Circular Economy and Waste Recycling: A Sustainable Solution

Today, more than 2 billion tons of municipal solid waste are produced worldwide each year. By 2050, this figure is expected to rise to 3.4 billion tons. However, the problem is not limited to municipal waste: human activity also generates significant quantities of agricultural, construction and demolition, industrial and commercial, and healthcare waste.

If we were to list the main causes behind this growing trend in recent years, we would have to mention population growth, urbanization, and economic development, factors that are unlikely to reverse. So, where should we act to address the growth in waste? The answer lies in our economic model.

After exploring the Circular Economy and its benefits in depth, this article focuses on the issue of waste and its management, with particular attention to recycling and the circular use of resources.

What is Recycling
Recycling in the Circular Economy
Recycling and Greenwashing
Green Economy
Benefits of Recycling
Successes in Recycling: exemples of Circular Economy in Companies

What is Recycling?

Recycling is the set of methods and activities aimed at recovering materials, mostly waste, with the goal of making them reusable in new production processes.

However, the recycling sector is incredibly complex, as it involves a multitude of different players who may act in collaboration or completely independently.

There are citizens, who are responsible for properly sorting their waste.

There are manufacturing companies, which implement circular waste management strategies within their operations.

There are institutions, which provide waste management services and infrastructure, promote recycling awareness, and protect the environment through regulation.

Then, there are companies that carry out recycling itself, collecting waste and processing it for recovery in dedicated facilities.

Finally, there are manufacturers and innovators like Tecnofer, who focus on designing advanced recycling technologies in line with today’s challenges, providing the right tools to both recyclers and manufacturers for waste valorization.

Together, these actors contribute to the development of a strong, beneficial, and environmentally low-impact economic system: the circular system.

The Recycling Cycle in the Circular Economy

The process that turns waste into something usable and useful again is not always clear to everyone. There are roughly three key phases to consider:

Phase 1: separate waste collection and sorting

The recycling process begins with the individual. In many cities and countries around the world, especially in more economically developed areas, door-to-door waste collection services are available.

Take Italy, for example: the percentage of households served by door-to-door separate waste collection rose from 66% in 2018 to 73% in 2021 (source: Istat).

However, this model is not present everywhere. In many regions, door-to-door collection doesn’t exist and citizens must personally sort and bring their waste to designated drop-off centers or public waste bins.

Phase 2: recycling and transformation process

Waste materials have different compositions and require targeted, specific treatments. Take plastic packaging for example, with its hybrid compositions made of various types of plastics, such as PET, PE, HDPE-PP.

The first essential step is sorting, performed by specialized systems that identify and classify waste based on type, size, and color.

Next comes the grinding phase, where previously sorted packaging is mechanically broken down and sent for washing. Washing is a crucial step as it removes a range of contaminants from the plastic material, food, glue, oils, soaps, and more, that would otherwise compromise the quality of the final recycled product.

This is exactly where our company comes in: for nearly 50 years, Tecnofer has been developing recycling and recovery systems, constantly innovating and responding to the increasingly specific needs of customers and the market. Among our latest innovations is a hot wash system for plastic film, designed to provide an even higher level of cleaning.

The final stages involve shredding and pelletizing. Shredding transforms the cleaned material into flakes, while pelletizing produces pellets, the final product that serves as raw material for manufacturing new plastic products.

Phase 3: reintegrating recycled materials into the economy

If the recycling process is carried out correctly and using the right technologies, the resulting pellets can be used to produce a wide variety of products. For instance:

Rigid plastic pellets such as HDPE or PP are used to make bottles and containers for detergents and personal care products and also for items like garden furniture, home accessories, and organizers.

PE (film) pellets can be used to manufacture reusable bags, agricultural film, and labels.

PET transformation

The PET recycling process differs slightly from the others. After extrusion, recycled PET can take several forms: pellets (granules); fibers or filaments, often used to produce synthetic textiles like polyester, sheets or rolls, used in thermoforming or for creating containers and packaging.

Here we move on to even more specific phases that address the areas for which the material has been recycled:

Crystallization

If PET is to be reused for food-grade applications, it is crystallized to enhance its mechanical and thermal properties.

Decontamination

Specific processes, such as inert gas washing or Solid State Polymerization (SSP), ensure contaminant removal and food safety compliance.

Production of new items

  • Packaging: recycled PET is used to make bottles, trays, and food containers
  • Textiles: much of recycled PET becomes fibers for synthetic fabrics
  • Industrial materials: sheets and components for industrial applications

Closed life cycle-loop system ("bottle-to-bottle")

In the most advanced processes, recycled PET returns to the market as new bottles, a perfect example of a complete circular economy.

As we can see, the recycling process is far more complex than it is often portrayed. Public communication tends to offer generalized or oversimplified information, which may give people a false sense of familiarity with the topic.

In some cases, this can even lead to a sense of fatigue or skepticism about sustainability, recycling, and environmental responsibility. And what is one of the main mover to this perception? Unfortunately, it’s a familiar issue: greenwashing.

Recycling and Greenwashing

The topic of greenwashing has been widely explored, and many people are now aware of how this marketing practice has entered, and continues to be present in the communication strategies of several companies.

As the term itself suggests, this is a misleading practice that exploits consumers’ sensitivity to environmental and sustainability issues in order to sell products or services.

But why are we discussing it here? Because recycling is one of the main themes used in greenwashing strategies.

Given the environmental issues that have come to global attention in recent years, a large portion of public opinion has become increasingly mindful of what they buy, paying close attention to product packaging composition and to the stance of brands and companies on sustainability and environmental protection.

To position themselves favorably in the eyes of consumers, some companies have launched marketing and product strategies focused on “green” themes, giving rise to the phenomenon of greenwashing.

Let’s look at a few statistics:

Half of product labels are unverified or based on weak data;

40% of claims have no supporting evidence;

53% of green claims are vague, misleading, or unfounded

How can we distinguish between transparent, truthful communication and misleading messaging? Unfortunately, there is no single rule to follow: it’s essential to carefully read product labels and educate ourselves on the topic, trying to understand the true meaning behind the claims presented on packaging.

For example, the labels “100% recyclable” and “100% recycled” are two very different statements, yet they can easily lead to misjudgments and misunderstandings.

Moreover, green colour has become dominant on certain packaging, often used to instantly persuade consumers of a product’s “sustainability” at first glance.

As producers of solutions for the recovery and valorization of plastic waste (and more), we firmly believe that clear, accurate information on these issues can bring tremendous value to the market, promoting truly sustainable products that are both environmentally friendly and economically beneficial for industries.

And we are not alone in this belief: many individuals, entrepreneurs, students, and professionals share this vision and have collectively laid the foundation for the Green Economy.

The Green Economy

Awareness of the need to develop a different kind of economy began to emerge around 2006, following the release of the Stern Review, named after its author. Commissioned by the UK government, this report was the first to highlight the economic consequences of climate change, as well as the social impact of environmental risks. Among the key issues it raised was the overconsumption of the planet’s resources, an annual rate of use that exceeds Earth’s ability to regenerate them.

It was at this point that the concept of the Green Economy was born: a new vision of the economy that takes these aspects into account and places them at the center of its model.

On a global scale, the Green Economy is seen as a dynamic process of economic transformation aimed at low-carbon development, greater efficiency in resource use, and improved overall well-being. This is achieved through the adoption of technologies and innovations that create new jobs while also reducing long-term environmental risks.

Many companies, from major international brands to small innovative businesses, are adopting circular and sustainable production processes aimed at reducing waste and losses, transforming waste into valuable resources, and ensuring worker well-being by providing the right tools and conditions.

Businesses and Green Economy

Patagonia

Leading brands like Patagonia, the U.S. based company known worldwide for outdoor clothing and equipment, are undeniable examples of commitment to environmental sustainability and responsible production practices:

Image source: https://brandthechange.org/

Carbon neutrality goal: the company has set the goal of achieving carbon neutrality by 2025, implementing measures to reduce greenhouse gas emissions throughout the entire supply chain.

Environmental donations: since 1985, Patagonia has donated 1% of its annual revenue to environmental protection projects, contributing over 89 million dollars to organizations and initiatives dedicated to protecting the planet.

Recycling and repair initiatives: through its “Worn Wear” program, Patagonia promotes the repair and recycling of its garments, encouraging customers to extend product lifespan and reduce waste.

Fair Trade certification: a significant portion of Patagonia’s clothing is produced in Fair Trade certified factories, ensuring fair and safe working conditions for workers in the supply chain.

Environmental responsibility programs: the company has implemented programs to ensure environmental sustainability and animal welfare in the production of its materials and products.

Eco-friendly materials: Patagonia uses recycled and organic materials in its products, reducing environmental impact and promoting the responsible use of resources.

Fairphone

While Patagonia is a prominent and well-established example in the clothing sector, there are also younger companies in other industries born from the momentum of the Green Economy, aiming to produce circular and sustainable consumer goods.

Let’s consider the electronics industry, where smartphones become obsolete in just a year, fueling a fast-paced and unsustainable consumption model. Yet in Europe, one company is revolutionizing this dynamic and challenging the “disposable” concept: Fairphone.

Image Source: https://www.youtube.com/@Fairphone

Fairphone is a Dutch company founded in 2013, with the mission of addressing the social and environmental challenges of the electronics industry by producing ethical and sustainable smartphones.

Ecco i suoi punti cardine:

Use of recycled and fair-trade materials: the company uses recycled and Fairtrade-certified materials in its smartphones, promoting fair and sustainable trade practices.

Modular design and repairability: Fairphone devices are designed to be easily repairable, allowing users to replace components such as the battery, screen, and camera easily. For example, replacing the battery costs about €40, while a screen replacement is around €100.

Supply chain transparency: Fairphone is committed to ensuring that the materials used in its devices come from responsible sources, avoiding conflict minerals.

Rifò Lab

Rifò Lab is an Italian sustainable fashion brand founded in 2017. The idea arises during an experience in Vietnam with the United Nations, where the company’s founder witnessed the negative impact of overproduction in the clothing industry, with mountains of unsold garments destined for incineration.

This scenario inspired the creation of a more responsible and sustainable alternative in the textile sector.

Image source: https://www.bcorporation.net/

Rifò Lab is a shining example of how innovation can blend with artisanal tradition to create ethical, sustainable fashion, respectful of both people and the planet. A truly circular approach.

Circular economy: Rifò is committed to transforming old garments into new high-quality pieces, reducing waste and promoting resource reuse.

Local production: all products are made within a 30 km radius of the company’s headquarters in Prato, supporting local artisanship and minimizing the environmental impact of transportation.

Use of regenerated materials: Rifò uses regenerated fibers such as recycled cashmere, cotton, and wool, reducing the consumption of natural resources and chemical use.

Reduced water consumption:the production process requires significantly less water than traditional textile manufacturing.

Transparency and social responsability: the company regularly publishes sustainability reports, highlighting the environmental and social impact of its activities.

Overproduction prevention:through a pre-order system, Rifò only produces what has been ordered, avoiding surplus and waste.

Green Economy and Jobs

The drive to adopt sustainable processes in companies is increasingly evident across multiple levels and in many different sectors. However, integrating the circular economy into a business requires the development of an innovative and collaborative approach to the market.

There are many strategies that can be implemented, from sustainable design to waste valorization. Below are some ideas that can be applied to the production process:

Sustainability Manager: responsible for overseeing strategic aspects such as corporate communication, marketing activities, improvements in energy efficiency, environmental protection, and the integration of corporate social responsibility into company policies.

Ecological Transition Manager: develops environmental strategies, promotes initiatives to reduce energy and water consumption, seeks solutions to lower waste production and enhance its recovery, and ensures the use of both primary and secondary raw materials within a circular economy framework.

Environmental Engineer: a highly specialized professional who deals with various aspects of planning and urban development related to environmental sustainability.

Technical Waste Management Officer: implements targeted initiatives to ensure the effective organization of company waste management and monitors compliance with current regulations.

But it’s not only the world of work that is undergoing a transformation, higher education and specialized training are evolving as well. It’s no coincidence that younger generations are the most engaged with these issues and the most eager to take action to drive change.

The Benefits of the Circular Economy in Waste Recycling

Looking at the green choices made by many well-known brands, one might assume that the circular economy is already a well-established reality in the industrial sector. In truth, the path toward a truly circular model is still long and full of challenges. However, the benefits that this transformation can bring, from resource optimization to waste reduction, are immense and increasingly recognized.

Waste Reduction

From “disposable” to recycling, reconversion and reuse. By implementing sustainability- and circularity-oriented corporate policies, it is possible to reduce the volume of waste produced and give it new value by transforming it into useful resources. Let’s not forget that 2.3 billion tons of urban waste are currently produced globally every year, and 1 billion tons of food are wasted worldwide annually.

Pollution reduction and responsible resource use

As waste decreases, so does environmental pollution. Consider the conversion of waste into energy (e.g., biogas) or the use of waste to create new products, helping to prevent dispersion into the environment or accumulation in landfills.

Conservation of natural resources

Every year, humanity consumes the planet’s natural resources at an unsustainable pace, depleting in just a few months what Earth can regenerate in an entire year. In 2024, Earth Overshoot Day, the date on which we exceed our annual ecological budget, fell on August 8, once again confirming the urgent need for a radical shift in our consumption and production models.

Adopting the Circular Economy is one of the most effective responses to this crisis, as it helps reduce dependency on virgin resources and limits waste through reuse, recycling, and resource recovery.

By implementing sustainable business strategies such as designing long-lasting products, reducing production waste, and using secondary raw materials (recycled, recovered, and regenerated), companies can not only mitigate environmental impact but also build a more resilient and competitive economic system.

Business and Economic Benefits

Recent research shows that younger generations, particularly Gen Z and Millennials, are the most sensitive to environmental issues and deeply engaged with sustainability. Integrating a circular economy model into a business plan is not only a responsible choice, it also represents a competitive advantage: it brings this segment of the population closer to the brand, both as conscious consumers and as potential talents interested in working for the company.

According to several market surveys conducted in Italy, including one by Fondazione Sodalitas, most citizens expect companies, especially large ones, to show a real commitment to sustainable waste management, emission reduction, and the use of renewable energy. Implementing these strategies not only strengthens brand credibility but can also translate into increased sales and consumer confidence.

Beyond environmental and reputational advantages, there are also tangible economic and energy-saving benefits tied to the valorization of industrial waste. Recurring costs for transporting and disposing of waste in landfills could instead be replaced by investments in recovery and reuse technologies, leading to mid-term payback and significant cost savings. In this context, sustainability is not just an ethical choice, but a smart and forward-thinking growth strategy.

Employment Opportunities

One fundamental, and often underestimated, aspect is the enormous job creation potential of the sustainability sector. The circular economy not only protects the environment but also generates new employment opportunities throughout the entire value chain. From the emergence of innovative startups focused on eco-friendly solutions, to the growth of companies specializing in advanced recycling and resource reuse, to the expansion of treatment and recovery facility networks, the sector is constantly evolving.

This transformation creates jobs not only in technology and engineering, through the development of sustainable materials and low-impact production processes, but also in logistics, waste management, and manufacturing, thanks to new recovery and regeneration methods for raw materials.

In addition, the growing interest from institutions and investors in sustainable business models is encouraging the development of new professional roles capable of guiding the green transition and supporting companies in achieving their ESG (Environmental, Social, and Governance) goals.

Recycling Success Stories: Examples of Circular Economy

More and more companies are choosing recycling and waste recovery solutions, not only to reduce their environmental impact, but also to optimize internal processes, cut disposal costs, and turn waste into added value.

In this section, we will explore a few case histories of companies that have adopted our recycling systems, embracing a circular and improvement-driven approach to boost efficiency and sustainability.

Caffè Borbone

Companies operating in the Food & Beverage sector are becoming increasingly attentive to production waste management, just like the Caffè Borbone brand, which has relied on Tecnofer to enhance its packaged waste and strengthen its sustainability policies.

Tecnofer developed a customized depackaging project for the client, aimed at separating the ground coffee contained in defective packaging waste. Our proprietary Depackaging technology is in fact one of the most widely adopted solutions in the industry for sustainable waste management.

This type of waste is particularly complex, as it includes both product and packaging: components that, when efficiently treated, can be recovered separately. For example, the internal product can contribute to green energy production, while the packaging can be recycled into new materials. In the case of Caffè Borbone, the solution was developed to manage two types of waste:

Rigid plastic coffee machine capsules

Filter paper coffee pods

By treating packaged waste in-house, in a dedicated area, the company has been able to reap several benefits, including a gradual reduction in waste management costs related to landfill disposal. Moreover, thanks to the separation of ground coffee from its packaging, the waste could be redirected through a circular process.

Recupac

In addition to companies that produce consumer food goods, many waste collection and management firms also rely on Tecnofer solutions, such as Recupac Chile.

The company has been operating in the waste management and recovery sector since 1989, providing waste collection and treatment services. Recupac runs four recycling facilities located in different areas of the country and continually invests in process improvement with a circular economy approach.

By adopting Tecnofer’s Depackaging technology, the company aimed at further optimizing its waste recovery processes, reducing the percentage of unrecoverable waste and cutting disposal-related costs.

So, what has been developed for the Chilean client? A tailor-made depackaging system designed for the recovery of food waste, with the additional goal of brand protection. The project was developed based on an analysis of the following products:

Liquid or viscous food products packaged in plastic, aluminum, or Tetra Pak containers (such as bottles, cans, trays, etc.).

Although recently developed (2024), the results are already visible: reduced disposal costs, recovery of separated materials through recycling, and improved brand reputation.

Reno de Medici – RDM Group

Recycling, as we know, is not just about plastic. Paper has long been one of the most widely used and historically recycled packaging materials, especially in Italy. In recent years, however, the use of paper-based packaging has surged due to policies aimed at reducing plastic in packaging and single-use products, leading to even higher production volumes of paper and cardboard.

To enable more effective and zero-waste recycling, Tecnofer has developed specific solutions for the paper industry: pulper rejects treatment systems.

In the recycled paper production process, paper and cardboard packaging is pulped and separated from contaminants (such as plastic packaging residues, aluminum, labels, etc.). These contaminants form a mix of materials known as pulper rejects, which is typically sent to landfill. However, this waste still contains a significant amount of paper fiber, sometimes in considerable quantities, which can be recovered and reintroduced into the recycled paper production cycle.

RDM Group, a leading player in the production and recycling of paper, has relied on Tecnofer’s technology to create value from this type of waste. Thanks to a custom-configured Tecnofer treatment system, the goals set at the beginning of the project were successfully achieved.

98% of paper fiber recovered

Plastic material output with a dry content between 80% and 90% (the other major component into pulper waste)

Up to 30% reduction in waste management costs

In conclusion

It is crystal clear that the business world is paying more and more attention to green issues, recycling, and waste recovery. However, the path toward a truly sustainable model is still long and full of challenges.

Technological innovation, targeted investments, and growing collective awareness are laying the groundwork for a future in which the circular economy will no longer be an option, but a necessity.

Only through a genuine commitment from companies, institutions, and citizens will it be possible to transform waste into resources, reduce environmental impact, and build a production system capable of regenerating itself.

The circular economy is not only a solution for the present, it is a winning model for the future: more efficient, more equitable, and above all, more sustainable.