CASE STUDY Staples: Recycled Denim Products A Marc Howard Project
CLIENT PROFILE Staples is the world s largest office products company and second largest Internet retailer. For 30 years, Staples has served the needs of business customers and its vision is to provide every product businesses need to succeed. Through [their] world-class retail, online and delivery capabilities, Staples offers office supplies, technology products and services, facilities and breakroom supplies, furniture, copy and print services and a wide range of other product categories. With thousands of associates worldwide dedicated to helping customers make more happen, Staples operates throughout North and South America, Europe, Asia, Australia and New Zealand. * OPPORTUNITY Textile waste is a growing global concern, and Staples has a strong interest in reducing the impact of their business through the development, use, and sale of more sustainable products. As textile fiber has been used in paper making for centuries, and many types of paper products are part of business operations today, using textile waste to create quality paper products was identified as an opportunity for sustainable product development at Staples. The project began with producing corrugated boxes made from 50% recycled paper and 50% recycled denim fiber. The indigo dye in the denim gave them an easily recognizable blue color, the boxes were stronger than conventional cardboard, and they received exceptional customer feedback. Because of this success, Staples set up a website to tell the story behind the sustainable box and expanded the project to include office products and corporate promotional items. RESULTS Staples was able to develop new sustainable products by working with a textile industry veteran whose expertise covers product development and production through zero waste to landfill solutions. This partnership allowed Staples to create quality sustainable products that are stronger than paper, work within their existing supply chain to produce them, and positively impact the environment. Calculations of waste diverted from landfill and total impact is available on any and all projects. SOLUTION Circular products expert Marc Howard was brought in to test the concept, develop the product, and implement the program. He spec d the project requirements, sourced the materials, and worked with Staples existing vendors and finished product converters to run trials and produce the new product within the established supply chain. * Company details from Staples.com LOOKING AHEAD A thorough understanding of the potential opportunities, inherent properties, and highest use value of waste streams is critical to successfully creating products using recycled textile. As the soft goods industry looks to close the loop, this type of textile-specific expertise will reduce the learning curve and greatly increase the success of any initiative. Interested in collaborating? Get in touch!
Blue Jean Boxes, used for shipping and as a promotional piece
Blue Jean Box, featured on Staples website
ADDITIONAL PRODUCT DEVELOPMENT Marc managed this project from start to finish, including being on-site for production testing of new products. Below are images from a trial run of file folders. Short denim fibers baled and ready for production into new products Denim is combined with recycled paper to create a pulp No additional dyes added, pulp is colored by indigo in denim fiber Calendaring makes the paper smooth and uniform
Rolled goods are ready to be slit for production Cutting a narrow roll into folders Folding and finishing Ready for shipment
Finished product: File folders
Fast Company article online and in print
WHO IS REVOLVE WASTE? REvolve is a collaborative consultancy that specializes in bringing together stakeholders to solve complex systems challenges. We connect brands, recycling technologies, waste streams, and non-profits to close the loop on textiles. Our team of experts provides consulting and research services, educates, standardizes and sources feedstocks, and plans and executes pilot projects. Our goal is to close the gaps slowing the development of better textiles and increase the positive human capital in the textile supply chain. REvolve s broad range of skills, depth of experience, and commitment to excellence make us a strong partner. We re geeks who love what we do... and it shows. Let s make the future better. Together.