Corrugated Plastic Recycling: Background and Best Practices
1. A Brief History of Corrugated Plastic
Before diving into corrugated plastic recycling best practices, let’s first discuss what exactly it is. Corrugated plastic, commonly known under trade names such as Coroplast, Correx, or Polyflute, really emerged in the 1990s as a lightweight, durable alternative to corrugated fiberboard (Coroplast). The material is made by extruding twin-wall plastic sheets—akin in concept to corrugated cardboard, but composed of high-impact polypropylene resin—producing a rigid, moisture-resistant board.
The first commercial twin-wall corrugated plastic sheets were introduced in the late 1970s, with Coroplast (founded in 1974 in Montreal, Canada) widely recognized as an early innovator. Throughout the 1980s and 1990s, industries began adopting corrugated plastic as a reusable, longer-lasting alternative to OCC (old corrugated containers). Signage, returnable packaging, and reusable totes became popular applications, especially in automotive, agriculture, pharmaceutical and manufacturing sectors. The demand grew rapidly as companies sought alternatives to single-use packaging.
2. What It's Made Of
Corrugated plastic is primarily made from polypropylene (PP)—specifically high-impact polypropylene resin. This plastic offers an excellent balance of strength, chemical resistance, impact resistance, and temperature stability. Its versatility makes it ideal for fabrication into everything from packaging dividers and reusable totes to signage and protective layering within pallets. Due to its rigidity and resilience, corrugated plastic is also used in custom die-cut applications, insulation panels, and horticultural propagation trays. Some variants use polyethylene (PE), particularly high-density polyethylene (HDPE), but PP remains the dominant resin due to its strength-to-weight ratio and ease of recycling.
3. Common Uses and Industry Applications
Corrugated plastic is widely used in industrial, commercial, and agricultural settings due to its reusability and weather resistance. Common applications include:
Packaging & Shipping: Boxes and dividers for food, electronics, automotive parts, and pharmaceuticals.
Reusable Containers: Agriculture bins, warehouse totes, and distribution center trays.
Signage & Displays: Real estate signs, event signage, and political campaign boards.
Protective Packaging: Edge protectors, layer pads, and product separators in crates and pallets.
Hazardous Materials: Safe transport of sharp or sensitive items where puncture resistance is critical.
Pharmaceutical Manufacturing: Used to organize, store, and safely transport cleanroom components, medical packaging materials, and batch samples. Its non-porous surface resists moisture and contamination, making it ideal for sterile and regulated environments.
Industries such as automotive, agriculture, pharmaceuticals, warehousing, and logistics regularly rely on corrugated plastic for both its durability and cost savings over multiple reuse cycles.
4. Market Growth and Production Trends
The global corrugated plastic market has seen strong, consistent growth across all segments:
Corrugated plastic board was valued at $2.66 billion in 2023, with a projected CAGR of 7.2% to reach $4.99 billion by 2032 (Business Research Insights).
Corrugated plastic packaging is projected to grow from $34.7 billion in 2023 to $62.95 billion by 2032 (CAGR: 6.1%) (Zion Market Research).
The corrugated plastic box segment is forecasted to grow from $3.6 billion in 2025 to $6.0 billion by 2035 (CAGR: 5.3%) (Future Market Insights).
The U.S. corrugated plastic sheets market is projected to grow from $175 million in 2024 to $283 million by 2034 (CAGR: 4.9%) (Polaris Market Research).
This growth is driven by increased demand for durable, returnable packaging, sustainability initiatives, and expansion in e-commerce and industrial logistics.
5. Best Practices for Corrugated Plastic Recycling
Corrugated plastic is highly recyclable when handled correctly. It is often more valuable than traditional cardboard due to its resin type, durability, and potential for reuse. However, recycling success depends on best practices:
Optimal Recycling Guidelines
Bale the material: Compressing corrugated plastic into bales increases density, reduces storage space, and improves transportation efficiency.
Avoid contamination: Though not necessarily required, it’s always a best practice when possible to remove adhesives, labels, and debris. Clean, uncontaminated PP yields higher recovery value and better resin quality.
Ship full truckloads: Large, baled volumes are far more attractive to recyclers and command better pricing.
Coordinate with specialty recyclers: While polypropylene is recyclable, it does not have as many processors as PET and HDPE plastic. Partner with industrial recyclers that handle plastic #5 (PP).
Do not mix with other plastics: Mixing with HDPE, LDPE, or other materials reduces bale quality and may lead to rejections.
Final Thoughts
Corrugated plastic has steadily grown from its origins in the 1970s and its industrial emergence in the 1980s and 1990s into a leading packaging material. Today, it serves as a durable, reusable, and recyclable alternative to cardboard, especially in supply chains where durability and strength matter.
With proper handling—baling, minimizing contamination, and shipping at volume—corrugated plastic not only supports sustainability goals but also yields higher scrap value than cardboard. As industrial users continue to prioritize circular packaging systems, corrugated plastic is poised to play an even greater role in sustainable materials management.
Looking to Recycle Corrugated Plastic at Scale?
At Waste Optima, we help manufacturers, warehouses, and distributors implement cost-effective, operationally simple solutions for corrugated plastic recycling. Whether you're shipping reusable totes or disposing of signage and packaging waste, we can help you divert it from landfill and unlock its value. Contact us today to get started.
