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Novapor foam packaging recycling at Novapor

The path to a circular economy: recycling at NOVAPOR

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Discover recycling at Novapor and how it helps to reduce waste and conserve natural resources.

The packaging industry plays an undeniable key role in reducing waste and conserving natural resources at a time when sustainability and environmental protection are becoming increasingly important. At NOVAPOR, we see ourselves as a manufacturer and developer of packaging solutions made of foam, corrugated cardboard and wood and also as a pioneer on the road to a circular economy. Our aim is to manufacture high-quality products and also to ensure that all materials generated during the manufacturing process are carefully recycled and reused.

Circular economy as a strategy

The circular economy is an economic model that aims to use resources more efficiently and reduce waste by continuously circulating products, materials and resources in closed loops. Instead of consuming resources after a single use and creating waste, they are recycled, reused or regenerated to extend their lifespan and reduce the need for new raw materials. In the circular economy, waste is viewed as a resource that can be returned to the production and consumption cycle, rather than as an inevitable end product.

Novapor foam packaging recycling at Novapor district economy
Novapor foam packaging recycling at Novapor district economy

Overall, the recycling of packaging materials at Novapor offers numerous advantages in the context of the circular economy. It reduces environmental impact, saves resources, reduces waste and promotes more sustainable use of materials. Recycling helps close material cycles by converting leftover materials into valuable resources and flowing them back into the production process.

Sustainable packaging solutions

Our packaging solutions are generally manufactured from raw sheets, which are used to produce the end product but also leave behind residues. We do not see these residues as waste, but as valuable resources that can be reintegrated into the material cycle in a careful recycling process.

Economic efficiency also plays an important role in implementing our sustainable packaging solutions. Our customers are increasingly recognizing that sustainable packaging not only offers environmental benefits, but can also bring economic benefits. By optimizing packaging processes and materials, companies can reduce costs, use resources more efficiently, and at the same time improve their brand image by positioning themselves as environmentally conscious.

Primary packaging Secondary packaging Tertiary packaging NOVAPOR foam boxes

We help our customers meet growing consumer demands by implementing sustainable packaging solutions. Consumers are showing increasing interest in environmentally friendly products and are willing to pay for products sold in sustainable packaging. This creates incentives for companies to invest in sustainable packaging solutions and develop innovative approaches to meet consumer demand.

How much material was recycled and reused at Novapor in 2023?

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metric tons

Uncrosslinked foams

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metric tons

Cross-linked foams

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metric tons

cardboard

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metric tons

Wood

Recycling at Novapor: Foam

At Novapor, we offer our customers a sustainable packaging solution that covers the entire product development cycle. It starts with a packaging design that saves space and reduces material consumption, as well as selecting the best sustainable materials, the most sustainable manufacturing methods and optimal recycling conditions. Recycling at Novapor reduces waste, saves raw materials and reduces environmental impact.

A look at 2023 shows that recycling at Novapor is already bearing fruit. Let's start with the uncrosslinked foams - over 30 tons of this material have been successfully recycled. A state-of-the-art baling press is used in our production, which shreds leftovers and old packaging made of uncrosslinked PE foam, compresses it and delivers it in the form of strands. These strands are collected and sent to a further recycling process in collaboration with our partner, who also supplies us with new raw material. 

The resulting recycled material is used not only in the production of virgin goods, but also in our recycled foam line called RENEW. We also successfully recycle cross-linked foams - over 50 tons were recycled and reused in 2023. Our own shredder shreds leftovers and old packaging made of cross-linked polyethylene foam into small flakes, which are collected in containers and picked up by our partner. This partner transforms the flakes into new foam mats, which are often used as an elastic layer in high-quality artificial turf systems for sports fields and playgrounds. In this way, the foams are given a second life and a “zero waste” approach is created in the truest sense of the word.

Recycling at Novapor: cardboard

Even paper, corrugated cardboard and honeycomb cardboard do not escape our comprehensive recycling initiative. In 2023 we were able to successfully recycle an impressive 29.5 tonnes of these materials. Both the paper and cardboard waste generated in our own production as well as the packaging we receive are professionally collected and compressed in a large press. Once enough material has been collected, our partner collects the containers and the paper and cardboard are professionally recycled to return to the material cycle.

Recycling at Novapor: wood

Another milestone in our commitment to recycling concerns wood. In 2023, over 40 tons of wood were collected and picked up by our partner. This wood comes from both the production of new packaging and used packaging and pallets. The collected wood waste ends up in a waste wood processing plant, where it is processed into a valuable secondary raw material. This can be used either materially or energetically, which represents a further step towards a circular economy.

Novapor foam packaging recycling at Novapor Holz

Innovative ways

When developing new packaging, we at NOVAPOR already rely on recyclable materials. Our recycled foams such as RENEW or the use of OSB instead of virgin material for export crates are very popular. Where possible, we use materials made from recycled materials and try to design the packaging in such a way that it can be easily separated after use, for example by gluing at specific points instead of gluing over the entire surface. This strategic planning is an important aspect of our efforts to further increase recycling rates.

For the future, we have set ourselves the goal of further increasing our recycling rates and finding innovative ways to conserve even more resources and support the transition to a fully circular economy. We are proud to contribute to environmental protection and will continue our efforts to create a sustainable and environmentally friendly future together.

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