Not every type of plastic can be recycled. Especially in regions with limited waste management infrastructure, non-recyclable plastic waste poses a major challenge. It often ends up in rivers, on illegal dumpsites, or is burned under harmful conditions. One way to manage this waste more responsibly is through co-processing. In this approach, non-recyclable plastic waste is used in the cement industry as an alternative fuel and raw material, replacing fossil resources.
The Challenge: Non-Recyclable Plastic Waste in Southeast Asia
In many Southeast Asian countries, valuable and recyclable materials are collected by local waste pickers and sold to recycling companies. Non-recyclable plastics, however, often have little or no economic value. As a result, they frequently end up in the environment, polluting waterways and landscapes, or are disposed of through open burning.
At everwave's cleanup sites, a significant share of collected waste is classified as non-recyclable plastic. To prevent these materials from re-entering the environment, everwave uses co-processing as a complement to conventional recycling.
What Is Co-Processing?
Co-processing is a waste recovery method in which suitable waste materials are used within industrial production processes.
In the cement industry, certain non-recyclable plastics can be used as a substitute for fossil fuels and, in some cases, as a raw material component.
Before further treatment, collected waste is sorted and prepared at everwave's Zero-Waste Centers. Recyclable materials are sent to recycling facilities, while non-recyclable plastics that cannot be effectively recycled are prepared for co-processing.
The goal is to treat waste as a resource while reducing the consumption of fossil fuels.
Co-Processing in Cement Production
Cement manufacturing is one of the most energy-intensive industrial processes in the world. Producing cement clinker requires temperatures of up to 1,450°C. Traditionally, these temperatures are achieved using fossil fuels such as coal, natural gas, or oil.
Through co-processing, non-recyclable plastic waste can partially replace these fossil energy sources. The plastic serves as an alternative fuel, providing the energy required for clinker production.
The process begins with the preparation of raw materials such as limestone and clay, which are processed into a fine raw meal. This material is then heated in a rotary kiln at extremely high temperatures. During this stage, prepared plastic waste is used as an alternative fuel source.
The resulting clinker is subsequently cooled, ground, and processed into cement.
Benefits of Co-Processing for Waste Management and Circular Economy Solutions
One of the key advantages of co-processing is the near-complete utilization of the material.
Due to the extremely high temperatures in cement kilns, plastic components are thermally broken down. Unlike conventional waste incineration, co-processing generates very little residual ash that requires further disposal.
The mineral content contained in the waste becomes incorporated into the cement clinker and remains part of the final product.
As a result, co-processing can:
Reduce the amount of non-recyclable waste requiring disposal
Decrease reliance on fossil fuels
Improve waste management practices
Support more resource-efficient production processes
For these reasons, co-processing can contribute to sustainability goals and strengthen circular economy approaches.
Why Co-Processing and Recycling Go Hand in Hand
Co-processing is not a replacement for recycling. The highest priority should always be to avoid plastic waste and recycle materials wherever possible.
However, non-recyclable plastics remain a significant challenge in many parts of the world. For these waste streams, co-processing currently provides a practical solution that helps prevent environmental pollution while making use of materials that would otherwise be discarded.
At everwave, co-processing is therefore viewed as a complement to recycling. Combined with stronger local waste management infrastructure and increasing recycling rates, it can help keep plastic waste out of the environment and support more sustainable waste management systems.
Conclusion: Co-Processing as a Solution for Non-Recyclable Plastics
Co-processing offers a responsible way to recover value from non-recyclable plastic waste while helping to prevent environmental pollution. By replacing fossil fuels in cement production and utilizing materials that would otherwise be discarded, it contributes to more efficient resource use.
As part of a broader strategy that includes waste prevention, recycling, and improved waste management infrastructure, co-processing can play an important role in advancing sustainability and supporting a functioning circular economy.