Downer's end-to-end sustainability initiative

06/05/2022

Soft plastic waste from Victoria’s newest train build program is being diverted from landfill to construct Victorian roads, in an Australian-first sustainability initiative.

Downer, as part of the Evolution Rail Consortium, is delivering 65 High Capacity Metro Trains – the largest single order of trains in Victoria’s history. The train manufacturing activity is being delivered with over 60% local content, centred on Downer’s Newport facility in Melbourne’s inner west.

In an Australian-first, the soft plastic used to protect the trains during transport is being diverted from landfill to be re-used in Downer’s ReconophaltTM road surfacing products. These products are then utilised in the construction of major road projects across Victoria, including upgrades to the M80 Ring Road and the Monash Freeway.

Downer’s ReconophaltTM product is Australia’s first asphalt product containing high-recycled content derived from waste streams that would otherwise be bound for landfill.

The inclusion of waste plastics from the High Capacity Metro Train manufacturing, means Downer is now providing a full end-to-end recycling solution. 

“Downer is proud to be a leader in the circular economy,” Downer’s Group Manager, Environment and Sustainability, Ross Brookshaw, said.

“We are committed to reducing the environmental footprint of the products and services we provide to our customers, and this initiative is a fantastic example of Downer’s ability to leverage our broad capability to provide an end-to-end solution that benefits our customers and communities.

“The demand from our customers, communities, industry and government for circular economy thinking to reduce waste continues to be an important issue and growth opportunity for Downer.”

Downer expects to divert over 10 tonnes of plastic waste used on the new trains from landfill, and following reprocessing, will be used in ReconophaltTM for building Victoria’s roads. 

Over the past 3 years, Downer has produced more than 300,000 tonnes of ReconophaltTM, using approximately 266 million plastic bag equivalents, 30 million glass bottle equivalents and 7.8 million printer toner cartridges, which would otherwise have ended up in landfill. 

A fleet of HCMTs at Pakenham East Depot

Soft plastics being churned through the machine

Soft plastics turned into liquid TonerPlas

TonerPlas pellets