BP Security—Tran$forma

Initially, the recovered fibers were used to produce colored paper, major sustainability advancement, as it reduced both the consumption of virgin raw materials and the volume of waste destined for disposal.

Seeking to advance even further, the team investigated whether this recycling technology could be extended to the production of security paper, such as that used for passports, banknotes, and identity documents.

The process involves a high-oxidation chemical treatment carried out in controlled batches. This allows for complete traceability and ensures operational safety. The oxidation process breaks down the original paper, destroying all inks and embedded security features such as threads and colored fibers. Afterward, the resulting pulp is passed through a cleaning system to remove plastics and other contaminants, depending on the final application.

Brazil

Innovative, unique, and/or inventive aspects of the project/program

The printed housenote has undergone testing by several partners, including central banks and security printing companies. The feedback has been overwhelmingly positive, especially regarding durability and quality compared to standard cotton substrate:

• Oberthur Fiduciaire: “Overall, the sampled housenotes demonstrated very good resistance. Both the paper and the various print elements achieved high scores in chemical, physical, and aging tests.”

• Banco de Portugal: “The results indicate that all tested variants exhibit high wear resistance when subjected to the same tests used in euro banknote production.”

Conclusion To date, we have processed more than 760 tons of banknote waste. The resulting recycled paper has already been commercially distributed in the Brazilian market for use as colored paper. Our partnership with Casa da Moeda do Brasil has enabled the creation of a reverse logistics and circular economy model for the Brazilian market— one that sets a precedent for sustainable innovation in the security paper industry.

This is how it can be done:

Totally eco-friendly, save millions of tons of banknote that go to the landfill every year!

Every year, tons of banknote waste are generated worldwide. Traditionally, this waste is either incinerated or sent to landfills—practices that mark the end of the material’s lifecycle. However, in the context of climate change and the urgent need to promote more sustainable consumption and production patterns, the application of circular economy principles presents a significant opportunity. These principles offer a pathway to rethinking how banknotes are produced, creating new material cycles and making these essential products more environmentally responsible.

With this understanding, BP Security and Casa da Moeda do Brasil launched a project two years ago to explore the recovery of cotton fibers from banknote production waste. The aim was to repurpose these fibers for the manufacture of new paper products, thus giving them a second life

Circular Economy appling to produce paper from banknote waste

Decrease costs for landfills/coprocessing and increase the paper margin using the recycled fiber