Within Sustainability
Why Recycled Bottles Did Not Become Bricks
LEGO's recycled bottle trial showed why a greener-looking material can raise emissions once additives, drying, and factory changes are counted.
On this page
- What LEGO hoped recycled PET would solve
- Why the material failed the brick test
- What the failed trial changed in LEGO's strategy
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Introduction
In its long‑term drive to cut carbon emissions and eventually make all bricks from “sustainable materials”, the LEGO Group explored many possible substitutes for the oil‑derived acrylonitrile butadiene styrene (ABS) that has formed the vast majority of its iconic bricks. One of the most visible and widely reported experiments was an attempt to make bricks from recycled polyethylene terephthalate (rPET) derived from used plastic bottles. After years of development and testing, LEGO ultimately abandoned the recycled‑bottle brick project because the material failed to deliver the environmental and performance benefits the company was seeking. The PET variant not only posed serious production challenges but, crucially, would have produced more carbon emissions once processing, additives and factory changes were factored in. This case reveals the tight coupling between material properties, manufacturing practicality and life‑cycle emissions in LEGO’s sustainability journey. [Packaging World]packworld.comPackaging World Recycled Bottles Not the Answer for LEGO | Packaging WorldPackaging WorldRecycled Bottles Not the Answer for LEGO | Packaging WorldOctober 5, 2023…
What LEGO hoped recycled PET would solve
When first announced in 2021, LEGO’s rPET project was pitched as a tangible step toward replacing petroleum‑based plastics with something that — in principle — had a much lower environmental footprint. Polyethylene terephthalate is the polymer used for many beverage bottles; it is widely collected for recycling and, unlike some plastics, can be recycled repeatedly without catastrophic loss of mechanical quality. LEGO even demonstrated prototype bricks made from recycled PET sourced from bottles, and claimed that one litre of PET bottle material could yield about ten 2×4 bricks. [Thomasnet]thomasnet.comLego Abandons Recycled Bottles ExperimentThomasnetLego Abandons Recycled Bottles ExperimentSeptember 29, 2023…
The objective was straightforward: if bricks could be made from rPET instead of ABS, LEGO could cut a significant slice of the life‑cycle carbon emissions associated with raw material production. This goal aligned with the company’s public sustainability targets — including a commitment to shift entirely to “sustainable materials” for its products by 2032 — and responded to rising pressure from consumers, regulators and investors for more climate‑friendly plastics. [Packaging World]packworld.comPackaging World Recycled Bottles Not the Answer for LEGO | Packaging WorldPackaging WorldRecycled Bottles Not the Answer for LEGO | Packaging WorldOctober 5, 2023…
Why the PET material failed the brick test
Despite the initial promise, a detailed evaluation over more than two years of research and development revealed that using recycled PET created worse environmental outcomes once the full production picture was considered:
- Carbon and energy costs of processing: Recycled PET required extensive processing, including additional additives and modifiers to approximate the rigidity and durability of ABS. Those extra steps — heating, drying and modifying the polymer — consumed significant energy. According to company statements, the result was that the total carbon footprint of PET bricks would have been higher than for the current ABS bricks once these factors were included. [Packaging World]packworld.comPackaging World Recycled Bottles Not the Answer for LEGO | Packaging WorldPackaging WorldRecycled Bottles Not the Answer for LEGO | Packaging WorldOctober 5, 2023…
- Material performance shortfalls: PET is inherently softer and less stiff than ABS. LEGO’s bricks must meet tough performance criteria: they need precise dimensions, long‑lasting mechanical strength and the characteristic “clutch power” that lets pieces click together reliably and separate cleanly — attributes that recycled PET struggled to match without modification. [Packaging World]packworld.comPackaging World Recycled Bottles Not the Answer for LEGO | Packaging WorldPackaging WorldRecycled Bottles Not the Answer for LEGO | Packaging WorldOctober 5, 2023…
- Manufacturing disruption: Scaling PET for mass production would not have been plug‑and‑play. According to LEGO’s sustainability lead, scaling up recycled PET would have required major changes to existing factories and production processes, adding complexity and likely additional emissions through equipment changes and process retooling. [Packaging World]packworld.comPackaging World Recycled Bottles Not the Answer for LEGO | Packaging WorldPackaging WorldRecycled Bottles Not the Answer for LEGO | Packaging WorldOctober 5, 2023…
- Energy intensity of drying: PET is hygroscopic — it absorbs moisture from the air. To achieve the dimensional precision LEGO requires, the material had to be dried extensively before moulding, adding to energy use. Combined with additives to boost strength, this undercut the assumed environmental advantage of the recycled feedstock. [Canplastics]canplastics.comLego Abandons Plan To Make Bricks From Recycled PETCanplasticsLego Abandons Plan To Make Bricks From Recycled PET - Canadian PlasticsSeptember 25, 2023…
Taken together, these factors meant that rPET, though technically a recycled input, simply didn’t deliver on the core sustainability objective: lower life‑cycle greenhouse gas emissions for the bricks themselves. In other words, a greener‑looking raw material turned out to be greener only on the surface unless every stage of production yields genuine emission savings. [Packaging World]packworld.comPackaging World Recycled Bottles Not the Answer for LEGO | Packaging WorldPackaging WorldRecycled Bottles Not the Answer for LEGO | Packaging WorldOctober 5, 2023…
What the failed trial changed in LEGO’s strategy
LEGO’s rPET experiment did not stop the company’s broader sustainability research; rather, it recalibrated expectations and focus:
- Continued material exploration: After shelving PET bricks, LEGO said it would intensify research into alternative sustainable polymers, including other recycled plastics and novel feedstocks such as those derived from e‑methanol — a synthetic carbon‑neutral feedstock produced from waste CO₂ and hydrogen using renewable energy. [Business Standard]business-standard.comBusiness StandardLego looks toward sustainable materials despite failed recycle attempt | Company News - Business StandardSeptember 25, 2023…
- Incremental improvements to ABS: Rather than entirely replacing ABS immediately, LEGO shifted some strategic emphasis toward making ABS itself more sustainable, for example by blending in more bio‑based and recycled content where feasible. [Plastics Engineering]plasticsengineering.orgPlastics EngineeringLego Drops Plan to Make Its Bricks From Recycled PET BottlesSeptember 25, 2023…
- Targeted use of bio‑plastics: Materials like bio‑polypropylene are already used in non‑structural parts (such as leaves and plant elements) where the demands on material properties are lower, indicating a phased approach rather than an abrupt switch across all bricks. [Business Standard]business-standard.comBusiness StandardLego looks toward sustainable materials despite failed recycle attempt | Company News - Business StandardSeptember 25, 2023…
- Investment increase and patience: LEGO reiterated its commitment to its 2032 goals and signalled it would continue to allocate significant resources — both engineering talent and capital — to the sustainability challenge. [Packaging World]packworld.comPackaging World Recycled Bottles Not the Answer for LEGO | Packaging WorldPackaging WorldRecycled Bottles Not the Answer for LEGO | Packaging WorldOctober 5, 2023…
In the broader context of LEGO’s resilience and innovation strategy, the rPET project served as a stress test of sustainability constraints on a highly engineered product system. It exposed the limits of simple substitution when the economics and emissions of downstream processing are considered, and highlighted that not all well‑intentioned alternatives will survive a rigorous life‑cycle and performance evaluation. In this sense, the failure did not weaken LEGO’s strategic direction, but it did clarify what kinds of innovation are feasible without compromising the brand’s quality and intergeneration compatibility — core elements of the company’s antifragile plastic‑based system. [Packaging World]packworld.comPackaging World Recycled Bottles Not the Answer for LEGO | Packaging WorldPackaging WorldRecycled Bottles Not the Answer for LEGO | Packaging WorldOctober 5, 2023…
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Endnotes
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Source: thomasnet.com
Title: Lego Abandons Recycled Bottles Experiment
Link: https://www.thomasnet.com/insights/lego-abandons-recycled-bottles-experiment/Source snippet
ThomasnetLego Abandons Recycled Bottles ExperimentSeptember 29, 2023...
Published: September 29, 2023
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Source: canplastics.com
Title: Lego Abandons Plan To Make Bricks From Recycled PET
Link: https://www.canplastics.com/sustainability/lego-abandons-effort-to-make-bricks-from-recycled-pet/1003462027/Source snippet
CanplasticsLego Abandons Plan To Make Bricks From Recycled PET - Canadian PlasticsSeptember 25, 2023...
Published: September 25, 2023
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Source: business-standard.com
Link: https://www.business-standard.com/companies/news/lego-looks-toward-sustainable-materials-despite-failed-recycle-attempt-123092500603_1.htmlSource snippet
Business StandardLego looks toward sustainable materials despite failed recycle attempt | Company News - Business StandardSeptember 25, 2023...
Published: September 25, 2023
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Source: engineering.com
Title: LEG O Abandons Recycled Plastic Project
Link: https://www.engineering.com/lego-abandons-recycled-plastic-project-why/Source snippet
Why? - Engineering.comOctober 2, 2023 — LEGO ABANDONS RECYCLED PLASTIC PROJECT. WHY? The iconic Danish toymaker is moving to carbon neutr...
Published: October 2, 2023
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Source: manufacturing.net
Title: lego will stick to its quest to find sustainable materials
Link: https://www.manufacturing.net/energy/news/22874036/lego-will-stick-to-its-quest-to-find-sustainable-materialsSource snippet
25, 2023 — LEGO WILL STICK TO ITS QUEST TO FIND SUSTAINABLE MATERIALS Even after an experiment to use recycled bottles did not work...
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Source: packworld.com
Title: [Packaging]({{ ‘packaging/’ | relative_url }}) World Recycled Bottles Not the Answer for LEGO | Packaging World
Link: https://www.packworld.com/sustainable-packaging/article/22875272/recycled-bottles-not-the-answer-for-legoSource snippet
Packaging WorldRecycled Bottles Not the Answer for LEGO | Packaging WorldOctober 5, 2023...
Published: October 5, 2023
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Source: plasticsengineering.org
Link: https://www.plasticsengineering.org/2023/09/lego_drops_plan_to_make_its_bricks_from_recycled_pet_bottles-002028/Source snippet
Plastics EngineeringLego Drops Plan to Make Its Bricks From Recycled PET BottlesSeptember 25, 2023...
Published: September 25, 2023
Additional References
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Source: standard.co.uk
Link: https://www.standard.co.uk/news/tech/lego-ditches-recycled-plastic-plans-environment-b1109535.htmlSource snippet
September 26, 2023 — LEGO DITCHES RECYCLED PLASTIC PLANS, SAYS IT IS NOT BETTER FOR THE ENVIRONMENT Lego is still pledging to reach net z...
Published: September 26, 2023
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Source: cbsnews.com
Link: https://www.cbsnews.com/news/lego-recycled-plastic-prototype-blocks-pet-didnt-reduce-carbon-emissions/Source snippet
CBS NewsSeptember 25, 2023 — LEGO DROPS PROTOTYPE BLOCKS MADE OF RECYCLED PLASTIC BOTTLES AS THEY "DIDN'T REDUCE CARBON EMISSIONS" Septem...
Published: September 25, 2023
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Source: natureworldnews.com
Link: https://www.natureworldnews.com/articles/58616/20230926/lego-bricks-recycled-plastic-bottles-scrapped-carbon-emissions-reduction-met.htmSource snippet
LEGO Bricks From Recycled Plastic Bottles Scrapped as Carbon Emissions Reduction Not Met, Company Studies AlternativesSeptember 26, 2023...
Published: September 26, 2023
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Source: cbsnews.com
Title: Lego no longer planning to make toy bricks out of recycled plastic bottles
Link: https://www.cbsnews.com/boston/news/lego-bricks-recycled-plastic-bottles-pet/Source snippet
CBS BostonSeptember 25, 2023 — LEGO NO LONGER PLANNING TO MAKE TOY BRICKS OUT OF RECYCLED PLASTIC BOTTLES By WBZ-News Staff Updated on: S...
Published: September 25, 2023
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Source: galaxus.nl
Title: No Lego made from PET bottles: Manufacturer abandons recycling project
Link: https://www.galaxus.nl/en/page/no-lego-made-from-pet-bottles-manufacturer-abandons-recycling-project-29744Source snippet
GalaxusSeptember 27, 2023 — NO LEGO MADE FROM PET BOTTLES: MANUFACTURER ABANDONS RECYCLING PROJECT Image: Lorenz Keller Lorenz Keller 27...
Published: September 27, 2023
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Source: chemeurope.com
Title: Lego discards plan to build bricks from recycled plastic bottles
Link: https://www.chemeurope.com/en/news/1181665/lego-discards-plan-to-build-bricks-from-recycled-plastic-bottles.htmlSource snippet
September 28, 2023 — LEGO DISCARDS PLAN TO BUILD BRICKS FROM RECYCLED PLASTIC BOTTLES 28-Sep-2023 Image: Computer-generated image Symbol...
Published: September 28, 2023
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Source: waste360.com
Title: lego ends plans to make bricks from recycled plastic bottles
Link: https://www.waste360.com/plastics/lego-ends-plans-to-make-bricks-from-recycled-plastic-bottlesSource snippet
September 25, 2023 — LEGO ENDS PLANS TO MAKE BRICKS FROM RECYCLED PLASTIC BOTTLES After years of testing, Lego announced that it would be...
Published: September 25, 2023
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Source: euronews.com
Title: Lego’s quest to make recycled plastic bricks has failed
Link: https://www.euronews.com/green/2023/09/25/legos-quest-to-make-recycled-plastic-bricks-has-failed-now-the-toymaker-is-turning-to-e-meSource snippet
Now the toymaker is turning to e-methanol | EuronewsSeptember 25, 2023 — LEGO’S QUEST TO MAKE RECYCLED PLASTIC BRICKS HAS FAILED. NOW THE...
Published: September 25, 2023
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Source: theguardian.com
Title: Photograph: Philippe Wojazer/Reu
Link: https://www.theguardian.com/lifeandstyle/2023/sep/24/lego-abandons-effort-to-make-bricks-from-recycled-plastic-bottlesSource snippet
Lego abandons effort to make bricks from recycled plastic bottles | Lego | The GuardianSeptember 24, 2023 — Image: A jumble of Lego brick...
Published: September 24, 2023
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Source: youtube.com
Title: The Truth Behind LEGO’s Failed Recycled Plastic Project
Link: https://www.youtube.com/watch?v=sU149-8z6lISource snippet
The Engineering Challenges of Sustainable LEGO Materials...
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