Working with professional hygiene business customers and partners, Kiilto has successfully completed a closed-loop project for detergent bottles. A total of 90,000 new packages will be produced for Kiilto’s products using recycled bottles.
The concept of closed-loop packaging is not new. However, what made this Kiilto-coordinated trial unique was that it was conducted specifically with high density polyethylene (HDPE) detergent packaging. Professional hygiene products require a different level of packaging quality compared to those found on supermarket shelves, particularly in terms of chemical durability.
“The value of a closed loop lies in the purity of the recycled material, as it consists solely of separately collected HDPE. The source of the recycled plastic is strictly controlled, allowing us to prevent contaminants from entering the recycled material. This ensures consistent high quality,” explains Heidi Kähkönen, who is in charge of packaging development in Kiilto’s professional hygiene and consumer business units.
Kähkönen is justifiably excited about the success of the pilot project. It was far from certain that the collected recycled plastic would be suitable for reuse in packaging designed for professional applications.
“This is a major step forward in advancing the circular economy. Now that we have demonstrated the feasibility of a closed loop, it opens up entirely new possibilities for developing packaging recycling,” Kähkönen enthuses.
Lessons learned – valuable insights into the potential of the circular economy
One of the companies involved in collecting packaging was the cooperative dairy Hämeenlinna Osuusmeijeri. In line with its environmental principles, the dairy minimises waste generation by maximising the reuse, recycling and recovery of materials in its production processes.
Hämeenlinna Osuusmeijeri’s quality, environment and product development manager, Anne Isokangas,explains that their environmentally certified production facility is accustomed to recycling. However, separately collecting specific packaging requires clear instructions. She also reflects on the pricing of recycling, suggesting that making closed-loop recycling a routine practice for companies of all sizes may require broader discussions about waste management and transportation costs.
The collection logistics for the detergent bottles were managed by LHJ Group. Pasi Kaskinen from LHJ explains that they are always keen to try new initiatives. When Kiilto’s familiar contact person contacted him, the planning for collection logistics began immediately.
“The pilot project was an excellent example of how recycling is technically feasible when users are motivated to sort their waste correctly. We received clean, high-quality material from customers. All too often, a lack of sorting skills or motivation leads to contamination, rendering the recyclable material unusable,” Kaskinen notes.
“This pilot provided valuable insights into the possibilities of closed-loop recycling across companies of different sizes and industries.”
Kaskinen also predicts that producer responsibility for packaging will introduce new obligations in the future. He believes that different collection methods will emerge, such as larger waste streams being collected together and sorted by material type later in the process.
Experience + professionalism = success
The recycling of collected packaging in the pilot was managed by Lassila & Tikanoja (L&T). Mikko Mäenpää from L&T says he was initially sceptical about the feasibility of the collection.
“When collecting small quantities at a time, one difficulty is accumulating a sufficient volume. Our target was 5,500 kilos. In the end, everything went smoothly, with great results.”
The relatively small volume of collected packaging required a high level of expertise from their staff. L&T has participated in numerous other closed-loop recycling projects, but detergent bottles and their material were new to them.
“We already wash and recycle plastic, but our processing lines are large, meaning that smaller volumes must be handled quickly. This required precise adjustments, fast.
The detergent bottles foamed a bit during washing, but this was easily resolved with an anti-foaming agent.”
A step forward for commercial packaging recycling
Autumn 2024 was an exciting time, as production of the new packaging finally began. Although it was clear that the recycled material could be used for Kiilto’s other products, the big question remained: would it meet the quality standards for professional hygiene products? The answer was eagerly awaited.
“The packaging was thoroughly tested, and the results were excellent. The material is of high quality and meets the intended requirements,” says Kähkönen.
The new 5-litre canisters contain 35% recycled plastic, which, according to Simo Heljanko, CEO of Muovi-Heljanko Oy (the company that manufactured the packaging), is currently close to the maximum feasible amount.
Although the properties of the recycled material match those of packaging made entirely from virgin plastic, there are some differences.
“The canisters are made of polyethylene, with different plastic layers. The recycled plastic is placed in the middle layer, while the outer and inner layers are made from virgin plastic. The outer layer accounts for about 20% of the wall thickness. Since the recycled plastic consists of various colours, the middle layer can show through the outer layer, resulting in slight variations in packaging colour.”
“Closed-loop packaging is one way to promote the recycling of commercial packaging. However, I see an even greater opportunity in challenging current practices on an industrial scale. A closed loop allows plastic to be recycled within a geographically limited area, such as Finland, rather than being transported around the world. Currently, many organisations mix all plastic types together due to the lack of an efficient separate collection process. I hope to see more discussions on how to tackle this,” says Kähkönen.
In brief:
The closed-loop pilot in figures:
- 5,500 kg of empty packaging
- 90,000 new canisters made of 35 % recycled plastic
The companies involved in packaging collection in the pilot were Hämeenlinna Osuusmeijeri, Valio, Juvenes, Perho Culinary, Tourism & Business College, the City of Kotka, the City of Hamina, the University of Helsinki, CC-Tukku and LTQ Partners.
Collection logistics were taken care of by LHJ Group.
Recycling from packaging to granulate was handled by Lassila & Tikanoja.
New packaging production was handled by Muovi-Heljanko.
Further information:
Heidi Kähkönen
Packaging Development Manager
Heidi.kahkonen@kiilto.com
+358 40 837 0830