Glass recycling: a comprehensive guide to sustainable waste management

Glass recycling: a comprehensive guide to sustainable waste management

Glass recycling: a comprehensive guide to sustainable waste management
No matter how many times glass is recycled, it retains 100% of its original properties. In fact, the recycling process for this material can be described as a “perfect circle”—an ideal example of circular economy and sustainability.

Why do we invite you to learn more about it? Because from the collection of glass bottles, jars, and any other objects made of glass to their transformation into new products, understanding the glass recycling chain is essential to raising awareness about how we can all take part in the process and help protect the environment.

MMR estimates that the global glass recycling capacity in 2022 was around 27 million tons, representing only 21% of the total glass produced. The same percentage was recorded in 2023, according to Statista. In Spain, the estimated glass recycling rate reached 70.1% that year—almost one million tons—over 90% of which was collected through the green container, according to Ecovidrio.

Within the EU-27, the average recycling rate that year was 76%, according to Eurostat. Denmark led the way with a 98% recycling rate, followed by Sweden, Belgium, Luxembourg, Austria, and Germany, all exceeding 90%. Meanwhile, in the United Kingdom, approximately 76.5% of all used glass was recycled. Unfortunately, in the United States, even the states with the highest recycling rates only reached around 65%.

What is glass recycling?
Before glass can enjoy as many new life cycles as we choose to give it, it must go through a series of stages:

Disposal in Containers. Residents and the hospitality industry contribute to glass recycling by placing jars and bottles in the appropriate recycling bins. For example, in Spain, these are the green containers.
Selective Collection. Trucks collect the glass from the containers and transport it to the cleaning and processing plant. There, the glass is sorted on different conveyor belts, separating it from ceramics and porcelain, which, like light bulbs, drinking glasses, wine glasses, mirrors, and crystal, cannot be recycled. The plant also removes lids, caps, metal, and plastic residues, as well as dirt and impurities. It is important to note that heat-resistant glass, such as oven glass and Pyrex, is also non-recyclable.
Crushing. At the processing plant, the glass passes through a series of screens and hammers, where it is crushed to the desired size. This crushing process does not require the use of water.
Removal of Residues and Production of Raw Material. The crushed glass is processed through machines equipped with optical readers—such as the ECOGLASS optical sorter, produced by PICVISA—which identify and remove any opaque residues from other materials. The processed, crushed, or imploded glass, ready for remelting, is known as cullet, a granular material obtained from crushed bottles and jars. Glass container manufacturers typically mix cullet with sand, limestone, soda ash, and other additives for color or special treatments. The molten glass obtained from the cullet is then used to produce new bottles and jars.
Benefits of glass recycling
Thanks to recycled glass, the extraction of raw materials is reduced, bringing immense benefits. By using cullet in the production of new containers, we prevent the release of large amounts of CO₂ emissions associated with the extraction and transportation of natural raw materials. Additionally, it reduces energy consumption during the process, as well as CO₂ emissions, since recycled glass melts at a lower temperature than the one required to manufacture glass from natural raw materials in glass furnaces. Moreover, the reduction in raw material extraction minimizes transportation needs.

The infrastructure for glass collection and separation varies by country. In some places, it may be limited, especially when there are not enough resources to manage contamination with other materials and dirt, which complicates the recycling process. Additionally, transporting recycled glass can be expensive due to its weight and volume. Another major challenge is the lack of public awareness regarding the importance of glass recycling—education and training are crucial but often insufficient. Ultimately, encouraging people to recycle properly is both a logistical and cultural challenge. If we look at the market, another difficulty can be the low demand for recycled glass, which may be limited in some regions.

Let’s not forget that recycled glass is used to manufacture many products. In addition to new containers with the same characteristics as the originals, it can be used to produce:

Aesthetic tiles and mosaics for construction and decoration
Durable countertops and bar tops
Reflective road signage
Fiberglass insulation for the automotive and construction industries
Glass foam or wool for thermal and acoustic insulation
Water filters, such as those used for keeping swimming pools clean
Granulated glass, which, when blasted under pressure, is used for cleaning surfaces like ship hulls
Let’s look at an example: With its innovative technology, PICVISA has collaborated with Zamakona Yards Canarias in launching Ecogrit Glass, a glass recovery and reuse plant for the naval and industrial sectors. This facility repurposes glass waste from the Canary Islands to create metal-free, non-toxic, and chemically inert abrasives, which are used for ship cleaning and sandblasting at Zamakona Yards’ shipyard.

Recycled glass can also be used to produce flat glass, which is widely used in construction, the automotive industry, and architecture. Its properties allow for the manufacturing of different types of glass, including lacquered, tempered, laminated, and bulletproof glass. Due to its transparency and resistance to temperature changes, it is an ideal material for outdoor applications.

Cutting-edge technology for more efficient recycling
When it comes to recycling glass waste, the ECOGLASS optical sorter, produced by PICVISA, stands out for its innovative technology, which enables more efficient glass waste management. In addition to sorting glass by color, ECOGLASS facilitates the removal of contaminants such as porcelain or clay, which are often mistakenly disposed of in the green glass recycling container.

Furthermore, PICVISA’s ECOGLASS systems are now equipped with Artificial Intelligence (AI), enhancing the detection of impurities, colors, and different types of glass with greater precision. This maximizes the recovery of valuable materials and improves the sustainability of the recycling process.

Key AI benefits in ECOGLASS:
Enhanced detection of dark glass: AI improves the ability to differentiate dark-colored glass, which has traditionally been more difficult to classify. This reduces the loss of recyclable material and increases the amount of high-quality recovered glass.
Identification of contaminants by shape: AI-powered computer vision technology not only distinguishes materials by color but also by morphology. This allows for more efficient separation of unwanted elements such as ceramics, plastics, and metals, preventing their presence in the recycled glass stream.
Higher precision in material separation: Advanced algorithms improve the system’s ability to differentiate various types of glass, ensuring higher purity in sorted materials and optimizing reuse potential.
Reduction of non-recyclable waste: By minimizing the presence of contaminants in recovered glass, the amount of unusable waste is significantly reduced, contributing to more efficient and sustainable resource management.
Operational optimization: The implementation of AI reduces manual intervention, decreases equipment wear and tear, lowers maintenance costs, and increases productivity in recycling plants.
Continuous learning: Thanks to machine learning capabilities, ECOGLASS systems continuously improve their performance over time, adapting to new waste compositions and optimizing efficiency.
Better detection of labeled glass: AI enhances the ability to accurately identify glass containers that still have labels attached, ensuring proper classification and improving the quality of the recycled material.
With efficient tools like ECOGLASS, PICVISA is driving the demand for recycled glass, helping to increase recycling rates. Companies like Mallorca-based TM ALCUDIA RECICLATGES have partnered with us to expand and modernize their glass recycling plant, incorporating three large-format, next-generation ECOGLASS systems.

Let’s keep this in mind! Something as simple as placing glass containers in the correct bin helps reduce air, water, and soil pollution, prevents ecosystem degradation, and lowers greenhouse gas emissions that contribute to climate change.

Glass recycling is not just a trend—it’s a necessity. Let’s remember that with a single, simple action, we can protect not only our health but also the beauty of our planet.