Lego adds e-methanol to plastic component manufacturing
Lego is taking another step to lessen its reliance on traditional fossil fuels by introducing e-methanol into the manufacturing process for certain plastic components. The Danish toy company has begun using the low-carbon alternative to produce over 90 elements such as steering wheels, connectors, cross axles and hands for its iconic Minifigures.
The company said in a release on September 30 that the e-methanol, also called electro-methanol, is produced with renewable energy and recycled carbon dioxide. It provides an alternative to conventional fossil fuel-based feedstocks for the production of some Lego products.
The scale of Lego’s Minifigure production shows just how far these changes can go. By 2020, an estimate suggested that the company had produced more than 4 billion Minifigures since 1978, and the cumulative total has probably increased significantly since then.
A collaboration to allow industrial-scale production
The use of e-methanol follows a partnership between Lego, Novo Nordisk and Danish renewable energy producer European Energy, made in 2023. The project seeks to replace some fossil fuel plastics with lower carbon alternatives in select products.
The partnership, Lego says, has helped to support the production of e-methanol at an industrial scale, allowing the renewable alternative to be used to produce certain plastic parts in products, which Lego calls “elements.”
In addition to its use in toy manufacturing, e-methanol may also provide environmental benefits compared to conventional methanol and petroleum-based fuels. Its production harnesses captured carbon dioxide as a feedstock for renewable fuels and chemical feedstocks, aiding to build a more circular carbon economy.
E-methanol has been identified by the World Economic Forum as a possible pathway to decarbonize sectors where decarbonization remains particularly challenging, such as shipping and chemical production. So it could be used in other sectors than consumer goods.
Five years of testing prior to deployment
The inclusion of e-methanol in its plastic manufacturing process came after five years of testing, learning and scaling efforts, Lego said. The time was required to test the material and make it ready for use in existing production operations.
The company said the move was another milestone in its strategy of buying more recycled and renewable materials to make its products while maintaining its existing standards for safety, quality and durability.
But the transition also has been accompanied by a number of technical and operational challenges. Lego has admitted that integrating the new material into its production system is a complicated process and it’s not just a matter of finding a renewable substitute.
“A lot of this has also been working with suppliers to bring e-methanol into existing manufacturing infrastructure and established production methods.
Progress toward long-term climate commitments
The initiative forms part of Lego’s broader sustainability strategy, which includes several climate-related targets established in recent years. The company aims to achieve net-zero emissions by 2050 and reduce its absolute carbon emissions by 37% by 2032, using 2019 as the baseline year.
Lego previously told ESG Dive that it was on track to meet its 2032 emissions reduction target. Expanding the use of renewable and recycled materials is one element of its wider efforts to reduce the environmental footprint of its operations and products.
The introduction of e-methanol demonstrates how alternative feedstocks can be incorporated into selected manufacturing processes. Nevertheless, Lego’s experience also illustrates the complexity of moving away from fossil fuel-based materials, particularly when new inputs must meet demanding production requirements and be integrated across established supplier networks.
By extending the use of e-methanol to more than 90 components, Lego is advancing its efforts to diversify the materials used in its products while working toward its longer-term climate objectives.
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