Recycled Material Integration and Design for Circularity
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Summary
Plastika Skaza, based in Velenje, Slovenia, is a family-owned plastic manufacturing SME established in 1977. Plastika Skaza has implemented a comprehensive circular product design strategy, focusing on the use of recycled and bio-based plastics.
Description:
Plastika Skaza, based in Velenje, Slovenia, is a family-owned plastic manufacturing SME established in 1977. Originally a small-scale garage business, it has grown into a company with 360–370 employees and annual revenues between €40–50 million. Skaza produces a wide range of home, kitchen, and garden plastic products, including contract-manufactured components and its own branded items such as the Bokashi Organko kitchen composters. Over the past decade, Skaza has repositioned itself as a leader in sustainable plastic design, incorporating environmental responsibility into both its materials and processes. Skaza has implemented a comprehensive circular product design strategy, focusing on the use of recycled and bio-based plastics: Material Innovation: • Over 35% of Skaza’s raw materials are now recycled or bio-based, with a target of 50% in the near future. • The Bokashi Organko 2 compost bin is manufactured entirely from 100% recycled polypropylene (PP). • The company also experimented with inputs such as recycled fishing nets and ocean-bound plastics. Product Design for Circularity: • Skaza designs products to be both made from and recyclable into high-quality plastic materials. • The Organko bin exemplifies “closed-loop thinking”—from recycled input to future recyclability. Process Modernization: Skaza upgraded its injection molding equipment with energy-efficient, all-electric machines and automation tailored to handle complex recycled plastics. R&D and Collaboration: • Participated in EU initiatives like INCREACE to co-develop recycled plastic compounds with improved performance. • Built partnerships with recyclers to ensure consistent material quality and reliable feedstock. Skaza’s strategy combines upstream design and material selection with downstream recyclability, offering a full-cycle approach to plastic circularity.
Environmental Perspective
Skaza’s shift from virgin to recycled plastics has led to significant environmental savings: • Carbon Footprint Reduction: LCA results show that using recycled PP in the Organko bin lowers its carbon footprint by 39.4% compared to virgin plastic. • Resource Conservation: By 2020, Skaza used over 1,000 tonnes of recycled plastic per year, reducing reliance on fossil fuel-derived virgin materials. • Waste Diversion: Substituting virgin plastics with recyclate keeps thousands of tonnes of plastic waste out of landfills and incinerators. • Consumer Behavior Impact: Products like the Organko bin promote household waste reduction and composting, further extending the environmental impact beyond manufacturing. • Systemic Contribution: Skaza’s use of ocean-bound plastics contributes to marine pollution mitigation, and its material transparency supports circular value chains. In short, Skaza’s environmental approach not only cuts emissions and resource use but also helps drive consumer awareness and waste prevention.
Economic Perspective
Skaza’s circular transformation has also proven to be strategically and financially sound: • Revenue Growth: Exceeded €40 million in revenue in 2019, with eco-products fueling expansion. Branded products like Organko grew to 8% of sales, with rising margins. • Cost Efficiency: By using recycled materials, the company hedges against virgin plastic price volatility and reduces material input costs, especially when oil prices are high. • Operational Savings: Investments of over €1 million in new smart machinery have boosted productivity and energy efficiency. • Brand Recognition and Awards: Skaza received multiple awards, including the Golden Practice Award, the German Economy Award for sustainability, and a listing in the London Stock Exchange’s 1000 Companies to Inspire Europe—enhancing brand visibility and attracting new partnerships. • Market Differentiation: The company’s sustainability positioning has opened premium market segments and strengthened its identity in a competitive plastics sector. Skaza demonstrates how circular product design can be a driver for market growth, cost control, and competitive differentiation. The information in this article is based on content from Plastika Skaza on pravakemija.si.











