October 16, 2025 at 7:32:55 PM CEST

For many decades, recycling was seen as the solution to our waste management problems. The reality is different. About half of the total 19 million tons of commercial municipal waste could potentially be saved. On average, each office worker generates about 120 kilograms of waste annually. These statistics clearly demonstrate a fundamental problem:

The conventional recycling process is reaching its capacity limits.”

What is the precise definition of a truly circular economy ? In this approach, there is no longer a fixed lifespan for products. Materials are continuously recycled and returned to the production cycle. Recycling and reuse actually have the potential to reduce production costs and lessen dependence on primary raw materials. Product designers play a central role in this transformation, as their decisions during the design phase significantly determine whether a product is capable of functioning in a circular system.

By minimizing waste and using raw materials efficiently, we can create a more stable material cycle that places less strain on the environment in the long term. It's encouraging that over 91 percent of consumers in Germany would largely respond positively to the introduction of reusable packaging.

Why are zero-waste strategies so essential for manufacturers and product designers today, and what concrete measures do they use to pursue them effectively?

Why traditional recycling is reaching its limits

The limitations of traditional recycling are determined by several factors. Although Germany is often considered a pioneer in recycling, current figures reveal a disappointing reality. The conventional waste recycling system is gradually reaching its capacity limits, due to various structural causes.

1. Low recycling rates for plastics

According to the Federal Environment Agency, the total amount of plastic waste generated in Germany in 2021 was 5.67 million tons. Only about 35 percent of this amount was actually recycled, meaning these recycled materials could be used as secondary raw materials for the production of new products.

Approximately 64.4 percent was thermally recycled, with the generated energy being used to generate electricity and heat. It is particularly alarming that plastic waste generated by packaging has increased by more than 100 percent since the mid-1990s.

2. Downcycling instead of a real cycle

Downcycling is a practice in which materials are in a lower-quality state after reuse, rather than true recycling. This is the opposite of a closed-loop system, where materials are continuously reused in an equivalent state.

The current material recycling system often operates in a downcycling economy. This process merely slows down waste rather than eliminating it entirely. Recycling materials that have already undergone one or more recycling cycles leads to a continuous deterioration in quality; they are therefore increasingly unsuitable for creating new, high-quality products.

Plastics undergo a complex sorting process; afterward, they are either incinerated or converted into lower-quality products before ultimately ending up as waste. Closed material cycles that reuse materials 100 percent are unfortunately still the exception.

A common problem is the lack of recycling into high-quality products. This means that the reuse of materials in high-quality products is not given sufficient attention. This can lead to inefficient use of resources and increased environmental impact.

3. Lack of recycling into high-quality products

Metals such as tinplate and aluminum can be recycled almost indefinitely in an infinite cycle with no discernible limit.

In contrast, plastic can only undergo the recycling process about seven times before losing its original properties and ultimately having to be disposed of. Therefore, recycled materials are often used in products that do not have such high material performance requirements. Throughout the entire sorting and treatment process, a portion of the fractions remains that is not suitable for material recycling.

4. High energy consumption during recycling

A significant amount of energy is required to process and revitalize materials in the recycling process. The properties of different materials vary considerably. Metal and paper recycling plants, on average, have a specific final energy consumption of only about 50 kilowatt-hours per ton when recycling these materials.

In comparison, plastics recycling plants require approximately 450 kilowatt-hours per ton of material, which is considerably more. Even compared to materials like tin and aluminum, the transportation and sorting of plastics requires a significantly greater amount of energy.

Zero-waste principles as a new design basis

Achieving zero waste requires a fundamental restructuring of the product design process. Unlike conventional recycling, this new strategy begins in the planning and design phase, bringing about a profound change in product design and manufacturing.

Think of waste as a resource

The basic idea of ​​the zero-waste philosophy is to change our way of thinking: waste is no longer an unwanted byproduct, but a valuable resource. This approach increases the appreciation of materials previously considered waste. This results in a fundamental shift in the design approach: products are designed right from the design phase so that they can be easily integrated into material cycles.

Especially in times when products are designed in an increasingly objective manner, materials with history can be given increased uniqueness and a kind of “soul” .

Lifecycle-oriented product design

The concept of lifecycle design encompasses the consideration of all phases in a product's life cycle, from raw material extraction to disposal at the end of its useful life. This approach considers maintenance and recycling constraints early on. By computer-aided design (CAD) , product lifecycle management (PLM) , and environmental assessment software, developers receive detailed information about the product's resource requirements immediately after completing the virtual product design process.

Take-back systems and reuse

The importance of take-back systems is growing because they help reintegrate products, their components, and materials into the value chain. Companies have the opportunity to take back old products in a structured manner, fulfilling their responsibility as manufacturers throughout their entire life cycle.

Successful take-back systems follow various motivations:

• Legal obligations
• Economic advantages
• Ecological objectives

Transparency over material flows

Clear transparency regarding material movements is crucial for an effective circular economy. In this context, digital product passports are a crucial tool that helps companies meet a wide range of transparency obligations. They allow the location of materials and chemicals to be tracked, which can significantly simplify the recycling process.

A thorough analysis of all raw materials and each individual production stage also reveals potential that is often not visible when the entire value creation process is examined in detail.

Training and awareness in the design process

To successfully integrate the principles of zero-waste design into the design process, it is crucial that everyone involved is trained and sensitized. This requires a profound shift in thinking and the development of new skills and competencies. Designers should learn to utilize every piece of material thoroughly, and their design should be guided by the available quantities.

Staff training and awareness-raising measures ensure compliance with regional regulations and company standards. To ensure long-term success, it is crucial that the training of designers (and those aspiring to become designers) incorporates circular principles.

Strategies for product designers: from idea to implementation

Today, product designers have innovative options for action that address every phase of the development process.

1. Opt for durable and recyclable materials

The choice of materials influences a product's performance, cost, lifespan, and environmental friendliness. The materials of choice are those that have a long service life and can also be recycled at the end of their useful life.

Metals like aluminum and steel are almost infinitely recyclable. In contrast, plastics only have about seven recycling cycles before they lose their properties. Designers should consider these differences early in the planning phase.

2. Design for disassembly and repair

Today, products are primarily designed for ease of assembly, with little consideration given to the possibility of disassembly. It is becoming increasingly urgent to develop product design that considers the entire life cycle. Design for Disassembly (DfD) makes it possible to easily disassemble and reuse components. Repairs are simplified, and valuable raw materials are recovered.

Screws and plug-in systems that offer removable connections are preferable to glued or welded ones. Although this decision may seem more complex in production, it pays off in the long run.

3. Use of monomaterials

Monomaterial items are made from a single material, which simplifies recycling. They offer significant advantages over composite materials:

• Easy categorization in recycling plants
• Increased material purity during recycling
• Reduced material losses

This is particularly evident in the area of ​​packaging: items that consist of multiple, yet connected materials can often only be separated with great effort or not at all.

4. Remanufacturing as a design goal

Remanufacturing is a standardized process that combines used, but reconditioned, parts with new components to create a product that functions at least as well as a new one. Remanufacturing previously used materials requires significantly fewer resources and energy than producing new ones.

The numbers speak for themselves: Remanufacturing can reduce emissions and energy consumption of a 4-cylinder replacement engine by up to 62% and 63%, respectively. Achieving such savings requires proper preparation right from the design phase.

5. Digital tools for material evaluation

Digital tools support designers in evaluating materials based on their sustainability and making informed decisions. Environmental impacts can be quantified using lifecycle management software , life cycle assessments , and specialized sustainability tools . These tools also support compliance with legal requirements.

During the virtual design of the product, designers receive immediate information about resource requirements. Early identification of optimization potential is an essential prerequisite for sustainable design.

Pioneers show the way: Inspiration from practice

Numerous companies around the world have zero-waste principles into their processes. These pioneers are a significant source of inspiration for manufacturers and product designers, demonstrating that sustainable solutions are not only effective from an ecological perspective but can also succeed in the market.

1. Reusable systems in retail on the rise

Retail is being fundamentally transformed by cross-company reusable systems. For example, a cross-industry reusable system for drugstore products has been in place since 2021. Practical implementation is often easier in the business-to-business sector than in the retail sector. The statistics are clear: In the fruit and vegetable sector, the share of reusable crates is already between 25 and 50 percent. Ease of use for consumers is crucial – 83 percent of people want to be able to return reusable packaging anywhere, regardless of where it was purchased.

2. The promise of a 100% circular economy

Premium travel accessories provider NORTVI is the first luggage brand to implement a sustainable and innovative recycling process for its entire product range. The Dutch brand fully recycles its luggage that no longer has a second chance. In this way, NORTVI achieves a 100% zero-waste approach and creates new products from 100% recycled components.

At the same time, all products come with a lifetime warranty with free repairs.

3. Fashion without waste: Puzzle instead of waste

The fashion industry also impressively demonstrates what's possible. The fashion industry is often criticized for consumerism and fast fashion, but the potential for ecological improvement in the fashion sector is enormous.

It's common for around 20 percent of all materials to be discarded after cutting. Designers like Natascha von Hirschhausen take a different approach: Their creative patterns allow curves and edges to fit together like puzzle pieces. What's the result? The amount of scraps is reduced to less than 1 percent. This approach not only saves material but also reduces CO₂ emissions by more than 60 percent.

4. Second-hand architecture

In the construction sector, impressive projects are being created using recycled materials. In Switzerland, the UMAR residential module a completely circular construction concept. All components are made of reusable, recyclable, or compostable materials. Only screws, clamps, or plug-in connections are used, instead of adhesives.

In Nigeria, things are getting particularly creative: thousands of PET bottles filled with sand are being converted into insulating walls that enable a constant room temperature of 18 degrees Celsius even in a tropical climate.

5. Service instead of ownership: the end of ownership?

Product Service Systems (PSS) offer a sustainable alternative to traditional product sales. Usage is now more important than ownership. Instead of selling tires, Michelin mileage, while Signify (formerly Philips Lighting) provides lighting as a service. This creates long-term partnerships instead of one-time purchases.

The key advantage: manufacturers retain ownership of their products and therefore improve their lifespan and quality.

6. Standards provide clarity: DIN SPEC 91436

DIN SPEC 91436 offers a certifiable standard for sustainable waste and recyclables management . It assesses not only proper waste separation but also its disposal. Depending on the recycling rate, companies can receive a bronze (85%), silver (90%), or gold (95%) certificate. The standard helps to use resources wisely and minimize residual waste—precisely the goal of the circular economy.

What happens next?

The facts are clear: Only 35 percent of plastic waste undergoes material recycling; everything else ends up in energy recovery or disposal. Much of what we consider recycling is actually downcycling—a system that slows down waste but doesn't prevent it.

Zero-waste products, which remain valuable resources even at the end of their lifespan, are created through the selection of durable materials, sophisticated disassembly concepts, and the use of monomaterials. Pioneers are already demonstrating that material waste can be reduced from the usual 20 percent to less than 1 percent, while CO₂ emissions can be cut by over 60 percent.

It's no longer a question of whether we should apply zero-waste principles. Change is inevitable due to resource scarcity and environmental pressures. Manufacturers and product designers are key players in this transformation. The decisions you make today determine whether products are part of the problem or part of the solution.