Design for Disassembly: The Key to Unlocking Circular Manufacturing

The demand for more sustainable manufacturing processes and more circular products has become impossible to ignore for business leaders around the world. Manufacturing technology has evolved far beyond basic recycling programs, with smart systems and advanced processing methods improving how industries handle waste. One of the latest manufacturing design developments has companies taking note of the potential for transforming resource efficiency and environmental impact. 

Design for Disassembly (DfD) is the concept of manufacturing parts with the intention of reusing them once the product has reached its initial end of life. This is similar to recycling, however, DfD removes the need to melt down any plastics or remanufacture parts, as they are simply ready to reuse once removed. 

Essentra has previously published articles on the importance of sustainable manufacturing which discuss the application of compostable plastic, as well as using components made from recycled plastic rather than conventional plastic from virgin resin. DfD, however, takes things in another direction for consumers and the environment.

So how does DfD work? Is there consumer demand? And how does it affect the future of sustainable manufacturing? We'll cover: 

What is Design for Disassembly?
Why DfD Matters for Circular Manufacturing
Benefits of Design for Disassembly
The Role of Consumer Behaviour in Driving Change
The Future of Sustainable Manufacturing

What is Design for Disassembly?

Consider a jigsaw where each piece serves a specific function in the puzzle. Now, imagine those pieces can be removed after completion and used for a different function in a completely separate puzzle. This is the essence of DfD, where each part can be used and reused depending on a customer’s given need. 

This is the next leap in sustainable product design, where products are intentionally created to be easily taken apart at the end of their lifecycle. DfD doesn’t discriminate between parts – everything is reusable no matter its size or function. Naturally, if a part is completely broken then immediate reuse may not be possible, but this is rare. Historically, small parts have often been discarded under the assumption they couldn’t possibly be reused, or that the manufacturer will simply have a large stockpile instead. Examples of these small parts include plastic rivets, cable clamps and ties, and card ejectors, among many others.

Once DfD becomes commonplace among manufacturers, end users should become accustomed to returning outdated products for suppliers to disassemble and reuse each part. 

Why DfD Matters for Circular Manufacturing

Circular manufacturing is becoming the industry standard for businesses who are committed to reducing their environmental impact. Driven by consumer demand for more sustainable products, reuse is essential to reduce the volume of virgin raw materials sourced throughout manufacturing. 

DfD supports the circular economy by enabling easier repair, refurbishment, and reuse of parts, thus reducing waste and conserving resources. Additionally, circular thinking provides an extra avenue for obtaining materials in an economy that is short of labour for sourcing and procurement. Manufacturers and suppliers will be grateful for the advances of circular manufacturing, as they attempt to keep up with demand amidst supply chain constraints and disruptions. 

Benefits of Design for Disassembly

Environmentally, DfD helps to reduce landfill waste by reusing parts that would otherwise be tossed aside by manufacturers and their customers. This reduces the amount of landfill tax required, saving money for manufacturers. In the UK, landfill tax is set to increase as of April 2025, placing more pressure on businesses to find sustainable alternatives. 

DfD supports recycling as regulations surrounding the topic ramp up, and lowers the carbon footprint of all parties. Each new use of a part represents carbon emission savings, as it replaces the need to source new materials. Small savings add up quickly and businesses who measure their emissions will quickly realise the environmental benefits. 

Economically, these reusable parts present manufacturers with the opportunity to resell the parts themselves. If returning parts to their supplier isn’t in their interest, it may be possible to open a secondary market for commonly disassembled parts. As the cost of some parts rises, this can help to offset those costs and provide economic stability during downturns. 

Operationally, DfD simplifies maintenance and repair duties by allowing for fast swaps of each part. With easier maintenance schedules, product lifespans may be increased, saving capital expenditure on replacements. Additionally, maintenance staff satisfaction can be improved with simpler maintenance duties, improving retention and reducing training requirements. 

The Role of Consumer Behaviour in Driving Change

A 2024 survey of UK manufacturers found that more than three quarters (77%) of firms had received ESG requests from customers. Further down the chain, end consumers are increasingly aware of their environmental footprint. One consumer insights report found that 70% of Gen Z and millennial customers think brands should do more to help them live a sustainable lifestyle. 

Essentra recognises its responsibility to both manufacturers and their customers, and continues to develop more sustainable solutions at its dedicated research centre. Launched in 2023, Essentra’s Centre of Excellence is a world-class facility for researching, testing and developing more sustainable products that reduce emissions while improving recyclability and circularity. This facility was formed in response to consumer demand for more sustainable manufacturing, as well as Essentra’s own pledge to achieve net-zero Scope 1 and 2 carbon emissions by 2040. 

The Centre of Excellence has served multiple purposes for Essentra, not only improving the business’s product range, but offering a competitive advantage and improving brand reputation as a responsible supplier and business partner. By now, the value of sustainability should be incredibly familiar to manufacturers and their customers. 

“Products making ESG-related claims averaged 28 percent cumulative growth over the past five-year period, versus 20 percent for products that made no such claims,” according to McKinsey & Company research. Additionally, brands that make more than half their sales from products with ESG-related claims were found to reap higher repeat rates – customers returning thrice annually – indicating a potential correlation between ESG claims and brand loyalty. 

Results are sure to vary across the spectrum of manufacturing, but early signs and statistics show that investing in sustainable practices makes business sense. 

The Future of Sustainable Manufacturing

Historically, manufacturing has been seen as a line from A to B – materials are sourced and turned into products for disposal at the end of their life. This approach worked tremendously well since the Industrial Revolution, but the demands on modern manufacturers are turning that line into a loop. 

More specifically, closed-loop manufacturing – a system where materials are continuously recycled into the production line to minimise waste and the need for raw materials.

With real design innovation, there’s no reason why parts cannot be used again. As DfD becomes the norm, the processes of production and disposal will be antiquated and the production line (or loop) will be better for it. 

Essentra is dedicated to shaping the future of sustainable product design and DfD is one of many steps on the path to achieving net-zero carbon emissions, zero waste, and true circularity. This is not just Essentra’s responsibility, but that of all suppliers, manufacturers and consumers, to demand better of our products and business partners. While the cost of more sustainable business practices and products may phase some, it has been proven that there are economically viable ways to achieve ESG goals.