Circularity in Unilin’s DNA: our approach through the R-strategies

To situate our progress, we make use of the the R-strategies. Institutions such as the European Commission apply this model with different levels to work towards a circular economy. The essence? Avoiding waste and loss as much as possible, maximising the value of products and minimising the negative impact on people and the environment. Below is an overview of the R-strategies we take into account:

Refuse
Rethink
Reduce
Reuse
Repair
Refurbish
Remanufacture & repurpose
Recycle
Recover energy

For us the different R-strategies of circularity go hand in hand. We always consider them in relation to each other, with attention to the order in which they can be applied. We start as high up the value chain as possible: first we examine whether refuse is feasible, and only then do we look at options such as repair or other steps further along. This ensures maximum value preservation in every project we carry out. At Unilin we have been highly advanced in recycling and recover energy for many years, but we have also taken steps with several of our products and services in the other levels.

Refuse

Refuse is about no longer using certain products by making their function redundant. For example, laminate, parquet and LVT vinyl floors used to be glued or nailed into the subfloor to create a strong, stable surface. Our patented click system changed all that: by completely rethinking the tongue and groove joint between the planks we no longer need any glue during installation and the planks can simply be laid loose on the subfloor. This achieves two goals at once: glue is no longer necessary and after use the planks can easily be taken apart, reused or recycled without contamination.

Rethink

Rethink is about redesigning products so they can be used more intensively or for longer. Thanks to mechanical fastening of roof insulation, these can be removed smoothly after use and reused elsewhere. The same is true for the glue-free installation with, among others, click systems in our floors. We also developed an innovative installation method for carpet tiles using Velcro instead of glue, making them easier to reuse and replace. As a result, products last longer, which significantly reduces the need for new raw materials.

Reduce

Reduce stands for curbing material and energy consumption in production or during use. Our production processes focus strongly on material and energy efficiency. For example, a large portion of our production waste is recycled internally. As for our R&D teams, they develop floors that are just as durable but require fewer raw materials. We have already reduced the use of fossil-based raw materials in our vinyl floors and are exploring thinner laminate floors, without compromising on quality. For our insulation boards we are working on reduced material use by boosting their performance, and in our panels we minimise glue use as much as possible by optimising composition and production processes.

Reuse

While reuse is often challenging for our types of products, it is certainly not impossible. In Australia, Godfrey Hirst runs the Loop programme, in which carpet tiles are collected, assessed and reused, even if they come from other manufacturers. For other flooring types, reuse can be more complex due to the wide variety of colours and dimensions. Our choice for timeless designs, standard formats and installation techniques without glue does make it possible to reuse them in the future.

Repair

Our products are designed for a long lifespan. Our hard floors are scratch- and water-resistant, reducing the need for repairs. Still, we provide repair solutions, such as repair kits for small damage to panels or floors. In case of more serious damage, individual planks or carpet tiles can easily be replaced, as they are not glued to the subfloor.

Refurbish

Refurbish is about restoring or upgrading old products so they can be given a second life. Our oiled parquet floors, for instance, can be sanded down at home to give them a new life. We are also exploring the possibility of setting up a system to have our parquet floors sanded and refurbished after use and removal, so they can be sold again.

Remanufacture and Repurpose

Remanufacture means reusing parts of an end-of-life product to manufacture a new product with the same function. Think of computer components that can easily be recovered and reused in new computers. Repurpose is similar, but here the question is whether a product or its components can be reused in a new product with a different application. Although these R-strategies are taken into account when making our products more sustainable, we do not currently have any concrete applications. After all, our current products don’t consist of separate, assembled parts that can easily be taken apart for reuse. That is why we often move on to the next R-strategy instead: recycle.

Recycle

Recycle focuses on recovering materials from products that are no longer usable in their current form. These raw materials are then reused as the basis for new products. Recycle is a very important R-strategy for Unilin. It allows us to make the most of the available raw materials while producing our products in a cost-efficient manner.

Wood is our main raw material and is naturally renewable. Moreover, more than 95 percent of the wood in our chipboards comes from recycling. Unilin is the largest wood recycler in Belgium. Every year we process up to 900,000 tonnes of wood waste – sourced from recycling parks, construction companies and the like – into high-quality chipboard.

In addition, we also take the lead by collecting chipboard offcuts from our customers, MDF, PIR and vinyl under the Unilin Recover banner. In 2024 this approach allowed us to recover more than 20,000 tonnes of material. On top of this, we also opened the world’s largest MDF recycling line in France. Last year Unilin Insulation launched the Rezillo construction boards, which are based on mechanically recycled PIR boards. This year they delivered another milestone: the world’s first installation capable of chemically recycling PIR insulation boards into new PIR boards.

Recover energy

Recover energy focuses on recovering energy from materials that can no longer be reused. When products or raw materials have reached the end of their life cycle and are no longer suitable for reuse, recycling or refurbishing, the remaining value can be harnessed through incineration to generate energy. For example, when wood waste can no longer be recycled because it has become too fine to process into our boards, we use it as a renewable energy source. Our green energy plants thus replace a significant amount of fossil fuels: our chipboard and MDF sites cover up to 90 percent of their total energy consumption this way.

Towards a fully circular future

These R-strategies show that circularity is not a buzzword to Unilin, but a strategic direction. With innovative recycling lines, material reduction and sustainable product designs, we work every day to build a sustainable future. Our goal is clear: to keep wood and other materials in the chain for as long as possible, maximise CO₂ storage and at the same time deliver products of the highest quality.

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