Sofia Martinez
Lego bricks have been made from plastic since 1949, when the company began producing an early version of the now-familiar interlocking bricks. These bricks were originally manufactured from cellulose acetate, but in 1963, Lego switched to using Acrylonitrile Butadiene Styrene (ABS), a thermoplastic consisting of a styrene monomer with the addition of an acrylonitrile monomer and a butadiene monomer. ABS is derived from fossil fuels and accounts for around 80% of Lego's production. Lego has been testing more sustainable alternatives, such as corn-based polylactic acid (PLA) and bricks made from polyhydroxyalkanoate (PHA), but as of 2023, no final replacement has been announced.
| Characteristics | Values |
|---|---|
| Main type of plastic used | Acrylonitrile Butadiene Styrene (ABS) |
| Percentage of Lego production that uses ABS | 80% |
| Other types of plastic used | Polycarbonate, Polyethylene, Polypropylene, Cellulose Acetate (CA) |
| Percentage of plastic toys in Lego's output by 1951 | 50% |
| Year Lego began producing plastic toys | 1947 |
| Year Lego began producing interlocking bricks | 1949 |
| Year Lego switched from CA to ABS | 1963 |
| Year Lego set a deadline to find an eco-friendly alternative to ABS | 2018 |
| Year of Lego's self-imposed deadline to find an eco-friendly alternative to ABS | 2030 |
| Percentage of plastic waste recycled by Lego factories | 99% |
| Types of plastic Lego has tested | PET, corn, algae, wheat |
| Types of sustainable bricks tested by other companies | PHA, Galalith (made from casein, a milk protein) |
| Lego's annual brick production | 36 billion |
| Lego's total brick production over five decades | 400 billion |
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What You'll Learn
Lego plastic is mostly ABS, a fossil fuel derivative
Lego bricks are mostly made from Acrylonitrile Butadiene Styrene (ABS), a type of thermoplastic. The plastic consists of a styrene monomer with the addition of an acrylonitrile monomer and a butadiene monomer. It is the butadiene component, a synthetic rubber used mainly in tires, that is largely responsible for the strength and impact resistance of the plastic. The final form of ABS was developed in the mid-1940s as part of the war effort.
Lego introduced ABS in 1963, switching from cellulose acetate (CA) to the new plastic. ABS provided a more stable, impact-resistant, and colorfast alternative to CA. It could also be easily injection-molded to more exacting tolerances. By 1966 in Europe and 1970 in North America, all CA stockpiles had been depleted, and all sets since have been made exclusively with ABS.
The Lego Group has acknowledged the environmental impact of using ABS, a fossil fuel derivative, and has committed to finding a more eco-friendly alternative by 2030. The company recycles most of its plastic waste from the manufacturing process, and any plastic that cannot be reused in Lego bricks is processed and sold on to other industries.
While Lego has tested hundreds of other plastics, including those made from corn, algae, and wheat, no final replacement has been announced. The company has also explored sustainable alternatives, such as biodegradable corn-based PLA bricks and bricks made from PHA by the company Bio-On.
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Lego has tested plastics made from corn, algae, wheat
Lego bricks have historically been made from acrylonitrile-butadiene-styrene (ABS), a plastic that accounts for around 80% of Lego's production. However, Lego has been actively working towards sustainability and has invested in wind power to offset the energy used in making its bricks. The company has also introduced sustainable paper pulp trays for its advent calendars.
Lego has tested over 250 variations of PET and hundreds of other plastics, including test bricks made from corn, algae, and wheat. A 2x4 brick made of corn-based PLA is not only bio-sourced but also biodegradable. Lego has also used a polyethylene plastic made from ethanol produced from sustainably sourced sugarcane for the trees, leaves, and other vegetation in its range. The company aims to produce all Lego pieces from bioplastic by 2030.
Lego has faced challenges in finding a suitable replacement for ABS, as plant-based plastics must meet certain requirements, such as durability, color fastness, strength, and clutch power. The prototype bricks made from sustainable plastics have suffered from marbling of color and lack of precise clutch power.
Despite these challenges, Lego remains committed to using fully sustainable materials in its products by 2030. The company has invested $155 million in a new Sustainable Materials Center, employing more than 100 people to work towards this goal.
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The company aims to find an eco-friendly alternative by 2030
The Lego Group began in the workshop of Danish carpenter, Ole Kirk Christiansen, who started making wooden toys in 1932. In 1934, his company was named "Lego", derived from the Danish phrase "leg godt", meaning "play well". In 1947, Lego expanded to producing plastic toys, and by 1951, plastic toys accounted for half of the company's output.
Since 1963, Lego pieces have been manufactured from Acrylonitrile Butadiene Styrene (ABS) plastic, which is derived from fossil fuels. ABS plastic is heated to 232 °C (450 °F) until it reaches a dough-like consistency. It is then injected into moulds and takes approximately 15 seconds to cool. The moulds are permitted a tolerance of up to twenty micrometres to ensure the bricks remain connected.
Lego has set sustainability goals over the years, including signing the United Nations Global Compact in 2003 and investing in wind power in 2012. In 2018, the company set a self-imposed 2030 deadline to find an eco-friendly alternative to ABS plastic. Lego has tested over 250 variations of PET, as well as materials such as corn, algae, and wheat. In 2020, Lego announced it would cease using single-use plastic bags, switching to recyclable paper bags. In 2021, the company stated its intention to produce bricks without using crude oil, but this decision was reversed in 2023 as it did not reduce carbon dioxide emissions.
Lego factories recycle almost all of their plastic waste from the manufacturing process, and any plastic that cannot be reused in Lego bricks is processed and sold to other industries. While Lego bricks are recyclable, they are not typically recycled in the traditional sense as they are durable and often passed down through generations.
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Lego plastic is recyclable, but not in the traditional sense
Lego bricks are primarily made from plastic sourced from fossil fuels, specifically ABS plastic. This accounts for around 80% of Lego's production. However, Lego has expressed its commitment to finding more sustainable alternatives and has invested over $1.2 billion in sustainability initiatives.
Lego has been working towards replacing fossil fuels with renewable and recycled plastic. They have tested over 600 different materials, including recycled plastic, bio-polypropylene, and plastics made from alternative sources such as e-methanol and bio-waste. Despite these efforts, Lego has faced challenges in finding a suitable replacement that does not compromise the quality and longevity of their products.
While Lego bricks themselves are not yet widely recyclable, the company has made strides in recyclable packaging. Lego boxes are made from cardboard and can be recycled where infrastructure for paper and cardboard recycling exists. They are also introducing recyclable packaging across all areas, including paper-based bags that have been verified as technically recyclable in the European Union, the United States, and Canada.
Lego encourages consumers to check with their local authorities for guidance on how to responsibly dispose of their Lego products and packaging, as rules vary between locations.
In summary, while Lego plastic is not yet widely recyclable in the traditional sense, the company is actively working towards sustainability by exploring alternative materials and implementing recyclable packaging solutions.
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Lego's plastic bags have been replaced with paper bags
Lego bricks have traditionally been made from Acrylonitrile Butadiene Styrene (ABS), a thermoplastic consisting of a styrene monomer with the addition of an acrylonitrile monomer and a butadiene monomer. The butadiene component, a synthetic rubber used mainly in tires, lends the plastic its strength and impact resistance. Lego has used ABS for its bricks since 1963, though the company has been testing more sustainable alternatives, including corn-based polylactic acid (PLA) bricks and bricks made from polyhydroxyalkanoate (PHA).
Lego has also been working to reduce its use of fossil fuels in manufacturing. In 2021, the company announced that it would aim to produce its bricks without using crude oil, instead using recycled polyethylene terephthalate (PET) bottles. However, in 2023, Lego reversed this decision, as it found that using recycled PET did not reduce its carbon dioxide emissions. Lego has set a self-imposed deadline of 2030 to find an eco-friendly alternative to ABS plastic.
Despite these challenges, Lego remains committed to sustainability. The company recycles all but about 1% of its plastic waste from the manufacturing process, and any plastic that cannot be reused in Lego bricks is processed and sold to other industries. Lego has also invested in renewable energy sources, such as wind power, and has set annual sustainability goals for itself since 2003.
Lego's transition from plastic to paper bags is a positive step towards reducing plastic waste and achieving the company's sustainability goals. While challenges remain in finding eco-friendly alternatives to ABS plastic, Lego's efforts to reduce its environmental impact are ongoing.
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Frequently asked questions
Lego bricks are made from Acrylonitrile Butadiene Styrene (ABS), a thermoplastic consisting of a styrene monomer with the addition of an acrylonitrile monomer and a butadiene monomer. Lego has been using ABS since 1963.
The butadiene component, which is mainly used in tires, is largely responsible for the strength and impact resistance of ABS. The plastic is also more stable and colourfast than cellulose acetate (CA), the plastic Lego previously used.
Lego uses polycarbonate for transparent elements like windows, and polyethylene sourced from sugarcane for softer pieces like plants. Lego has also tested bricks made from corn, algae, and wheat.
Lego bricks are recyclable, but not in the traditional sense. Lego recycles almost all of its plastic waste from the manufacturing process, and any plastic that cannot be reused in Lego bricks is sold to other industries. Lego has also taken steps to reduce its use of single-use plastic, such as by switching to paper bags in 2020.
Yes, Lego has set a self-imposed deadline of 2030 to find a more eco-friendly alternative to ABS. The company has also invested in wind power and set sustainability goals, such as using 100% renewable energy by 2020.
