The ReWall Co., Des Moines, Iowa, has announced it is doubling its manufacturing capacity of roofing products and other construction materials made from recycled food and beverage cartons.

The manufacturer of green building materials, which are 100 percent recyclable, says this move is in response to growing demand for its products.

Founded in 2008, ReWall converts cartons into sustainable building materials through its low-energy, ecofriendly recycling technology. In July 2017, ReWall installed new equipment to expand the capacity of its manufacturing facility in Des Moines. This increases its need for recycled cartons from about 200 tons a month to approximately 600 tons a month, “and likely to even higher,” says the company.

“We have discovered that the unique properties of cartons—such as strength, durability and resistance to mold and moisture—make cartons an ideal material for creating high-quality building materials,” says Jan Rayman, CEO of The ReWall Co. “With demand growing for our products, our focus is on expansion and identifying additional North American locations for our next facility.”

Sharing a joint interest to increase carton recycling, the Carton Council of North America says it has been a longtime supporter of ReWall with the goal to expand carton recycling nationwide by growing infrastructure for recycling aseptic and gable-top cartons. The Carton Council has worked with ReWall to provide financial and technical support to help expand this innovative end market for cartons used for many common food and beverage products, the organization says.

Through innovative technology developed specifically for ReWall’s needs, the company says the process uses no water, formaldehyde glues or hazardous chemicals. No waste is generated, and every part of the carton is incorporated into the finished products, which include roof cover board, exterior sheathing, wallboard and floor underlayment. The life cycle of the cartons will continue as the building materials also can be recycled, ReWall says.

“ReWall’s success clearly demonstrates that the use of recovered cartons has evolved,” says Jason Pelz, vice president of recycling projects for the Carton Council of North America and vice president, environment, for Tetra Pak Cluster Americas. “We are excited about the growth of this innovative end market for food and beverage cartons.” 

There are 800 half-pint cartons in each 4-inch-by-8-and-a-half-inch roof cover board. This means that each truckload of finished ReWall products prevents nearly 600,000 cartons from going to landfills, according to the company.

The Carton Council is composed of four leading carton manufacturers, Elopak, SIG Combibloc, Evergreen Packaging and Tetra Pak, as well as an associate member, Nippon Dynawave Packaging. Formed in 2009, the Carton Council works to deliver long-term collaborative solutions in order to divert cartons from the landfill. Through a united effort, the Carton Council says it is committed to building a sustainable infrastructure for carton recycling nationwide and works toward its continued goal of adding access to carton recycling throughout the U.S.