Doloop Preform production from recycled material for bottles Circular economy

The manufacture of plastic packaging has been under particular scrutiny for years. Hardly any other industry is so directly confronted with issues of resource use, emissions, and sustainability. Doloop has been operating in this field for decades—and is increasingly focusing on materials and processes that go beyond traditional solutions.

From bottle blowing to specialized preform production

The company entered the industry in the mid-1990s with traditional bottle production. The blowing of finished bottles gradually led to a deeper technical understanding of pre-products and material properties. This development culminated in a clear focus: preform production. Today, it forms the core segment of the company, complemented by existing bottle solutions and a third pillar, the production of rigid film. It is precisely this triad that is of interest to many bottlers and brand manufacturers. It allows packaging solutions to be considered along the entire value chain – from the preform to the finished bottle or film application. Doloop thus positions itself not as a pure supplier, but as an industrial partner that understands and develops processes.

Preforms made from 100 percent recycled material as an industrial benchmark

A key product in the current development is a preform made entirely from recycled material. It is used to produce spirits bottles, among other things, a segment with high demands on material quality, appearance, and stability. The use of recycled plastic for this purpose is not a marketing detail, but a technological requirement. The ecological impact is obvious: the use of 100% recycled material significantly reduces the need for new plastic. At the same time, CO₂ emissions are reduced because energy-intensive primary processes are no longer necessary. However, the decisive factor is that these bottles can be recycled again after use. This closes the material cycle – at least where appropriate collection and processing systems are in place.

Circular economy as an industrial principle

In this context, circular economy is not an abstract term, but a concrete process logic. Materials are not consumed, but used, returned, and reused. For plastics processing, this means ensuring quality over several cycles. The advantages of such preform solutions are clear:

• Reduced CO₂ emissions by avoiding the use of primary plastics
• Multiple recyclability of the material
• Industrial applicability even in demanding segments
• Contribution to relieving existing raw material markets

Bio-based materials as a prospect, not a substitute

In addition to the established recycling approach, attention is also turning to bio-based and plant-based plastics. Compostable materials are widely regarded as an option for the future, especially in areas where closed recycling loops are difficult to implement. The company is participating in research projects with universities and bottling partners to test these materials under real-world conditions. However, the outlook remains sober. Bio-based bottles are currently not allowed to enter existing recycling streams. They must be collected and processed separately, as they would otherwise disrupt established processes. This is precisely where one of the major challenges lies: new materials require not only new products, but also new infrastructure and clear information along the entire chain – from the bottler to the end consumer.

Education as part of industrial responsibility

Introducing new materials alone is not enough. It is equally important to communicate transparently about how they should be disposed of and recycled. Doloop therefore emphasizes that recycling processes must be explained in an understandable way. Only when consumers, waste disposal companies, and recyclers know how to handle materials can the circular economy actually work. This attitude distinguishes technological development from short-term trend promises. Bio-based materials are not presented as an immediate solution to all packaging problems, but as a long-term addition that requires time, research, and clear rules to integrate.

Between industrial reality and long-term transformation

The plastics industry is facing a fundamental restructuring. Recyclate-based preforms show that more sustainable solutions are already industrially feasible today. At the same time, bio-based materials highlight how complex the next step will be. Doloop consciously navigates between these two poles. The company focuses on market-ready recycling solutions, invests in research, and openly identifies the limitations of existing systems. It is precisely this combination of pragmatism and future orientation that shapes the current course—and makes it clear that transformation in the packaging industry will not happen in leaps and bounds, but in sustainable stages.