Revolutionizing the Recycling Industry

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Customer

The customer is pivotal for the purchases of items such as plastic bottles (PET), rigid plastic food packaging (PP), plastic bags and film (LPDE), home cleaning/beauty bottles (HDPE), clear plastic containers (PET), and aluminum.

CRU3

The Community Recycling Unit is a free, self-service drop-off container for your recyclables, available at select retailer locations. Help us reduce waste, recycle more and reuse materials.

Material Collection

We specialize in the collection of thermoforms and various recyclable materials from multiple Material Recovery Facilities plus have developed additional Consumer Direct collection programs, operating seamlessly on a domestic scale to divert waste headed to landfills and recycle more PET.

Sortation

We carefully sort materials using state-of-the-art optical technology. This ensures that each item is accurately placed into its proper category, making the sorting process reliable and efficient.

Bales

Once we've consolidated all the materials together, we compress them into neat bales. This not only streamlines storage but also makes it a breeze to identify different material types.

Clean/Wash

As we process materials, we'll wash, clean and further separate materials to remove contaminants. This cleansing process ensures that the materials are fully sanitized and ready to be broken down.

The LSP Reactor

The LSP Reactor breaks down plastic waste (PCR) and converts it into monomers, which can then be used to produce pellets to a near virgin state.

Bottle and Thermoform TCWF (Thermoform Clean Wash Flake)

Our extrusion process involves feeding TCWF into an extruder, where we specialize in creating tailored blends to meet our customers' needs, including the option to manipulate PCR blends up to 100% upon request.

Extruder

Inside the extruder, the flake is heated and melted, then forced through a die-a specialized tool that shapes the molten plastic into a continuous sheet. This sheet is then cooled and solidified, resulting in plastic sheet roll stock.

Thermoformer

The plastic thermoforming machine processes roll stock by loading it into the oven, shaping it in molds, cutting, punching, and stacking the formed products, while any excess material is recycled through an industrial grinder for re- extrusion into new roll stock. This ensures that no waste will go to landfill and will be added back to into our circular economy.

Private Branded Packaging

Once the packaging is formed and stacked, we meticulously pack it into gaylords or cases, preparing it for shipping. Our product undergoes rigorous quality checks, ensuring its perfection for customers. Additionally, we have an advanced tracking system in place, allowing us to locate the product at all times, providing peace of mind to both us and our clients. We utilize PCR (Post Consumer Recycled) content within our packaging meeting the needs of our Sustainability goals and supporting a circular economy.

Customer & Private Brands Suppliers

At our core, we prioritize collaboration with our clients, designing packaging tailored to their exact specifications. Our commitment to their needs is unwavering, reflected in our strategic positioning for efficient logistics. This ensures that we're always poised to deliver exceptional and efficient service and meet our clients' requirements with precision and agility.

Retailer

Retailers stock their shelves with products supplied by our clients. Our focus on sustainability means that all our products have a maximum chance of avoiding landfills and being recycled instead.

Customer

The customer is pivotal for the purchases of items such as plastic bottles (PET), rigid plastic food packaging (PP), plastic bags and film (LPDE), home cleaning/ beauty bottles (HDPE), clear plastic containers (PET), and aluminum. After the customer uses the packaging, they will bring the materials to the Community Recycling Unit for drop off, helping us work towards zero waste.

Our Approach

A shared vision for the future

As we move towards a more sustainable future, every action counts. The choices we make today have a lasting impact on our environment and communities. At D6, we believe that creating a circular economy starts with a clear purpose. That’s why we design, manufacture, and recycle with intent, transforming the way we think and act to ensure a better tomorrow for everyone.

Innovate

Alongside Walmart and Sam’sClub, D6 is working to create aunique direct-from-consumer recycling model via its Community Recycling Units(CRU) to expand the loop to recycling deserts where traditional “blue bin” programs are not viable.

Invest

D6 has allocated significant resources to its recycling, wash line, extrusion, and conversion operations to provide an auditable, closed-loop from raw materials to shelf, to post-consumer, and ultimately back to shelf – a process that is repeatable indefinitely.

Inspire

D6 has allocated significant resources to its recycling, wash line, extrusion, and conversion operations to provide an auditable, closed-loop from raw materials to shelf, to post-consumer, and ultimately back to shelf – a process that is repeatable indefinitely.

Alongside Walmart and Sam’sClub, D6 is working to create aunique direct-from-consumer recycling model via its Community Recycling Units(CRU) to expand the loop to recycling deserts where traditional “blue bin” programs are not viable.

D6 has allocated significant resources to its recycling, wash line, extrusion, and conversion operations to provide an auditable, closed-loop from raw materials to shelf, to post-consumer, and ultimately back to shelf – a process that is repeatable indefinitely.

Awareness is one of the most significant obstacles to a flourishing recycling ecosystem. We take a
grassroots approach, engaging with communities to demonstrate CRU best practices and the impact recycling has at the local and global levels.

Innovative

Alongside Walmart and Sam’s Club, D6 is working to create a unique direct-from-consumer recycling model via its Community Recycling Units (CRU) to expand the loop to recycling deserts where traditional “blue bin” programs are not viable.

Invest

D6 has allocated significant resources to its recycling, wash line, extrusion, and conversion operations to provide an auditable, closed-loop from raw materials to shelf, to post-consumer, and ultimately back to shelf – a process that is repeatable indefinitely.

Inspire

D6 has allocated significant resources to its recycling, wash line, extrusion, and conversion operations to provide an auditable, closed-loop from raw materials to shelf, to post-consumer, and ultimately back to shelf – a process that is repeatable indefinitely.

There are many facets to being vertically integrated, and we've carefully taken each step to ensure complete control over our entire process.

From bale to shelf, we maintain full chain of custody to guarantee transparency and sustainability at every stage.

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Unmatched Turnaround Time

In-house Engineering & Prototyping

Our in-house Engineering and Prototyping departments work efficiently and flexibly to bring your product to life. As the fastest design-to-shelf packaging manufacturer in the world, we've streamlined our processes to create the leanest, most rapid manufacturing ecosystem possible. From the initial concept to production and distribution, every step is optimized for speed.

Efficiency and precision

Advanced Equipments & Cutting-Edge Lab

Our dedicated facility, equipped with advanced 3D printers and handcrafted custom samples, powers our Rapid Prototyping service. This service is engineered to be the world's fastest design-to-prototype solution, with our cutting-edge lab consistently producing millions of prototypes to ensure the quickest transition from design to prototype in the industry.

Industrial Recycling Responsibility

Responsible Manufacturing

Our state-of-the-art plastic thermoforming machines process roll stock with precision, shaping it in molds, cutting, punching, and stacking the formed products. Excess material is recycled through an industrial grinder and re-extruded into new roll stock, aiming for zero waste sent to landfills and contributing to a sustainable circular economy.

Environmentally Focused Manufacturing

Reduced Greenhouse Gas Emissions

By incorporating recycled aluminum in our packaging, our foil department significantly reduces greenhouse gas emissions compared to production using virgin ore. This material stream seamlessly integrates into our closed-loop economy, as aluminum is infinitely recyclable and retains its properties indefinitely.

MachineMachineTrash binsFactory
Machine
Unmatched Turnaround Time

Responsible Manufacturing

Our state-of-the-art plastic thermoforming machines process roll stock with precision, shaping it in molds, cutting, punching, and stacking the formed products. Excess material is recycled through an industrial grinder and re-extruded into new roll stock, aiming for zero waste sent to landfills and contributing to a sustainable circular economy.

Machine
Efficiency and precision

Advanced Equipments & Cutting-Edge Lab

Our dedicated facility, equipped with advanced 3D printers and handcrafted custom samples, powers our Rapid Prototyping service. This service is engineered to be the world's fastest design-to-prototype solution, with our cutting-edge lab consistently producing millions of prototypes to ensure the quickest transition from design to prototype in the industry.

Trash bins
Industrial Recycling Responsibility

Zero Waste Prototyping and Manufacturing

Our state-of-the-art plastic thermoforming machines process roll stock with precision, shaping it in molds, cutting, punching, and stacking the formed products. Excess material is recycled through an industrial grinder and re-extruded into new roll stock, ensuring zero waste is sent to landfills and contributing to a sustainable circular economy.

Factory
Environmentally Focused Manufacturing

Reduced Greenhouse Gas Emissions

By incorporating recycled aluminum in our packaging, our foil department significantly reduces greenhouse gas emissions compared to production using virgin ore. This material stream seamlessly integrates into our closed-loop economy, as aluminum is infinitely recyclable and retains its properties indefinitely.

Custom Tailored Blends up to 100% PCR
traytray dark

Innovative

Packaging

Solutions

Gravity Tray Packaging
Gravity Tray Packaging
Gravity Tray Packaging

At D6, we have perfected our packaging presentation by utilizing Post Consumer Resin (PCR). Our innovative packaging solutions provide numerous efficiencies, including full perimeter locking, increased container facings, streamlined case packs, and reduced waste through the use of thinner plastics. Each package is custom designed for our clients, ensuring a cohesive design across the entire set.

Among our innovative products are the Gravity Tray (Purge Trapping Tray), Peel and Reseal Film, and more. These offerings exemplify our commitment to cutting-edge packaging technology and sustainability.

Learn More
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North America Network

Recyclables sorted, washed, and then ground. Ground materials then extruded into new PCR plastic sheet.

Canada

Recyclables sorted,
washed, and then ground. Ground materials then extruded into new PCR plastic sheet.

Global Network

Recyclables sorted, washed, and then ground. Ground materials then extruded into new PCR plastic sheet.

WalmartSam's ClubNew Seasons
Walmart
Walmart

In an effort to reduce waste and promote recycling, Walmart introduced Community Recycling Units (CRUs) at select Walmartand Sam’s Club locations. These free, self-service drop-off containers are designed to help customers recycle six different waste streams, including aluminum, plastic containers, plastic bags, rigid food packaging, and bottles.

The Four-Step Recycling Process

D6 is a key partner in Walmart’s CRU initiative, overseeing the four-step process for recycling materials:

1
Drop-Off: Walmart CRUs allow customers to drop off eligible materials at designated locations. The units accept various types of packaging from any brand, ensuring accessibility and convenience.
2
Collection Pick-Up: Once collected, D6 sorts the materials to removeany contaminants, ensuring that only eligible and recyclable items proceed to the next stage. Contaminated materials or items not suitable for recycling are filtered out to maintain the integrity of the recycling stream.
3
Sort and Processing: D6 processes the clean, sorted materials, focusing on recycling as much of the waste as possible.
4
Materials Recycled or Reused: The processed materials are reintegrated into the manufacturing supply chain, helping to reduce the need for virgin materials.
Impact

Through this partnership, D6 and Walmart demonstrate their shared commitment to sustainability. CRUs make recycling accessible to a wider audience, while D6’s expertise ensures that as many materials as possible are properly processed and reintroduced into the supply chain. This collaboration highlights the importance of community involvement, corporate responsibility, and innovative recycling solutions in addressing the global challenge of waste management.

CRU Locations
Sam's Club
Sam’s club

In partnership with D6, Sam's Club launched Community Recycling Units (CRUs) at select Sam's Club and Walmart locations to promote recycling and reduce waste. These free, self-service units offer a convenient drop-off solution for members to recycle various materials, including aluminum, plastic containers, plastic bags, rigid food packaging, and bottles. The initiative aims to make recycling more accessible and sustainable by providing a simple way for the community to contribute to environmental conservation efforts.

The Four-Step Recycling Process

D6 plays a vital role in the CRU initiative, ensuring that the recycling process is efficient and effective through a well-defined four-step system:

1
Drop off: Sam's Club CRUs allow members to drop off a variety of recyclable materials at designated locations. These units accept packaging from all brands, regardless of where the items were purchased, providing convenience and accessibility.
2
Collection Pick-Up: After the drop-off, D6 collects and sorts the materials, meticulously separating recyclable materials from contaminants. This step ensures that only eligible materials move forward in the recycling process, maintaining the quality of the recycled output.
3
Sort and Processing: D6 processes the sorted, clean materials, focusing on maximizing recycling rates and converting as much waste as possible into reusable materials. This step is crucial to reducing environmental impact and supporting the circular economy.
4
Materials Recycled or Reused: The recycled materials are reintegrated into the manufacturing supply chain, reducing the need for virgin materials. By reintroducing these materials, D6 and Sam’s Club work together to minimize resource extraction and waste, supporting sustainable production cycles.
Impact

The collaboration between D6 and Sam's Club exemplifies their mutual commitment to sustainability. By providing members with an easy-to-access recycling option and ensuring that materials are processed efficiently, they encourage community participation in waste reduction.

CRU Locations
New Seasons
New Season’s Program

“When looking to improve the environmental performance of our packaging, our approach is holistic. We worked with our vendors to create lightweight packaging that incorporates 100 percent post-consumer recycled content, while simultaneously developing partnerships that allow the materials to be recycled back into the packaging system. With each product, we also prioritize food preservation to avoid any unintended consequences of food waste that often result from packaging changes. We’re thrilled that our customers can be a part of this circular packaging solution, bringing #1 PET containers back to our stores and knowing they’re part of a larger solution to reduce waste.”

Athena Petty

Senior Manager Of Sustainability | New Seasons.
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How It Works
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Customer
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in store drop-Off
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PET bales
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Clean PET
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Clean Flake PET
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Extrude New PET
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Manufacture
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PET Packaging
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Deliver
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Available in store
Recycling
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Working towards being carbon negative by 2030+

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