Marley NZ, part of the global Aliaxis business, supplies plastic piping systems made from uPVC and high-density polyethylene (HDPE) for use in building, infrastructure and agriculture industries. Marley was looking for ways to recycle its materials to keep them in use and reduce the need for virgin uPVC and HDPE resources. The company realised that a circular solution to its problem could change the face of industrial recycling in Aotearoa New Zealand and support a transition to a low carbon circular economy.
While there was demand for a uPVC recycling system Marley had to ensure it could collect, transport and sort the materials to make it viable.
The solution
Firstly, Marley worked with Waste Management New Zealand to trial the collection and sorting of uPVC and HDPE at a couple of store locations. The trial helped form the working relationship between the two businesses. With support from Auckland Council’s Waste Minimisation Innovation Fund they were able to further pilot and test the system.
The pilot proved a success with 10 tonnes of uPVC recycled a month. The two organisations started a joint venture to invest $12 million in purpose-designed recycling centres to handle much larger volumes in both the North Island (Te Ika a Maui) and South Island (Te Wai Pounamu). They gained a $4.46 million grant from the Ministry for the Environment’s Plastics Innovation Fund. At this point they were joined by Unitec Te Pukenga’s Environmental Solutions Research Centre.
The first plant is expected to be running before the middle of 2024 and will be able to process at least 100 tonnes of uPVC a month, along with HDPE and PP products. As well as Marley products, the plant will recycle suitable uPVC, and HDPE from other businesses. This will help create a circular system for uPVC with the recycled material being used to make new pipes in in Aotearoa New Zealand
Benefits
Although this project is still in progress, there have been plenty of learnings already. Collaboration with others, particularly those with different backgrounds, skill sets and roles, has been an essential part of the success of the initiative. Starting with a small pilot project to test the approach and establishing strong links between the partners has led to effective processes that have had significant impact on systemic challenges. Each business has a role to play; whether it’s a conversation with a supplier to source a less energy-intensive material, or joining an industry group to collaborate on solutions or lobby for change.
“While the project itself has been a massive success, the real achievement here is the collaboration,” says Dwayne Carroll, Recycling Project Lead at Marley NZ.
“The problem of uPVC waste is a big one but if you get everyone working together then systemic problems like this can be solved. That’s exactly what we’re doing, and is the reason why we’re able to solve such a big challenge.”
This project begins a new era of recycled uPVC in New Zealand. New pipes will be made from recycled material and then used for another 100 years, before the process simply repeats. This will help close the loop and keep valuable materials in circulation. There are still some crucial issues to solve. Accessibility to drop off and collection points still remains a challenge, raising the need for an effective returns system to be established for this and similar projects. Get in touch with Waste Management NZ if you can help or have clean uPVC offcuts to be recycled.
Business/organisation name: Marley
Project: uPVC recycling initiative
Owner: Aliaxis
Collaborators: Waste Management New Zealand (WMNZ)
Date of completion: 2020 - Ongoing
