Written by Kerryn Caulfield, Executive Director, Composites Australia Inc.
In an era where sustainability and environmental consciousness are at the forefront of consumer concerns, Eco Benchtops is a pioneering force in Australian building materials. This Victorian based Australian company, originally founded
in 2017 uses composite technology to transform recycled glass into stunning, durable benchtops. The result of seven years of research and development in collaboration with allnex resins, Eco Benchtops’ breakthrough technology, fuses recycled glass with a binding agent and pigments to create a composite bench top with over 80 % recycled glass.
According to CSIRO, more than a quarter of the glass we consume becomes rubbish that goes to landfill. With the current rate of glass recycling around 46 per cent, Australia is aiming to achieve an 80 per cent average resource recovery rate from all waste streams, including glass, by 2030.
Eco Benchtops is actively contributing to this goal by repurposing recycled glass and driving circular economy innovation.
Post-consumer glass collected from local council recycling programs is sorted, often by optical sorting machines, into three recognisable legacy colours: amber (brown), green and flint (clear), each with distinct chemical compositions. Broken or waste glass, known as “cullet,” is a 19th-century term for scraps of glass gathered for remelting during the hand-making of glass by gaffers and master glassblowers. Contaminants such as labels, caps and other impurities are removed during a subsequent cleaning process.
Once cleaned, the cullet is crushed into smaller grains, less than 5 mm in size, resembling the sand from which glass originates. This controlled process ensures that the glass grains are consistent in size and shape—rounded and subrounded— important for subsequent manufacturing steps and contributing to the properties of the final product.
These glass particles are combined with a specially formulated polyester resin and cured at elevated temperatures in a compression moulding process during which several polymerisation and cross-linking reactions take place, enhancing the density and durability of the final product while mitigating the potential for alkali-silica reactions. The end product contains no more than one per cent crystallised silica, making it significantly safer than traditional engineered stone.
Each formed slab incorporates approximately 750 recycled glass bottles and measures 3000 x 1500 x 20 mm. They are chemically sealed to create a long lasting surface that uniquely resists stains, which, when polished, is as smooth as marble, offering a luxurious feel. The recycled glass particles create unique textures and patterns in each slab, providing the warmth and individuality often associated with natural stone. Colours, shades and patterns are created by blending the amber, green and flint-coloured particles with pigments for additional decorative effects, offering design flexibility for a wide range of applications in commercial, retail and residential spaces.
Earlier this year, Eco Benchtops was acquired by Andrew Rottinger and Matthew Quinn, both of whom bring decades of experience in the building materials industry in Australia. “Homeowners are increasingly recognising the importance of choosing eco-friendly building materials that not only enhance the beauty and functionality of their spaces but also significantly reduce environmental impact. Eco Benchtops is a sustainable solution that transforms waste glass into stunning, durable benchtops, helping to drive the circular economy and promote a healthier planet,” advised Andrew.
One of the most significant advantages of Eco Benchtops is their extremely low crystalline silica content. While engineered stone can contain up to 95 per cent crystalline silica, Eco Benchtops contain only trace levels (under one per cent). This drastically reduces the risk of silicosis and other respiratory diseases associated with silica exposure during cutting, installation and maintenance.
As the demand for sustainable building materials continues to grow, Eco Benchtops is strategically positioned to capitalise on circular economy practices within the construction and design industries.
As consumers become more environmentally conscious, products like Eco Benchtops are likely to gain increasing market share, driving further innovation in sustainable materials.
From 1 July 2024, Australia has implemented a nationwide ban on the manufacture, supply, processing, and installation of engineered stone benchtops, panels, and slabs to protect workers from silicosis caused by crystalline silica dust. New South Wales and Western Australia will have transitional periods until the end of 2024 to honour pre-existing contracts. This ban responds to the significant rise in silicosis cases among workers, particularly in the engineered stone industry, where no safe exposure threshold exists.