Leading the circular economy revolution in PVC-U

As Veka Recycling surpasses 25 million recycled PVC-U windows, we look at how the company is redefining sustainability in fenestration through its circular supply chain.

Through cutting-edge practices and a clear vision for the future, Veka is proving that recycling isn’t just about waste reduction – it’s about redefining the lifecycle of materials.

As construction sectors face increasing pressure to reduce their carbon footprints, our innovative recycling processes, local manufacturing commitment and focus on long-life products are setting new benchmarks for sustainability.

At the heart of that success is our unwavering dedication to the circular economy model.

Rather than seeing discarded PVC-U windows and doors as waste, we view them as resources – and we’re dedicated to keeping these materials within the domestic supply chain.

Closing the loop

Each year, Veka Recycling processes 18,000 tonnes of PVC-U waste from customers at our Wellingborough facility, which has recently been expanded to boost capacity to 25,000 tonnes. Approximately 95% of the waste collected is recycled, with 60% being reformed into new windows.

Our commitment to recycling has seen 25 million PVC-U windows recycled and 40 million windows produced with recycled cores.

Currently, we are aiming to increase the recycled content of its new frames, having started the year with 28% and projecting an average of 32% by year-end.

This closed-loop system is where Veka excels: we recycle, refine and reintegrate PVC-U waste back into the production chain.

This process is not just efficient but essential to meeting the growing demand for recycled content.

Shifting market perception

Recycled PVC-U had struggled with a perception problem – it was often viewed as an inferior element behind virgin material in terms of quality and durability.

The shift in market perception aligns with broader environmental goals. As companies and consumers alike seek greener building solutions, we have made recycled PVC-U an essential part of our frames.

By diverting thousands of tonnes of plastic from landfills and reducing reliance on virgin PVC-U, we are demonstrating that recycled products can be high-quality and high-performance.

By continuously investing in advanced recycling technology, we ensure that are recycled PVC-U pellets meet the highest industry standards, giving customers confidence in the material’s durability and performance.

Recycling the tired narrative

While single-use plastics dominate negative headlines, Veka’s focus on long-life products flips the script.

Windows are designed to last up to 350 years, but the lifespan of PVC-U doesn’t have to end after that period. The material may no longer be suitable for use in windows, but it can be repurposed into other products for closer to 500 years.

Recycled PVC-U can find new applications in products like drainpipes and ducting, ensuring it continues to contribute to the broader economy.

Veka Recycling’s operations are deeply rooted in meeting evolving industry standards, particularly in the face of regulatory changes.

And our ability to anticipate market trends and regulatory shifts has allowed us to stay ahead of the competition, even in the face of global challenges such as the COVID-19 pandemic.

During the pandemic, supply chain disruptions caused a shortage of virgin materials, and the cost of recycled and all other materials skyrocketed as a result.

This crisis helped shift the industry narrative on recycled PVC-U as manufacturers turned to it out of necessity, with the period helping prove that recycled PVC-U could perform just as well as virgin alternatives.

Relationship-driven success

In a competitive market, what sets Veka apart isn’t just our technological innovations but our approach to relationships. We don’t view our customers and suppliers as transactional partners but as long-term collaborators.

This trust has been pivotal in Veka’s ability to maintain a steady flow of post-consumer material, even during times of fluctuating supply and demand.

We process up to 1,300 tonnes of post-consumer frames each month, adjusting to seasonal variations and market pressures. This commitment to our partners ensures a reliable supply chain, which is critical to sustaining its closed-loop recycling system.

British supply chain

One of Veka Recycling’s most notable differentiators is a dedication to the UK supply chain.

While some similar ventures ship end of life products abroad for processing, we keep our operations entirely within the UK.

Operating entirely out of our Wellingborough facility, Veka Recycling supports British manufacturing by keeping material in the supply chain for repurposing at our UK headquarters in Burnley. This closed-loop system ensures that we can maintain a high level of quality control while also reducing carbon emissions.

The future is recycled

Traditionally, the market was dominated by white PVC-U windows, but today, the demand for coloured windows has surged.

The growing popularity of coloured windows presented the industry with a further perception challenge, with coloured PVC-U proving more difficult to repurpose.

Historically the market was split heavily in favour of white windows, with only around 30% being coloured. Current trends have seen coloured foils dominate the market, but we have adapted our processes to handle a larger volume of coloured PVC-U waste and integrate it into white window production.

One notable example is our 150mm ReCore Cill. The Cill features a core made from recycled material encased in a virgin white PVC-U exterior, creating a highly sustainable option that retains the quality and durability our customers expect.

Additionally, we have developed a 15mm frame extension, designed to incorporate recycled PVC-U within its core. This frame extension can withstand added installation pressures, allowing for seamless installations. The use of recycled material does not impact the product’s structural integrity or quality, providing a sustainable solution that meets our high standards.

This adaptability demonstrates our forward-thinking approach, ensuring that we remain at the forefront of industry trends. By investing in technology that allows for the repurposing of coloured PVC-U, Veka Recycling is further expanding the possibilities of what can be done with recycled materials.

As the PVC-U recycling industry evolves, Veka remains committed to leading the charge.