Tetra Pak and Yellow Dreams are making a joint investment of around €3 million to launch operations at a recycling plant for polyAl from used beverage cartons – set to begin operations in the second half of 2025 and boost recycling capacity in the EU.
Designed to achieve an annual capacity of 20,000 tons, the plant is apparently capable of processing the entire volume of polyAl from beverage cartons recycled in Belgium and the Netherlands, and part of Germany’s volume. It is strategically located in Ittervoort, near the Belgian and German borders.
It is anticipated that, while recycled paper fibres can be used to reinforce paper products like e-commerce boxes and shopping bags, the recycled polyAl can replace virgin and other recycled plastics in injection moulding, extrusion, and thermoforming applications. Pallets, crates, and reusable pallets are among the potential applications envisioned by Tetra Pak.
The plant is set to complement the 8,000-tonne capacity of Recon Polymers’ existing facility in Roosendaal, developed in partnership with Tetra Pak until operations commenced in 2021; this facility received a further injection of €1 million in 2023.
As well as increasing recycling capacity in the Dutch region, the Ittervoort plant hopes to build upon the EU’s ‘existing and well-established’ recycling infrastructure; polyAl is currently processed in ten facilities and beverage cartons in twenty specialized paper mills, Tetra Pak explains.
“We are pleased to announce this new plant, which significantly enhances the recycling capacities of used beverage cartons in the region,” says Kinga Sieradzon, vice president Collection & Recycling at Tetra Pak. “By collaborating with Yellow Dreams, we have the opportunity to exceed the Netherlands’ official recycling targets.
“This is another milestone in our collaborative journey with all stakeholders across the value chain, to drive collection, sorting, and recycling. Our ongoing investments, up to €40 million each year globally, reflect our commitment to advancing beverage carton recycling and supporting sustainable practices.”
Bas Gehlen, managing director at Yellow Dreams, added: “The joint endeavour of Yellow Dreams and Tetra Pak not only showcases the potential of polyAl recycling but also sets a remarkable example of the value of collaboration towards building a circular system.
“Through this project, we are continuing to spearhead the transformation of carton recycling, leaving a lasting impact on the environment and inspiring further the adoption of circular economy practices.”
Last year, Tetra Pak joined forces with Axjo Group to conduct a feasibility study for a new recycling plant dedicated to the polyAl layers in carton packages. It hoped to use its findings to build a new recycling plant in Sweden with an annual recycling capacity of 10,000 tonnes.
It also joined Stora Enso in a €29 million joint investment into a new recycling line for post-consumer beverage cartons in Ostrołęka, which was anticipated to triple Poland’s annual beverage carton recycling capacity from 25,000 to 75,000 tonnes. It sought to absorb additional beverage volumes sold in Czechia, Hungary, Slovakia, Latvia, Estonia, and Lithuania.
Additionally, SIG received two awards under the 4evergreen alliance’s Circularity Success Stories initiative, including the Circularity Best Practices award for the Palurec PolyAl recycling plant. Launched in Germany by the Fachverband Kartonverpackungen für flüssige Nahrungsmittel, this facility stemmed from a joint investment from SIG, Tetra Pak, and Elopak, and converts polyAl into raw materials.
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