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Paper Cups Mixed with Recycled Pulps
Tokan Kogyo Co., Ltd.
Beverage paper cups re-utilized with used paper cups and the paper waste from plant*
Used paper cups that were previously incinerated for thermal recycling have been recycled into pulp, which is then blended into the base paper as part of the raw material.
* Defects and waste from the die cutting process
This product is made through horizontal recycling, in which discarded paper cups are recycled into new paper cups. To enable this horizontal recycling, we have established a dedicated recycling scheme*.
* Used paper cups can be brought to recycling paper production plants after food and beverage residues are removed, allowing the extraction of recycled paper material. At Toyo Seikan Group, we are promoting the 'CUP to CUP' initiative, which involves manufacturing new paper cups using recycled paper material derived from used cups. Aiming to realize a circular economy where limited resources are reused from one product to another, we are also engaged in awareness activities for cup cleaning and recycling using the Re-CUP WASHER.
This product contains recycled pulp from used paper cups and factory waste paper. By incorporating 25 % recycled pulp into high-quality paper cup stock, we are able to reduce virgin pulp usage and achieve approximately a 10 % reduction in GHG emissions*.
*Compared to our standard 7oz paper cup(SM-205, full capacity: 211 ml), this product achieves approximately a 10% reduction in GHG emissions during base paper production by using 25% recycled pulp from used cups and factory waste paper.
Tiny fragments of ink and laminated film that may remain during the re-pulping process can appear as specks on the surface of paper cups. To prevent this, the base paper of this product is designed with a three-layer structure, using recycled pulp only in the middle layer. As a result, such fragments are not visible on the surface, which improves the overall appearance.
Yusuke Ikeda
Technology Development Division
Tokan Kogyo Co., Ltd.
We were already considering environmental issues before we even started developing this product. That’s when the idea of using recycled pulp in our paper cups came up. While there have been paper containers made with recycled pulp before, this is the first time our company has used it in something that comes into direct contact with your mouth and drink.
We had a tough time improving hygiene standards. Paper used for food and drink containers, such as paper cups must comply with strict hygiene regulations. To make sure customers can use our product safely, we needed to guarantee that paper containing recycled pulp met these same high standards. So, we reviewed the hygiene requirements and asked the paper manufacturer to produce paper that meets them.
We also had to adjust the strength and thickness of the paper so it could be shaped using the same process as regular paper cups. We believe that this product was made possible through collaboration with a paper manufacturer that has the technology to sort our high-quality recycled paper from market-collected materials.
When we presented the developed product to our clients, they said the presence of ink specks was not a concern. However, since we could not know customers’ reactions until they actually used the product, we introduced it on a trial basis at first. Even after the introduction, we did not receive any feedback that the ink specks were a concern, and we’re glad to see that it has been accepted just as smoothly as the current product.
Starting with our current small-sized paper cups for beverages, we plan to expand into various formats, including food-grade paper cups. Our long-term goal is to launch paper cups made from 100% recycled pulp. We are also continuing our efforts to raise awareness that paper cups can be recycled. However, since paper cups are often laminated with a water-repellent coating, they are typically excluded from conventional paper recycling streams. As a result, their recyclability is not widely recognized.
We aim to introduce our products across a broader range of industries and collaborate with customers, base paper manufacturers, and trading companies to raise awareness that paper cups can indeed be recycled.
Utilizing materials that were previously discarded as recycled resources is a commendable initiative. While multi-layering technology has long been available, I believe various innovations have been made to make effective use of materials collected after use. From a technical standpoint, I hear that it is possible to use 100% recycled pulp, and I sincerely hope that those efforts will further encourage greater awareness among users and society in the future.
