Can a Home Appliance Fix the Problem of Soft-Plastic Waste?

Soft plastics are notorious for jamming sorting machines, slipping through processing lines, and wreaking havoc on the environment. They’re also not accepted in most municipal curbside recycling programs.

Facilities for recycling these types of plastic exist, but getting waste to these locations clean and free of what some call “wishful recycling” items (compostable cups, plastic utensils) is such a challenge that the majority of soft plastics, even the bags recycled at the front of grocery stores, end up in the trash. The SPC is what Arbouzov calls a “pre-recycling device,” designed to simplify this stream and deliver plastic that’s contained, traceable, and more likely to make it through the system.

I tried to envision how the blocks would turn into patio furniture, as advertised, but didn’t learn exactly how until months later, when Arbouzov sent me a video of the blocks at their final destination—a facility in Frankfort, Indiana, that specializes in processing polyethylene and polypropylene films. The blocks get shredded into crumbles resembling, at least on video, handfuls of wet newspaper, which are then compressed into composite decking, chairs, garden edging, and more.

“The full cycle from mailing a block to it entering recycling processing typically takes a few weeks,” Arbouzov said, “depending on shipping time and batching schedules.” Right now, the Frankfort location is the only facility processing the blocks, but Arbouzov said he hopes this is only temporary.

“Our goal is to shift more of this processing closer to where the material is generated, so blocks can move in bulk through regional recycling infrastructure rather than through mail-based logistics,” he said. “The mail-back system is essentially a bridge that allows the material to be captured today while that larger infrastructure develops.”

Recycling, Rewired

I found that my household of three was able to produce a block every couple of weeks, which quickly outpaced the provided supply of mailers. As the blocks started piling up on the floor of my office, I found myself wishing the SPC made something useful for consumers. Spoons, straws, 3D-printing filament … anything that could be used at home.

However, a 2023 Greenpeace report found that recycling plastic can actually make it even more toxic than it already is—heating it can not only cause existing chemicals to escape into the air and water supply, but even create new ones, like benzene. Would I want this in my house? Does recycled plastic actually belong in a circular economy? I asked Arbouzov what he thought.