Planned facility will recycle food, beverage cartons into building materials

The Carton Council, Elof Hansson and the Upcycling Group have partnered to open a new facility in the second half of 2025 that will turn postconsumer food and beverage cartons into durable, sustainable building materials and create another domestic market for recycled cartons.

The partners say the initiative combines the environmental and economic benefits of carton recycling with market demands to create more sustainable building products. The manufacturing method involves shredding cartons and then bonding them together into large, durable sheets through a high-pressure and heat treatment process.

“The innovative technology at this future facility comes at a critical time when the building industry is actively seeking methods to decarbonize processes and enhance the circular economy,” Upcycling Group co-founder and CEO Jay Rayman says. “Our zero-waste process, which eliminates the need for water, formaldehyde glues and hazardous chemicals, significantly reduces carbon emissions by utilizing whole food and beverage cartons to produce boards for various construction applications.”

Jason Pelz, vice president of recycling for the Denton, Texas-based Carton Council, says the new facility not only will validate the value of carton recycling, but also will provide a significant boost to recycling efforts across the West Coast, offering local material recovery facilities (MRFs) a domestic option for their recycled cartons.

“This partnership is a testament to the vision and mission of our founder’s commitment to pursuing innovative solutions to expand sustainable markets,” Elof Hansson USA Inc. Managing Director Staffan Nordin says. “We are proud to be at the forefront of this growing marketplace that will not only deliver exceptional value to our customers, but also contribute significantly to the health of the planet. This collaboration marks a significant milestone in our journey toward a more sustainable future.’

The precise location of the proposed facility likely will be announced later this summer. Upon completion, it is expected to use an average of 750 tons of recycled cartons per month.