From Waste to Resource: An Evaluation of Circular Economy Practices in Furniture Production

The European woodworking and furniture sector faces increasing sustainability challenges, including dependence on virgin raw materials and low recycling rates of furniture waste, highlighting the need for integrated environmental and economic assessments to support circular solutions. The purpose of this study is to evaluate and compare the environmental and economic performance of boards produced with different proportions of Polyethylene Recycling Waste (PRW) sourced from a Portuguese plastic recycling company, using an integrated Life Cycle Assessment and Life Cycle Costing approach. The environmental performance was assessed following ISO standards using the ReCiPe 2016 Midpoint (H) method, while the economic analysis included internal and external costs. First, the environmental and economic performance of PRW was assessed per 1 kg of material. Subsequently, four board formulations produced at pre-industrial scale, in a Portuguese company, were compared per 1 m3 of board: 100PRW; 80PRW20FW (with 20% furniture waste, FW); 80PRW20PE (with 20% virgin polyethylene, PE); and 80PRW20PU (with 20% virgin polyurethane, PU). Results show that waste-based boards (100PRW and 80PRW20FW) consistently present lower environmental impacts and improved cost-efficiency compared to formulations incorporating virgin polymers, particularly PU. Global warming and terrestrial ozone formation were the main contributing impact categories, largely driven by energy consumption. The dominant impact stage varied by formulation, with pressing prevailing in waste-based options and raw material production in virgin-polymer-based boards. These findings demonstrate that increasing the share of waste materials can significantly improve both environmental and economic performance, supporting the transition towards circular material solutions in the furniture sector. This study provides a novel contribution by integrating LCA and LCC in the assessment of pre-industrial PRW boards, offering practical insights for industry decision-making and sustainable material design.