Poly Print, Inc. in Tucson, Arizona, recently collaborated with the Tucson City Council and ByFusion, a California-based company specializing in transforming discarded plastic into sustainable building materials, to recycle and repurpose plastic waste.
The hope is the partnership will reshape how plastic waste is handled in the community, showcasing a progressive approach to environmental responsibility.
Pilot Program
Tucson Council Member Steve Kozachik introduced a pilot program, encouraging residents to drop off unrecyclable plastics at designated sites around the city, including his ward office.
The collected plastics were sent to ByFusion, which uses cutting-edge technology to convert nonrecyclable materials into construction-grade blocks.
The process involves a patented machine that uses steam and compression to churn out 22-pound blocks that fit together with interlocking pegs, allowing for items that typical recycling plants reject such as food packaging and plastic bags to be reused and repurposed.
While the pilot program aimed to gather around 20 tons of plastic, it exceeded expectations, collecting over 35 tons.
This initiative not only aims to recycle plastics but also to create a vibrant local economy that prioritizes sustainability, turning what was once waste into valuable resources for the community.
If the program continues its positive momentum, it could serve as a model for other cities, showcasing how local initiatives can make a significant difference.
Goals
This early success prompted an ongoing effort to explore the logistics of making this plastic reuse initiative a permanent city service. The goal is to potentially bring ByFusion’s manufacturing capabilities to Tucson, allowing for local production of these innovative blocks.
Poly Print has emerged as a key player in this initiative. As a local food packaging company, it generates approximately 100,000 pounds of plastic waste each month.
The company had struggled to find recycling solutions until discovering ByFusion’s unique capabilities.
“We have tried other companies for recycling for years, and they could not take it because of the mixed substrates and laminates,” says Elsie Genova, an owner of Poly Print.
ByFusion provided a great opportunity because it was able to process a vast variety of substrates.
Helping the Community
The initial pilot program from Poly Print’s contribution yielded about 1,200 blocks.
Those plastic blocks have been used to construct four new benches at a local Tucson Park, while preordered blocks were used for a trash enclosure at the Old Pueblo Community Center and to construct two benches in the San Gabriel neighborhood.
Volunteers from the Poly Print team participated in local events hosted by the City of Tucson over the holidays in 2023, and the plastic blocks were used to erect holiday Christmas trees at public parks and in downtown Tucson.
While this was over a year ago now, Poly Print had been involved in this pilot program for a couple of years. As it continues to develop, Poly Print plans to continue its participation.
As discussions progress, the financial feasibility of maintaining and expanding these services will be a focal point for city leaders. Currently, the operational costs of collecting and processing plastics are being assessed to ensure a sustainable approach moving forward.
In partnership with ByFusion, the City of Tucson, and Poly Print, a proactive approach to plastic waste is taking shape.
This initiative not only aims to recycle plastics but also to create a vibrant local economy that prioritizes sustainability, turning what was once waste into valuable resources for the community.
If the program continues its positive momentum, it could serve as a model for other cities, showcasing how local initiatives can make a significant difference.
Editor’s note: In the feature photo, recycled plastic has been used for several projects, including building park benches and creating decorations over the 2024 holiday season in Tucson, Arizona. Photo was submitted.
Joe Genova is an owner and vice president of Poly Print.