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US carton recycler looks west

A new facility in Colorado for an innovative manufacturer is set to expand the end markets for recycled food and beverage cartons in the western United States.

The plant is due to open in April 2019 and will be operated by the ReWall company which makes high-performance, sustainable building and construction materials out of the recovered cartons through a proprietary process that uses neither chemicals nor water.

Once operational, the Colorado facility will process around 9 000 tonnes a year of aseptic and gable top cartons into roof cover board, exterior sheathing, wallboard, underlay and other building materials. It takes about 400 cartons to produce one sheet of roof cover board. Every truckload of finished ReWall products means nearly 600 000 cartons have been diverted from landfill.

New end market

‘This new facility marks a major milestone for ReWall and our efforts to turn cartons into environmentally friendly building materials,’ says Jan Rayman, founder and ceo of ReWall. ‘As demand for our products continues to grow, we are excited to open a new end market for cartons in the western part of the country.’

Jason Pelz, vice president of recycling projects for the Carton Council of North America and circular economy director for Tetra Pak, said the new facility reinforced the value in used food and beverage cartons.

‘ReWall’s expansion is a huge boost for carton recycling and should encourage even more communities and their residents to recycle food and beverage cartons,’ says Pelz. ‘End markets are expanding both in the US and globally.’

Big four support

The Carton Council, composed of leading carton manufacturers, Elopak, SIG Combibloc, Evergreen Packaging and Tetra Pak, was formed in 2009 to create a sustainable infrastructure for recycling and to help develop innovative end markets. It has been a long supporter of ReWall, which also turns cartons into building materials at its headquarters in Des Moines, Iowa.

ReWall’s Colorado facility was part-funded by the state’s Recycling Resources Economic Opportunity grant programme.

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