Lego uses about 100.000 tonnes of virgin plastic per year. They have set a target to reduce carbon emissions by 37% by 2032, and net zero by 2050. In 2021 they presented a prototype brick made from recycled water bottles, engineered in more than 3 years by over 150 scientists.
However, in September 2023, after 2 years of testing, Lego claims the carbon footprint is worse compared to its traditional product. This has to do with the softer density of the product, requiring it more energy to process due to the sorting and processing and the higher energy required to make the bricks.
Critics point out Lego is looking only at the plastic production, and not at the reuse of the PET waste.
Lego is working on expanding its “replay” program to reuse rather than recycle. The program which now donates to charity might be a stepping stone in a circular business model.
It is another example of all the complexity surrounding sustainability issues.