Interview with 99recycle: How recycled plastic and recycled materials are used in eco-design and industrial design in Russia

Ahead of Industrial Design Day, we discussed key aspects of working with recycled materials with Alexander Semenov, co-founder of the sustainable development bureau 99recycle. He shared his views on the importance of environmental awareness in design and how a sustainable approach influences current trends in this field. Alexander emphasized that using recycled materials not only reduces the burden on the environment, but also opens up new opportunities for creativity and innovation in design.

In this interview, you will learn about:

what are the challenges a company faces when working with recycled materials;
who are the bureau's main clients;
where do they get materials for recycling in Russia;
how has the company changed over three years;
how many people are needed to produce 7,500 eco-bags.

Alexander Semenov is a co-founder of the sustainable development bureau 99recycle. This enterprise specializes in the production of souvenirs, clothing, and furniture using recycled materials. The main goal of 99recycle is to implement the principles of sustainable development and care for the environment through the use of secondary resources. The projects implemented by the bureau are aimed at reducing waste and popularizing environmentally friendly solutions in everyday life.

About the launch of the 99recycle project

Our project has been in existence for almost four years. It all started in the summer of 2018, when my friends from school, Anton Rykachevsky and Seryozha Ibragimov, decided to try recycling. We were inspired by the Dutch project Precious Plastic, which became an important benchmark for us. Our goal is not only to reduce waste but also to raise public awareness of the importance of recycling and sustainable consumption. We strive to create a community of like-minded individuals who drive change in the field of ecology and recycling.

Dave Hakkens, co-founder of the Precious Plastic project, has developed equipment that mimics industrial plastic recycling systems. The basic idea is that these machines can be installed even in a typical garage. Hakkens created detailed plans and organized an international community where anyone can visit the Precious Plastic website, download the necessary plans, and assemble a system from readily available materials for recycling plastic waste. When Anton and Seryozha decided to implement the ideas of this project, I immediately joined them.

Shopping bag made from recycled bags Photo: 99recycle

My personal story began with sorting garbage and delivering it to collection points where PET containers were located. Waste sorting activists were concerned about whether a forklift that collects two different fractions and dumps them into a single container would actually recycle them properly. My friends and I also had doubts, so we decided to try recycling our own waste. This experience became an important step for us in understanding the importance of waste sorting and recycling.

I originally studied physics, while my two colleagues were programmers. We had no experience in industrial design. Six months after launching the project, we began expanding our team, and now we include industrial designers, technologists, and creative specialists. This has allowed us to significantly improve the quality of the product and expand its functionality.

We started with the simple idea of recycling waste. However, after assembling the system, we realized we could go further and create something new from recycled materials.

While developing the systems according to Precious Plastic's designs, we encountered difficulties in implementing the stated assembly format from available materials. One of the main challenges was the lack of motors with the required specifications, which forced us to create our own designs. Initially, we adapted existing designs, but a year later, we began developing equipment that was unique to the Precious Plastic project. This included the creation of large-scale 3D printers and large-scale heat presses, significantly expanding our plastic recycling capabilities. Six months after the project began, we launched our first production line and began producing products. We were invited to the "Sign of Equality" festival in St. Petersburg, where we decided to showcase our bags and jewelry for sale. This experience proved successful and allowed us to gauge interest in our products. Our first production line consisted of two units. The first unit was a crusher designed for plastic recycling, capable of effectively crushing plastic waste. The second unit was an extruder, which receives the resulting plastic chips. It extrudes the recycled material, which can be used for pouring into molds or winding onto other surfaces. With this technology, we recycle plastic and promote the creation of secondary materials, which has a positive impact on the environment.

After a successful attempt at selling souvenirs at the festival, we realized that we wanted to develop our own business. This inspired us to actively develop the various areas of our project.

Features of Working in an Eco-Environment

Our company operates in various areas, which is a key feature of our business. We manufacture our own equipment used in our work. Previously, we offered custom equipment manufacturing services, but have now decided to focus on in-house production. Using our equipment, we manufacture bags and keychains from recycled plastic, as well as furniture for various companies. This allows us to control product quality and ensure environmental sustainability, which is especially important in today's conditions.

Box for the limited collection of adidas Stan Smith Photo: 99recycle

We are actively involved in education in the field of recycling. Traveling around the country, we conduct master classes, give lectures and share knowledge about waste recycling and its process. Environmental education plays a key role in both raising public awareness and promoting our services. At our workshops, anyone can bring their own plastic cap, recycle it into crumbs, and then create a unique badge to take home. This hands-on approach allows participants not only to gain theoretical knowledge about recycling but also to see how it works in practice.

We're not the only ones manufacturing from recycled materials. However, 99recycle stands out from the competition in that our products are made almost entirely from recycled materials, achieving 100% recycling.

In industry, recycled plastic is typically not fully utilized, but combined with virgin material. Experience shows that adding even 20% recycled plastic is considered quite risky. A widely used technology involves mixing recycled plastic with sand to create polymer-sand tiles. This method allows for the efficient use of recycled materials and reduces the negative impact on the environment.

Fabrics made from recycled materials can be 100% recycled, but most are produced in China. Similar production has not yet been established in Russia. The use of recycled fabrics helps reduce the negative impact on the environment, but for this industry to develop in the country, conditions for domestic production must be created.

In addition to deep processing, known as recycling, there is also the practice of upcycling. Unlike recycling, upcycling does not process or remelt materials, but rather gives them a new life as new products. This not only reduces waste but also creates unique and functional items. Upcycling promotes more sustainable consumption and helps conserve natural resources.

Boats and trampolines are made from PVC fabrics, which contain a small amount of plastic, making them difficult to recycle. As a result, such materials cannot be recycled in the traditional sense and can only be used to cut up and create new products from fragments. We use this material to produce bags and backpacks, which not only reduces waste but also creates unique accessories.

Cosmetic bag for Flacon Magazine Photo: 99recycle

Working with recycled materials is associated with certain difficulties, especially at the stage of raw material preparation and processing. For example, PVC scraps arrive in imperfect condition: they may have punctures, abrasions, and are often crumpled in bags. A significant amount of resources is spent on selecting suitable scraps, straightening them, and washing them. Unlike regular fabric, which can be simply purchased, cut, and used immediately, recycled materials require thorough cleaning and inspection for defects before further processing. This significantly increases labor costs and preparation time, which is important to consider when planning recycling processes. Working with hard plastics presents significant challenges. Plastic caps are the easiest to process, as they are not susceptible to heavy contamination and are easy to clean. However, other types of recycled materials often have complex shapes, making them difficult to process outside of industrial scale. Food scraps and improper open storage of raw materials by collectors also negatively impact the quality of the work and the final products. To improve recycling efficiency, it is important to ensure proper storage and cleaning conditions for recyclable materials.

Badges for AvitoPhoto: 99recycle

Determining the pricing of souvenirs can be difficult, especially when it comes to items made from recycled materials. The question often arises as to why products made from recycled resources cost more than similar items made from new materials. It's important to emphasize that the higher price is due to the complex production process, which involves many stages. This includes not only the use of unique recycling technologies but also the significant amount of handcrafting that ensures the individuality of each piece. Understanding these aspects will help buyers appreciate the value of souvenirs created from waste and realize that such items are not only beautiful but also environmentally sustainable.

When choosing interior materials, it's important to consider their limitations. Our plastic sheets, for example, have specific characteristics that surprise many. People are often accustomed to working with plywood: having bought a sheet in the store, they can easily cut it and create the necessary elements. However, polyethylene, which is used to make bottle caps, is highly flexible and requires a special approach. For tabletops and paneling, they must be securely attached to a metal frame. Furthermore, polyethylene does not interact well with other materials, making it virtually unstickable. Thus, we use mechanical connections to ensure the strength and durability of structures.

Virgin plastic is a homogeneous granule with a consistent chemical composition and size. In contrast, recycled plastic is produced by recycling waste, resulting in non-uniform granules. For example, caps with the same markings may not have the same properties, as each manufacturer adds different additives and dyes to the polyethylene. This creates difficulties in assessing the quality of recycled plastic, as its composition can vary. Therefore, the importance of understanding the differences between virgin and recycled plastic becomes clear for the correct selection of materials in production and recycling.

Chair for the Shu Archive store Photo: 99recycle

Recycling and corporate culture

About 50% of the requests we receive are related to the production of souvenirs. Most often, we are contacted by agencies cooperating with large companies. The remaining inquiries relate to interior design solutions. Architects are integrating recycled materials into their projects. We also receive requests from restaurant owners who are aware of our capabilities and are eager to incorporate, for example, recycled plastic countertops into their interiors. We offer environmentally friendly and stylish solutions for various needs, which makes our cooperation profitable and relevant for business.

Letters for an advertising sign Photo: 99recycle

Some companies contact us to train their employees in proper waste sorting. They offer to collect plastic bottle caps, which we use to create tabletops or tables. It's important to these companies that they collect and sort the materials, and that their raw materials are transformed into something useful and functional. We also accept old banners from companies and events and recycle them into bags. In this way, we not only contribute to environmental sustainability but also help businesses implement sustainable development and responsible consumption ideas.

Some people don't place much importance on the origin of materials, but for them, it's important that their merch is environmentally friendly. In such cases, we prefer to use raw materials already in stock, which minimizes waste and reduces our carbon footprint.

Souvenirs made from recycled plastic are becoming a necessity for every company. Using such products not only demonstrates environmental responsibility but also contributes to a positive brand image. In today's market, where consumers are increasingly focused on sustainability and environmental awareness, souvenirs made from recycled materials can be an effective marketing tool. They help attract attention to a company and highlight its values. By investing in souvenirs made from recycled plastic, companies not only support the environment but also create unique, memorable branding solutions.

Some organizations, including government agencies and large corporations, base their marketing strategies on current trends. This is not a negative aspect, as we produce high-quality souvenirs, often made from recycled materials, which is an important step toward sustainability. We also have clients who turn to us because they share our values and approach to ecology.

About Material Sourcing

When working with hard plastic, we actively collaborate with the "Lips of Kindness" project from St. Petersburg. This project installs containers in kindergartens and schools and sorts lids by color. We purchase the sorted lids and use them in our production. When a certain color is missing, we purchase recycled pellets from a manufacturer, which are primarily made from industrial waste. This allows us to effectively use recycled plastic, reducing the negative impact on the environment and promoting sustainable development.

Phone stand Photo: 99recycle

We have partners - "Spasibo" stores, which collect old things in special containers. People can drop off clothing in plastic bags, which are then sorted, and we recycle the bags themselves. We also partner with boat and trampoline manufacturers, purchasing PVC fabric for further use. Our partners at Sew Dept. help us recycle recycled sewing materials. This sewing operation was once part of our project and now operates as an independent business. Our collaboration with partners allows us not only to effectively recycle waste but also to create new products from recycled materials, which contributes to sustainable development and environmental protection.

We can effectively work with a variety of materials, but currently, our most well-established processes are recycling bottle caps, PVC scraps, and plastic bags.

Three Directions and Three Eco-Businesses

Our team started with three people, and by the end of last year, we noticed significant growth. From the very beginning, we had several different visions for business development, which led to the decision to split into three separate projects. Each became a unique brand: 99recycle, Sew Dept, and EBURET studio. Despite the separation, we continue to maintain friendly relations and actively leverage each other's resources to achieve common goals. The sewing workshop, like our other production facilities, was designed for fluctuating workloads, which resulted in periods of downtime due to a lack of orders. At some point, it became clear that to ensure stable operations, we needed to attract external clients. Currently, the sewing production operates under the Sew Dept brand, managed by Olesya Kulik. It continues to implement 99recycle projects and at the same time accepts orders from new clients, which contributes to its development and expansion of capabilities.

Reception desk of the Get Ready Space beauty salon Image: Maria Kataryan / courtesy of 99recycle

EBURET studio is a furniture and interior design studio specializing in We produce furniture using 3D printing from recycled polystyrene. We are confident that going in-house will allow us to optimize our distribution processes and increase the efficiency of order fulfillment. Our goal is to create unique and environmentally friendly interior solutions that meet modern sustainability requirements.

99recycle, the company I lead, continues to create unique products such as merch, furniture, and various interesting items available for purchase in our online store. We strive to offer eco-friendly and original solutions for your home and lifestyle.

From shoppers to global change

In 2019, SIBUR approached our company with a request to manufacture 7,500 bags. At the time, such an order size seemed incredible and unexpected to us. We didn't fully understand the scale of this task and all the nuances associated with its implementation. Now, such orders have become routine for us, and we successfully handle such projects.

Our team was faced with the task of solving several problems simultaneously. First of all, we were pressed for time, and we understood that we might not meet the established timeframe. In response, we launched an active search for assistants through social media. Within a week, we received over 100 responses, from which we selected approximately 50 people. These assistants worked as a team, rotating between each other, and supported us in reviewing and sorting materials. This approach allowed us to optimize the process and significantly speed up the project.

Colors of waist bags for SIBUR Photo: 99recycle

The second problem was the source of raw materials. We had PVC bags and scraps from trampoline production in our warehouse, but the exact quantity of these materials was unknown. After measuring and weighing, we discovered we only had a quarter of the required volume. We took steps to source additional materials, contacting boat and trampoline manufacturers in St. Petersburg and across the country. We were able to find the required amount of raw materials, although many companies initially didn't understand why we were interested in purchasing scraps that would typically be recycled. Thanks to our efforts, these companies learned that such waste could be in demand and that they could be profitable. As a result, one of these companies is now our main supplier.

We successfully completed the project within the established deadlines, which allowed us to develop many effective infrastructure solutions.

Flower Key Tag Photo: 99recycle

Our company's recent project is the office of the department store management company Tsvetnoy. We created a modern space that reflects the style and concept of the department store, ensuring functionality and comfort for employees and customers. The office is designed using the latest design trends, fostering a productive work environment. Our solutions take into account all aspects of the management company's operations, making the office not only aesthetically pleasing but also efficient.

Earlier this year, we were approached by the architectural firm Blockstudio, which developed the design for the entire Tsvetnoy complex, including their office. Designers often approach us in search of custom materials. However, our production is not focused on the production of plastic sheets, so we prefer to implement turnkey projects. This means that we create not only individual elements, such as bar counter panels, but also offer complete solutions, including a complete counter.

Sink counter in the office of the Tsvetnoy department store Photo: 99recycle

This order was an exciting challenge for us. When designing the bathrooms, the designers chose massive sinks, which necessitated the creation of robust brackets made from recycled plastic. We focused on developing engineering solutions, including a structure capable of supporting significant weight, as well as a fastening system to securely connect the sheets to the frame. Our approach to sustainable and functional materials highlights the importance of eco-friendly solutions in contemporary interior design.

Competitors in the market are engaged in similar activities: they create souvenirs, sew bags from recycled materials, or banners. There are also emerging consulting projects that work with companies, training them in sustainable practices in the corporate environment. These initiatives help organizations implement sustainable development principles and minimize their negative impact on the environment.

There is a clear trend of change in the business environment. Many companies today are focusing on environmental sustainability because they recognize the importance of this practice. Sustainability is becoming not only an ethical choice but also a strategic advantage in the market. Companies that embrace environmentally friendly solutions are able to attract a wider audience and enhance their reputation. Thus, the pursuit of sustainable development is becoming an important indicator of changes in the modern economy.