Hygiene Paper of the Future: Innovation through Recycled Cardboard

Project description

WEPA introduced an innovation in hygiene paper production by using postconsumer recycled cardboard as a raw material. WEPA demonstrates that premium-quality hygiene paper can be manufactured from recycled cardboard, offering significant benefits compared to virgin fibre products, including a reduced ecological footprint and the elimination of bleaching agents.

Traditionally, recovered paper sources, such as office paper, have been used, providing primarily white fibres suitable for a wide range of products.

Recycled cardboard and corrugated board already contain frequently recycled beige fibres of lower quality. With its innovation WEPA moves further down the wood fibre cascade utilisation, maximising the potential of fibres before they reach the end of their life cycle.

To support the market launch of its sustainable beige products, WEPA initiated a business-to-consumer campaign called ‘Beige is better’.

The implemented solution

The development of this new generation of raw material is the result of intensive research and development and a step by step upgrading of production plants. The transformation spans the entire production chain, from stock preparation with new sorting technologies, through optimised paper machine settings, to the final converting of tissue, without compromising product quality. The initial goal to match the quality standards of white recycled paper has been surpassed: the result is a hygiene paper that is not only sustainable but also significantly softer than conventional recycled paper.

The key hurdles solved

Despite the positive response from our partners, consumer awareness of the environmental benefits of beige recycled hygiene products is still limited.

Many people still hold a prejudice against non-white paper. It is therefore essential to further engage consumers and raise acceptance of these products through measures such as the marketing campaign ‘Beige is better’.

Key Suppliers / Partners

While the development and technical implementation of the project were carried out entirely in-house relying fully on internal resources, European retailers welcomed the innovation and have integrated WEPA’s beige products in their product range.

“This innovation reflects a strong commitment to recycling, resource efficiency, and circular economy. It is about the continuous improvement of recycling practices that are particularly well-suited for single-use products such as hygiene paper and contribute to a bio-based economy – an approach that requires widespread support. It is rewarding so see our beige hygiene products reaching customers across Europe and receiving such recognition within industry circles, including several prestigious awards. Being part of WEPA, a company so open to innovation, is incredibly motivating and reinforces the value of being part of a team that drives meaningful change.”

Wolfgang Köster
Director Group Fibre Management, Germany

The Project’s Achievements:

Investment
WEPA has made significant multimillion investments to upgrade stock preparations across multiple sites, enabling a transition to the new raw material process.
Additionally, extensive resources have been dedicated to intensive research and development work in order to optimise production processes. While substantial funds have already been invested, this transformation is ongoing and will continue over the coming years. In parallel, we invested in our nationwide marketing campaign ‘Beige is better’.

CO2 emissions saved
Our recycled fibres produced with renewable electricity can reduce CO2 emissions by approximately 30% compared to the virgin fibres we use. This equates to about 110 kg CO2 eq per tonne of fibres.

Any other sustainable benefits
By using our recycled fibres, we reduce water consumption by 87% and energy use by 78% compared to our used fresh fibres.
Utilising lower grade recovered paper enables local sourcing and helps protect biodiversity while reducing land use pressure.

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