A partnership between the Carton Council, Elof Hansson USA Inc. and the Upcycling Group will bring a new recycling manufacturing facility to Lodi, California, by the end of Q3. Designed to transform post-consumer food and beverage cartons into durable, sustainable building materials, the facility will support regional recycling efforts and help meet the growing demand for sustainable construction materials.
The manufacturing method involves shredding used gable top and aseptic cartons and bonding them into large, durable sheets. The high-pressure and heat treatment process eliminates the need for water, formaldehyde glues and hazardous chemicals, and relies entirely on cartons and other materials collected for recycling.
“The carbon footprint of our boards is at least 80 percent lower than the traditional building materials that we replace,” said Jan Rayman, co-founder and chief executive officer of the Upcycling Group. “No mining, no tree cutting, and no water used or contaminated, creating a variety of boards that can be used for roofing, wallboard and other building materials, all produced more sustainably than their traditional counterparts.”
“We believe this facility will play a crucial role in supporting California’s efforts to expand recycling by providing a new, regional end market,” said Jason Pelz, vice president of recycling for the Carton Council. “By using collected, sorted and baled cartons from California and bordering states, we are not only making recycling more efficient for West Coast communities but also ensuring these materials stay in use and out of landfills.”
Once fully operational, the facility is expected to recycle approximately 750 tons (1,500,000 pounds) of food and beverage cartons each month and employ an estimated 15 people. The facility will source cartons from California and other parts of the West Coast.
Published February 2025
