The Complete Paper & Cardboard Recycling Process: How It Works and Why It Matters

Paper and cardboard are ubiquitous materials that play a significant role in virtually every industry. From packaging and shipping to printing and advertising, paper and cardboard have long been indispensable to the modern world. Yet, they are often considered disposable, leading to large-scale waste and environmental challenges. As concerns over deforestation and resource depletion continue to grow, recycling these materials has become a vital component of sustainability efforts worldwide.

Thankfully, both paper and cardboard have been the focus of recycling campaigns for decades. As recycling processes improve, a growing number of products are manufactured from recycled materials. But how effective is the paper and cardboard recycling process, and how does it work? This article takes a deep dive into the entire recycling process, from collection to production, and examines both its strengths and limitations.

How Effective is the Paper and Cardboard Recycling Process?

According to the Environmental Protection Agency (EPA), 67.4 million tons of paper and paperboard were part of the municipal solid waste (MSW) in the United States in 2018. This accounted for 23.1% of the total MSW that year, demonstrating the prominence of paper and cardboard in waste production. However, 68.2% of that paper and paperboard was recycled, amounting to 46 million tons—the highest recycling rate of any material in MSW.

While these figures are encouraging, the recycling rate varies depending on the type of paper product. Not all paper and cardboard make it into the recycling process, and various challenges prevent certain products from being recycled.

Limitations of the Cardboard and Paper Recycling Process

The paper and cardboard recycling process is highly effective, but it has some inherent limitations that hinder its overall efficiency. These limitations include the degradation of paper fibers through multiple recycling cycles, contamination, and the difficulty of recycling certain multi-material products.

1. Fiber Degradation

One of the primary limitations is that paper fibers degrade each time they are recycled. Each time paper is processed, the fibers become shorter and weaker, which limits the number of times they can be reused. Paper and cardboard can typically be recycled four to six times before the fibers are too short to be useful in creating new paper products.

In comparison, materials like plastic can be processed seven to nine times, while aluminum and glass can be recycled indefinitely without any loss in quality. This means that while paper recycling is beneficial, it has a shorter lifespan compared to other recyclable materials.

2. Contamination by Soiled Items

Soiled paper products cannot be recycled and must be kept separate from other recyclable items. Soiled paper refers to paper that has been contaminated with substances such as food or oil. Items like pizza boxes lined with grease, used napkins, and paper plates fall into this category. If these items end up in the recycling stream, they can contaminate the entire batch of paper slurry, rendering otherwise recyclable paper unusable.

3. Challenges with Coated Paper

Paper that is coated with materials like plastic, wax, or foil is generally not recyclable. This includes products like juice cartons or some food packaging. However, recent advancements in recycling technology have made it possible for certain facilities to process some coated papers. It’s important to check with local recycling providers to determine whether coated papers can be included in the recycling stream.

Types and Grades of Paper and Cardboard

The quality and type of paper or cardboard used in recycling affect how it is processed and what it can become. The EPAoutlines four basic categories of paper and cardboard in the recycling process, each with specific uses and recycling potential:

1. Old Corrugated Containers (OCC)

Often referred to as corrugated cardboard, this is the material used for most shipping boxes. As online shopping and delivery services increase, OCC has become one of the most commonly recycled paper products. It is often processed into new corrugated cardboard or paperboard, which is used in products like cereal boxes or shoe boxes.

2. Mixed Paper

This broad category includes a wide variety of paper products, from magazines and catalogs to junk mail and paperboard. Shredded paper also typically falls into this category. Mixed paper is commonly recycled into paperboard, tissue, and other low-grade paper products. Additionally, recycled mixed paper can be used in the production of non-paper products, such as drywall, insulation, and roofing felt.

3. Old Newspapers (ONP)

As the name suggests, this category consists primarily of newsprint. ONP is most often recycled into new newsprint, but it can also be used to create paperboard and tissue.

4. High-Grade De-inked Paper

This category covers office paper, envelopes, and other high-quality paper products. Before being recycled, the paper must be de-inked to remove any ink or markings. High-grade de-inked paper is typically repurposed into new high-grade paper products, such as printer paper or writing paper.

The Step-by-Step Process of Paper and Cardboard Recycling

The paper and cardboard recycling process follows a clear set of steps, beginning with collection and ending with the creation of new products. Here’s a breakdown of each stage:

1. Collection

The process begins with the collection of paper and cardboard from households, businesses, and recycling centers. Paper and cardboard are often included in curbside collection programs, making them some of the most accessible materials to recycle. For businesses that generate large quantities of paper waste, private recycling services may be needed.

In certain industries, such as healthcare or finance, where sensitive information is handled, recycling services may offer confidential shredding in conjunction with recycling to ensure privacy and compliance with regulations.

2. Separation by Type and Grade

Once collected, paper and cardboard are sorted based on their type and grade. This separation is crucial to maintaining the quality of the recycled paper. For example, high-grade office paper is separated from lower-grade items like newsprint or cardboard, as combining these materials could result in contamination or degraded quality.

3. Cleaning and Filtering

The next step involves chopping and breaking down the paper into smaller pieces, after which it is mixed with water to create a paper slurry. This slurry is then heated and passed through filters to remove contaminants such as plastic, staples, and other debris. Special chemicals are also used to remove ink from the paper.

4. Processing the Slurry

The cleaned slurry is further processed to create a mixture of fibers suspended in water. At this point, colorants, thickeners, and other additives may be introduced, depending on the intended end product. The slurry is now ready to be transformed into new paper products.

5. Draining and Flattening

The slurry is spread or sprayed onto mesh screens to allow the water to drain and form a thin layer of fibrous pulp. At this stage, the pulp may be mixed with virgin wood fibers to reinforce its strength. The ratio of recycled to virgin fibers depends on the type of paper product being made and the manufacturer’s specifications.

6. Formation of New Paper

The layer of fibrous pulp is passed through a series of rollers, which flatten it and remove additional water. The material is then fed through heated rollers to dry it completely. Once dry, the continuous sheet of paper is rolled up and cut into smaller sections, ready for transportation and processing into final products.

The EPA’s Comprehensive Procurement Guidelines for Recycled Paper and Paper Products

To promote sustainability and support recycling efforts, the EPA has established the Comprehensive Procurement Guideline (CPG) Program, which outlines recommendations for the use of recovered fibers in various paper products. These guidelines help businesses and government agencies make environmentally responsible purchasing decisions.

The CPG Program divides paper and cardboard products into several categories, including:

• Printing and Writing Papers: Includes items like office paper and stationery, which are recommended to contain a minimum of 30% post-consumer fiber.
• Newsprint: EPA recommendations suggest that newsprint contains 20% to 85% post-consumer fiber, depending on the type and source.
• Commercial Sanitary Tissue: Products like paper towels and napkins are recommended to contain between 40% and 60% post-consumer fiber.
• Paperboard and Packaging: Products such as corrugated containers (used for shipping boxes) are recommended to contain 40% to 80% post-consumer fiber.
• Miscellaneous Paper Products: This category includes products like tray liners, which should contain 50% to 75% post-consumer fiber.

Turning the Page on Paper Waste

While paper and cardboard are biodegradable, the environmental costs of using virgin paper are significant. By recycling, we can help alleviate the strain on forests, reduce energy consumption, and minimize the amount of waste sent to landfills or incineration.

Sustainable waste management begins with reducing and reusing products before sending them for recycling. This approach helps keep materials in circulation for as long as possible, maximizing their value and minimizing environmental impact. The paper and cardboard recycling process is essential to this effort, allowing us to reduce waste while maintaining a steady supply of recycled materials for new products.

As recycling processes continue to improve, and as more individuals and businesses embrace the importance of recycling, we can make meaningful strides toward a more sustainable future. So, the next time you toss a piece of paper or cardboard into the recycling bin, remember that you’re making a significant contribution to protecting the environment. Each piece of paper or cardboard that goes into the recycling bin helps reduce the need for virgin materials, conserves energy, and decreases the demand on natural resources. Recycling isn’t just about managing waste—it’s about creating a sustainable loop where valuable materials are reused and repurposed, lessening the impact on our planet.

By choosing to recycle, you’re playing a crucial role in the following areas:

1. Conserving Forests

Virgin paper production relies heavily on logging, which contributes to deforestation, habitat loss, and increased carbon emissions. Recycling paper helps mitigate these impacts by reducing the number of trees cut down each year. For instance, recycling one ton of paper saves approximately 17 trees, and considering how much paper is consumed globally, the collective impact can be enormous. Recycling directly helps preserve forests, which act as critical carbon sinks and are home to diverse ecosystems.

2. Reducing Energy Consumption

The production of recycled paper uses 40% less energy than producing paper from virgin wood pulp. This energy savings is significant, as the paper industry is one of the most energy-intensive sectors. By recycling paper, we can reduce the demand for fossil fuels and lower greenhouse gas emissions, contributing to the global fight against climate change. Additionally, less energy is needed to transport recycled materials compared to harvesting and processing virgin resources.

3. Minimizing Landfill Waste

Paper and cardboard account for a large portion of the waste generated in both households and businesses. When these materials end up in landfills, they take up valuable space and contribute to methane emissions as they decompose. Methane is a potent greenhouse gas, and landfills are one of its primary sources. Recycling paper and cardboard diverts these materials from landfills, reducing methane emissions and helping to manage waste more effectively.

4. Lowering Water Usage

The paper production process is water-intensive, particularly when using virgin fibers. Recycling paper uses less water, which is increasingly important as water scarcity becomes a concern in many parts of the world. By recycling, we can help reduce the overall water footprint of paper production and protect this vital resource.

5. Promoting a Circular Economy

Recycling paper and cardboard is a key part of the circular economy, a system designed to eliminate waste by continually using resources. In a circular economy, products are designed to be recycled, reused, and repurposed, creating a closed-loop system that minimizes waste and maximizes resource efficiency. By participating in the recycling process, we support the development of sustainable practices that can be applied across industries.

How Can You Contribute to Paper Waste Reduction?

While recycling is an essential part of the solution, it’s also important to reduce and reuse paper and cardboard products wherever possible. Here are a few ways you can help:

• Reduce Paper Usage: Shift to digital alternatives where feasible. For instance, opt for electronic documents, emails, and e-books instead of printed versions. At home or in the office, print only when necessary and use double-sided printing to minimize paper use.
• Reuse Before Recycling: Reuse cardboard boxes for storage or shipping, and repurpose paper products for scrap notes or craft projects before recycling them. Every time you reuse an item, you extend its life cycle and reduce the need for new materials.
• Buy Recycled Products: Support the demand for recycled materials by purchasing paper products made from recycled fibers. This helps close the loop and ensures that recycling efforts translate into a tangible reduction in resource extraction.
• Properly Sort Your Recycling: Ensure that paper and cardboard are free of contaminants like food or grease before placing them in the recycling bin. Sort items according to local recycling guidelines to prevent contamination of the recycling stream.

The Future of Paper Recycling

As technology continues to improve, so will the efficiency and effectiveness of the paper recycling process. Innovations such as better de-inking techniques, more advanced sorting methods, and greater processing capabilities are making it easier to recycle a broader range of paper products. Additionally, more companies are recognizing the value of recycled paper products and incorporating them into their supply chains, driving greater demand for sustainable materials.

The move towards zero-waste initiatives and increased awareness of environmental sustainability is pushing both individuals and corporations to rethink how they use and dispose of paper. With the right systems in place, it’s possible to drastically reduce paper waste and make recycling even more effective.

Final Thoughts: Recycling for a Sustainable Future

Recycling paper and cardboard is one of the simplest, yet most impactful actions we can take to protect our environment. It reduces the strain on natural resources, lowers energy consumption, and helps to manage waste sustainably. As consumers, our daily choices around paper usage and recycling have the power to create positive change.

The next time you’re holding a piece of paper or a cardboard box, remember that by recycling it, you’re contributing to a larger movement toward a sustainable future. Each small action adds up, and together, we can make a significant difference in conserving our planet’s precious resources.

So, whether at home, in the office, or out in your community, make recycling a habit and encourage others to do the same. By turning the page on paper waste, we can help create a greener, more sustainable world for future generations.

Contact Us

Whether you need packaging solutions, kraft paper, or waste paper management services, Stack Enterprises is here to help. Our team of experts is ready to assist you in finding the perfect packaging solution for your business.

For more information, inquiries, or to place an order, contact us directly:

Tamilarsan M

• Email: stackenterprises2022@gmail.com
• Phone: +91 9751637945

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