated or waxed cardboard is separated for specialised processing, while corrugated cardboard and thinner materials, such as “boxboard”, are further divided to meet specific recycling needs.

Step 3: Shredding and pulping

Once sorted, the cardboard is shredded with water and chemicals to break it into pulp. The pulp is often combined with virgin fibres to improve its strength, helping ensure that the recycled product maintains a high quality.

Step 4: Filtering

The pulp is filtered through various processes to remove contaminants like tape, glue, plastics, and metal staples. A centrifuge helps separate heavier materials, such as metal staples, while chemicals remove ink, ensuring the pulp is clean and ready for the next stage.

Step 5: Finishing

The pulp is spread out to dry on a conveyor, which removes excess water and presses the material into a sheet. The pulp’s moisture content is carefully controlled to form a durable paper suitable for producing new packaging.

Step 6: Converting to corrugated

The finished paper sheets are used to create new corrugated cardboard at this stage. This material is then sold to packaging manufacturers who use it to make a variety of packaging solutions for businesses, including those focused on eCommerce, retail, and transit packaging.

Recycling cardboard offers significant environmental benefits that can help businesses reduce their carbon footprint:

• Energy savings: Recycled cardboard requires 25-50% less energy to process than virgin material.
• Reduced virgin material usage: Recycled cardboard helps conserve natural resources by reducing the need for new raw materials.
• Water consumption: Using recycled materials can reduce water consumption by up to 99%, contributing to more sustainable practices.
• Lower emissions: By recycling locally, businesses can avoid the environmental impact of transporting raw materials from overseas.

When considering cardboard packaging, you may come across the terms virgin and recycled fibres.

Virgin fibres are sourced from new wood pulp, processed to create paper products, and often used in packaging that requires additional strength or durability.

Recycled fibres are derived from post-consumer recycled cardboard. Although they are sustainable, they tend to be weaker than virgin fibres and can be reused up to 20 times before degradation.

The balance between using recycled and virgin fibres depends on your business’s specific packaging needs. Recycled fibres help reduce waste, but virgin fibres are necessary in applications where additional strength and longevity are required.

While recycled cardboard packaging offers a range of environmental and cost benefits, it’s not always the best solution for every application. In certain circumstances, other materials might be more efficient.

For example, businesses that require long-lasting packaging, such as in a closed-loop supply chain, might find reusable packaging like plastic totes more practical than single-use cardboard.

Or, for sensitive products that are easily damaged, additional protective materials may be required. Using recycled cardboard might not offer the necessary protection in these cases, leading to potential loss and increased costs.

Adopting recyclable packaging can give your business a competitive edge in several ways:

• Demonstrating your commitment to sustainability can enhance your brand’s image and appeal to eco-conscious consumers.
• Using recycled pacakging can reduce your material costs and transportation expenses.
• Packaging that is easy to recycle or made from recycled materials often boosts customer satisfaction and encourages repeat business.

Whether you’re a business focused on reducing your environmental footprint or simply looking for reliable packaging solutions, understanding the cardboard recycling process is essential. At Suttons Performance Packaging, we provide sustainable and recyclable pacakging options that support your environmental goals while ensuring your products are well-protected.

If you’re looking for high-quality, eco-friendly packaging that helps your business reduce waste and improve its sustainability profile, get in touch with us today to find out more.