Lego abandons project to stop using petroleum-based plastics

Lego has abandoned its most important effort to eliminate petroleum-based plastics from its bricks after discovering that its new material resulted in higher carbon emissions, in a sign of the complex trade-offs companies face in their quest for sustainability.

The world's biggest toymaker announced two years ago that it had tested a prototype brick made from plastic recycled from bottles rather than the petroleum-based ABS currently used in about 80% of the billions of pieces it produces each year.

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However, Niels Christiansen, CEO of Lego, said that using recycled polyethylene terephthalate (RPET) would have caused more carbon emissions throughout the product's useful life, as it would require a lot of new equipment.

For this reason, Lego decided to try to improve the carbon footprint over time of ABS, which currently needs about 2 kg of oil to produce 1 kg of plastic.

“In the early days, the belief was that it was easier to find this magical material or this new material” that would solve the sustainability issue, Christiansen said., but “that doesn’t seem to be there. We tested hundreds and hundreds of materials. It was simply not possible to find material like that.”

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Lego's change of tack highlights the difficult decisions companies face around sustainability, where different goals, such as eliminating the use of fossil fuels and reducing carbon emissions, can conflict.

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