Ahead of Resource Conference Cymru next week (26 March), resource efficiency adviser Brian Mayne FCIWM discusses the recent CIWM Cymru visit to the Pura NappiCycle facility in Capel Hendre, Wales.
I recently joined a CIWM Cymru site visit to the Pura NappiCycle facility in Capel Hendre, West Wales. NappiCycle offers a unique and innovative treatment system for the recovery of cellulose and plastics from absorbent hygiene products (AHP).
AHP covers a range of multi-material products used in everyday life – such as disposable nappies, incontinence pads and feminine hygiene products – which are mostly made of absorbent tissue-fibre and plastic.
They account for over 3% of the household waste and recycling that we produce as a country. Based on WRAP’s compositional analysis, Wales produces approximately 47,000 tonnes of AHP a year, including almost 150 million nappies.
Craig Masters, Operations Manager, and Rhiannon Chapple, Technical Manager, gave an illustrative talk on the background and the development of the project as well as a tour of the site.
What did we learn on the tour?
The presentation began by highlighting that director Rob Poyer developed the business concept over 15 years ago, leading to a partnership with eco-friendly baby products company Pura in 2020.
Craig and Rhiannon explained that AHP is collected from the kerbside by over a third of Welsh local authorities and transported to the site for treatment.
Once the material arrives at the facility, it is washed and shredded and the plastics separated from the cellulose fibre.
This fibre fraction is then used for a range of applications, including notice boards. It is also currently being trialled for use in the manufacture of fibreboard and wood-plastic composite.
Other applications currently undergoing research and development include the use of the end product in road construction.
In 2022, they were supported by the Welsh Government as part of a scheme to resurface the A487 road in Wales with the fibre from nappies being added to the bitumen – the binder that holds the asphalt together.
The company has also worked on a trial project to surface roads with recycled nappies collected by Carmarthenshire County Council.
The nappies recycled into fibrous pellets were delivered to local contractor GD Harries who fused them into the Stone Mastic Asphalt (SMA) surfacing material which was laid onto a road for surface improvement.
The first project diverted four tonnes of nappies, which is approximately 80,000 nappies from landfills. As well as the environmental benefits of repurposing nappy waste, this asphalt formula is expected to make the road quieter and longer lasting.
The aim is now to make this product available more widely for asphalt laying companies.
What innovations are possible?
Continuing the theme of innovation with local companies, we were informed of a unique project between NappiCycle and the Bluestone National Park Resort who are the world’s first holiday destination to use its own customers’ nappies to provide enhanced asphalt in paths on site.
NappiCycle recently commissioned a Life Cycle Analysis to evaluate the environmental impacts at each stage of their process, enabling customers to determine the carbon benefits of using the service.
There is no doubt that there are numerous advantages to be gained from nappy recycling, especially for councils looking to collect refuse every three weeks or longer as one of the main obstacles is the storage of AHP for such extended periods.
Additionally, recycling this waste contributes to the overall recycling rate of local authorities. It also has financial benefits, with estimates that local authorities saved £442,421 in 2023/24.
As for the future, the company is going from strength to strength as they get ready to accept nappies from Bristol, consider expanding the treatment capability by establishing a similar site in East Wales, and continue to research additional applications for the product from the process.
Ben Maizey, chair of CIWM Cymru thanked Rhia and Craig on behalf of the delegation for their time and praised their enthusiasm and commitment.
