Regardless of your beliefs about the afterlife, this case study might offer a new perspective. At Cyrkl, we believe in giving materials a second life, especially challenging ones. That’s why we’re excited to share insights from our work with waste from the tobacco industry.

The Scale of the Problem

On average, 10 million cigarettes are sold every minute, with each cigarette having a short lifespan of about six minutes. Unfortunately, more than 50% of cigarette butts are not properly disposed of, leading to significant littering and environmental pollution.

Globally, it is estimated that 340–680 million kilograms of cigarette waste are discarded annually. This figure excludes nearly two million tonnes of packaging materials such as paper, ink, cellophane, foil, and glue used in tobacco product packaging.

Addressing Waste from Cigarette Production

Cigarette production involves multiple stages, from tobacco treatment to filter production and packaging. During the filter production process, cellulose acetate is treated with a plasticizer to enhance mechanical performance. However, filters that are deemed faulty due to improper length or other defects create a unique waste stream of clean cigarette filter elements.

Currently, in countries like Poland and the Czech Republic, this waste is predominantly incinerated with energy recovery. However, its low caloric value means it is often used as an additive to more caloric wastes. This method falls short of the waste hierarchy's higher recovery options.

Tackling Post-Consumer Waste

Cigarette butts remain one of the most common types of waste collected during clean-ups, especially on beaches. They account for over 40% of items removed from public spaces like parks and beaches.

A Slovakian company, EcoButt, has developed an innovative solution by turning cigarette butts into an additive for asphalt. While post-consumer waste is a major challenge, the potential for innovative uses continues to grow.

Finding Solutions for Post-Production Waste

At Cyrkl, we’ve worked with two companies generating post-production waste, including one of the largest tobacco product manufacturers. Observing the production process and the clean nature of filter waste inspired us to explore better recovery options.

Motivated by the cleanliness and potential of this waste stream, we facilitated connections between the waste producers and companies willing to test this material for recycling. Thanks to these efforts, the material is now being tested in two countries for use in the building sector, demonstrating its potential to be much more than waste.

A Step Toward Circularity

By transforming post-production cigarette filter waste into valuable materials, we’re helping businesses adopt sustainable practices and align with circular economy principles.

At Cyrkl, we remain committed to discovering innovative solutions that redefine waste as a resource. If your business is looking to unlock the potential of its waste streams, contact our experts today and join us in creating a more sustainable future.