Used pickleballs get second life in UK recycling initiative

The growing popularity of pickleball is creating more plastic waste, prompting two UK companies to develop a recycling solution.

Pickleball is one of the world’s fastest-growing sports, with up to an estimated 50 million players worldwide. Dorset-based plastics manufacturer Brothers Make has joined forces with sustainable sports start-up Crack’d to recycle millions of used plastic balls generated over the years.

The initiative was founded by former international tennis player and sustainable design graduate Millie Smythe. She launched Crack’d in 2025 after noticing the number of broken balls discarded during competitions and training sessions.

Growing waste stream

Crack’d collects used pickleballs from clubs, leagues and individual players across the UK. Brothers Make then processes the material using mechanical recycling techniques. The balls are shredded into flakes before being melted and moulded into products such as keyrings, coasters, clips and trophies. Each new item is designed to remain recyclable at the end of its useful life.

According to the partners, the scheme has already diverted more than 100kg of plastic from the waste stream. The balls are hollow and weigh about 22grams each. This means around 4 500 balls have been recycled

‘Pickleball is growing incredibly quickly, which is fantastic for the sport,’ says Smythe. ‘However, it also means more equipment reaches the end of its life.’ She aims to demonstrate that damaged sports equipment can retain its value when collected and recycled properly.

Circular foundation

Brothers Make specialises in manufacturing products from recycled plastics using circular design principles. Co-founder Matt Browning believes pickleballs are well suited to mechanical recycling because they are made from a durable engineering plastic.

‘Circularity has been considered from the start,’ Browning points out. ‘The balls become new products, and those products can be recycled again in the future.’ The recycled material is 100% clean plastic, free from any contaminants.

The partners are now expanding their UK collection network and encouraging more clubs to participate.