Recycling Solution for Cardboard Fibre Pulping Glass & Grit Rejects

Client:

Large Australian cardboard manufacturer

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Waste Type:

Glass/sand grit screening fines

Client Overview

A leading cardboard fibre pulping manufacturer partnered with Circular Futures to address the growing environmental and financial burden of glass and grit screening rejects.
 With no onshore recycling solution available, the waste was sent to landfill, resulting in high disposal costs and a significant carbon footprint.

Challenge: Diverting Glass & Grit Waste from Landfill

The client’s manufacturing screening rejects—a mixture of glass, grit, organics, and metal—could not be processed through conventional recycling systems.
 The lack of domestic recycling infrastructure in Australia meant that valuable materials were being lost to landfill, increasing operational costs and environmental impact.
Circular Futures was engaged to develop a sustainable waste diversion and recycling strategy, turning the waste into usable construction materials and creating a viable circular economy solution.

Approach: Analysis, Collaboration, and Business Case Development

Our waste management consultants conducted a detailed material analysis to determine composition and moisture content, assessing the suitability of the waste for reuse as aggregate in road base or cement block production.
Circular Futures then worked with technology partners and existing facilities to identify the most efficient and cost-effective methods for mechanically sorting and washing the material to meet infrastructure and building specifications.
Finally, we developed a commercial model and business case to help the client invest in a dedicated processing plant through a joint venture (JV) partnership, enabling long-term operational and financial sustainability.

Outcome: Onshore Recycling Pathway Established

Circular Futures successfully identified and secured a manufacturing partner and market for the recycled product.
 A wash plant was developed to separate organics and metals, producing clean grit material suitable for use as non-structural concrete aggregate substitutes in cement blocks and construction products.
This solution enabled the client to close the loop—recovering materials that were previously wasted and converting them into low-carbon, value-added construction materials.

Impacts & Benefits

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100% landfill diversion achieved through onshore recycling

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Significant cost savings from reduced waste disposal and material recovery

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Lower carbon footprint through reuse in construction products

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New market opportunities for circular manufacturing partnerships

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Sustainable, circular economy solution supporting Australian infrastructure

Driving Innovation in Waste-to-Resource Solutions

This project highlights Circular Futures’ expertise in waste management consulting, recycling technology partnerships, and circular economy strategy.
 By combining technical analysis, industry collaboration, and commercial modelling, we deliver innovative recycling pathways that reduce environmental impact and create sustainable value for Australian industries.