The E-Methanol Pivot: Decarbonising the Plastic Supply Chain

The global manufacturing sector has reached a pivotal turning point in its goal to halve the use of virgin fossil plastics, shifting focus from experimental pilots to the industrial-scale reality of sustainable manufacturing.

The transition is reshaping the production of high-performance materials used in everything from medical devices to automotive components.

Leading this charge is the LEGO Group, which has integrated these advancements into a broader framework aimed at achieving net-zero greenhouse gas emissions by 2050.

LEGO has committed to an interim target of a 37% reduction in emissions by 2032. To support this, the company has followed through on doubling its investment in environmental sustainability compared to 2023 levels.

Ongoing operations at the Kassø facility in Aabenraa, Denmark, demonstrate that Power-to-X technology has moved from theoretical concept to industrial application. This facility signals a strategic shift in how global manufacturers approach their upstream supply chains.

The Kassø e-methanol facility was developed in 2025 and is supplying e-methanol to industry leaders including Maersk, the LEGO Group and Novo Nordisk. 

"The operations at Kassø mark a major step forward in bringing Power-to-X technologies into real-world use," says Knud Erik Andersen, CEO of European Energy.

"This is renewable energy in action, transforming how we use electricity."

By establishing access to renewable e-methanol, LEGO is working to reduce its dependence on fossil-based feedstocks, advancing its target to halve its use of virgin fossil plastics throughout 2026.

The strategy also includes material transition, with plans to move all products to sustainable materials by 2032 using mass balance principles. The LEGO Replay programme facilitates the donation and redistribution of used bricks, while packaging initiatives focus on replacing single-use plastic bags within sets with recyclable, paper-based alternatives.

Rabab Raafat Boulos, Executive Vice President at A.P. Moller - Maersk, adds: "We are excited to utilize e-methanol from the Kassø facility, marking an important milestone in our global efforts to source alternative fuels.

"The future of shipping must include multiple fuel types operating alongside each other, with methanol playing a key role in the industry's net-zero ambitions."

All supply chain, sustainability, Scope 3 and net zero leaders should attend:

• Procurement and Supply Chain LIVE: The Net Zero Summit - QEII Centre, London, March 4-5
• Procurement and Supply Chain LIVE: The US Summit - Navy Pier, Chicago, April 21-22

Co-located with Sustainability LIVE, these events brings together CSCOs, CSOs and senior decision-makers at a moment when sustainability, supply chains and commercial performance are increasingly interconnected.

Tickets can be booked online today for The Net Zero Summit and The US Summit. Group discounts available.

How e-methanol becomes LEGO bricks

The technical foundation of this production model centres on e-methanol (electronic methanol). This liquid fuel is synthesised by combining green hydrogen – produced through electrolysis using wind or solar power – with captured biogenic CO2.

According to the companies involved, this process results in a feedstock with a carbon footprint up to 97% lower than traditional fossil-based alternatives. For LEGO, this e-methanol is processed into a sustainable version of polyoxymethylene (POM), referred to as ePOM.

This material is now integrated into high-performance elements requiring precision and "clutch power," including:

• Technic elements: cross axles and connectors
• Minifigures: the hands that grip accessories securely
• Mechanical parts: wheel axles requiring low friction and high durability

"Sourcing renewable e-methanol is part of our ambition to reduce carbon emissions," says Carsten Rasmussen, Chief Operations Officer at the LEGO Group.

"We now use the material to produce select LEGO elements while maintaining our high standards of safety, durability and quality. This partnership is a powerful example of how collaboration and innovation can accelerate meaningful progress."

These sustainable elements are designed to be indistinguishable from those manufactured decades ago, maintaining product compatibility without compromising safety or quality standards.

In a period characterised by volatile energy markets, the company continues to refine a supply chain model that prioritises resilience and long-term sustainability.