More than two decades ago, Timberpak began as a small, cautious experiment in wood recycling. Today, it's a critical link in EGGER’s supply chain, processing hundreds of thousands of tons of recycled wood annually and serving as a sustainability benchmark on both sides of the Atlantic.
During a recent visit to EGGER's Timberpak Charlotte, NC facility, Mark Hayton, Head of Timberpak UK, sat down to reflect on how far the business has come, the differences between the UK and U.S. markets and why the circular economy is at the heart of Timberpak’s mission.
Material Differences: UK vs. U.S.
One of the most striking contrasts between the UK and U.S. operations lies in the type and quality of materials received. In the UK, over 30% of the incoming wood comes from household waste sites , with varying degrees of contamination, including everything from MDF to upholstered furniture.
“In the early days, we only accepted clean solid wood. That was easy,” Hayton says. “But the market changed when biomass subsidies came in. Suddenly, waste streams got mixed, and we had to start accepting lower-quality wood, including MDF, which we don’t want but often have to process.”
In Charlotte, however, the story is different. “It’s predominantly clean, grade-A packaging wood,” Hayton noted. “You’re really only dealing with metal contaminants, which is a dream compared to what we often see in the UK.”
Still, challenges lie ahead. “As the U.S. recycling market matures, you’ll likely face the same issues we’ve dealt with, like rising MDF content and inconsistent feedstock. But the experience we’ve built in the UK will help you stay ahead.”
Tackling Tomorrow’s Challenges
Despite its success, Timberpak is not without obstacles. The biomass industry in the UK remains a major competitor for wood feedstock, making it harder to secure high-quality material. And while technology continues to improve, the efficient removal of MDF remains a technical and economic hurdle.
“Our plants can remove most non-wood contaminants – plastic, metal, you name it,” said Hayton. “But MDF? That’s still the real challenge.”
Globally, Timberpak is focused on strengthening partnerships with manufacturers who share a sustainability mindset. In the U.S., Patrick’s team is actively pursuing relationships with large-scale businesses that prioritize carbon reduction and circular material flows.
“We don’t call them customers, we call them partners,” Hayton emphasized. “Because we grow together. We want their waste wood to come back to us and re-enter the cycle.”
A Message to the Industry
For Hayton, wood recycling isn’t just a business, it's a philosophy. “It’s the circle of life,” he said. “We send chipboard to a customer, they use it, and ideally, it comes back to us to be recycled again. Chipboard has an infinite lifecycle if it’s handled right.”
In the early days, customers were hesitant about using recycled content. “Now,” he said, “they ask why we can’t use more of it.”
It’s a shift in mindset that speaks to the growing importance of sustainable material use across industries, from architecture and design to retail and manufacturing. Timberpak’s journey, from a leased site with a diesel shredder to an advanced, multi-site operation, is proof that circularity is not just possible but profitable and scalable.
As Hayton put it simply: “Recycling wood isn’t the end of the story, it’s the beginning of the next one.”