Coffee for Circular Products
An initiative where we have been commissioned to transform coffee waste into a new product application. In collaboration with Scandinavian innovators, we repurpose used coffee grounds into valuable, circular materials suitable for mass production.
Regaining Value from Coffee Byproducts
In Scandinavia, coffee is more than just a beverage; it's an integral part of the daily workplace routine. Yet, the substantial biomass left after brewing, which constitutes only a small portion of the total materials used, often goes unnoticed. Recognizing this overlooked resource, our goal is not just to manage waste but to transform it into something more valuable. This effort seeks to rethink traditional disposal methods that result in significant methane emissions at landfills, advocating for sustainable waste practices and driving progress in the circular economy within the region.
The Challenge
Elevating Coffee Waste
Faced with strict European regulations that prohibit landfill disposal of coffee grounds due to methane emissions, and dissatisfied with simple incineration for energy, we pursued a more meaningful solution. In partnership with Scandinavian coffee breweries such as Peter Larsen Kaffe and Lofbergs, we investigated innovative applications for post-brew coffee waste, exploring everything from sustainable building materials to eco-friendly furniture and packaging. However, the most promising application emerged in the form of injection moulding—an approach perfectly suited for mass production.
The Approach
Crafting Value From The Ground Up
The project begins at the origin, gathering coffee grounds from local Scandinavian breweries and coffee shops. Immediate drying is crucial to stave off mold and ready the grounds for further processing. We utilize a patented technique to convert the grounds into a composite material for designated applications, ensuring that the material is both safe and stable for its new life in product production. Lets have a look at the process:
Collecting
Collecting coffee grounds from breweries is straightforward, but gathering them from coffee shops at scale presents more complex challenges. Recognizing the need for an effective, scalable process, we partnered with local waste management companies. These partners facilitated the collection of coffee grounds in separate containers, concurrently handling other types of waste. Our small initial trials demonstrated efficiency, enabling us to rapidly expand the process.
Cleaning and Drying
Coffee grounds, as an organic substance, are prone to mold and contamination. It was essential to dry them immediately after collection to prevent mold growth, setting the stage for further processing. Here, having a local supply chain with efficient logistics was crucial to keep time on our side. During the process, any contaminants like paper or plastic were removed.
Grinding and Plastication
The coffee grounds are finely ground to achieve a consistent grain size, and for specific products, they are subjected to plasticization. This process uses patented technology, specifically designed for designated material applications to ensure the coffee grounds remain uncontaminated throughout the product's lifecycle. Particularly for products that come into contact with food, maintaining the purity and safety of the materials during use is critical.
Compounding
After processing, the coffee grounds are mixed with a sustainable plastic binder, which is either recycled or bio-based, to maximize the coffee content while complying with industry standards. Through multiple trials, we established an optimal ratio of 35% coffee grounds. This proportion ensures that our material production aligns with most conventional plastic specifications, creating a strong basis for manufacturing.
Peletizing
It was important to make sure that our material matched the quality and usability of traditional plastic solutions. Alternative materials often demand more time, effort, and cost, potentially diminishing their value and resulting in limited adoption. To confirm the viability of our process, we verified its scalability for serial production, striving to make our material not only acceptable but also preferred by manufacturers. In order for new materials to be successful on the market, it is important making the materials both attractive and economically viable.
Injection Moulding Trials
With a strong network of partners, we have successfully converted coffee grounds into injection-grade material, compatible with standard machinery. While being a feasible process, it also has to be attractive, offering a strong story. Through this process we are able to customize the finish by adjusting the color pigments, granularity of the coffee grounds, and their ratios.
The Outcome
Circular Products with a Coffee Core
Through the collective efforts of our network, we transformed coffee grounds into injection-grade material. These coffee-based pellets are engineered to be compatible with existing manufacturing equipment, enabling seamless integration into production lines. The resulting products, such as durable and aesthetically pleasing cups, showcase the potential of repurposed coffee waste, turning everyday consumption into a catalyst for circular innovation. The coffee cups have effectively communicated the breweries' circular coffee initiative to customers. We also ensured that these products can be collected and recycled into new materials with our partners.
The transformation of coffee waste into injection-grade materials sets a new standard for sustainability, complying with EU regulations and offering a scalable, cost-effective solution. This process allows coffee breweries to capitalize on by-products, driving innovative, circular economy practices.
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