Scaling Sustainable Sourcing: Lessons from LEGO

The global manufacturing sector has reached a turning point in its procurement approach to sustainable materials, shifting focus from experimental pilots to the industrial-scale reality of circular sourcing strategies.

The transition is reshaping procurement frameworks for high-performance materials used in everything from medical devices to automotive components.

Leading this charge is the LEGO Group, which has integrated sustainable sourcing advancements into a broader procurement 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 procurement reality. This facility signals a strategic shift in how global manufacturers approach their upstream supply chains and supplier partnerships.

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."

Sourcing renewable feedstocks at scale

By establishing access to renewable e-methanol through strategic supplier partnerships, LEGO is working to reduce its dependence on fossil-based feedstocks, advancing its target to halve its use of virgin fossil plastics by the end of 2026. The procurement 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, whilst packaging initiatives focus on replacing single-use plastic bags within sets with recyclable, paper-based alternatives. This represents a comprehensive approach to supply chain transformation that extends beyond direct material sourcing.

Rabab Raafat Boulos, Executive Vice President at A.P. Moller - Maersk, adds: "We are excited to utilise 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."

Sourcing requirements for e-methanol

The technical foundation of this procurement model centres on e-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 could result 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 such as cross axles and connectors
• Minifigure hands that grip accessories securely
• Mechanical parts such as 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."

Procurement resilience

These sustainable elements are designed to be indistinguishable from those manufactured decades ago, maintaining product compatibility without compromising safety or quality standards. The procurement approach demonstrates how supplier collaboration and long-term partnerships can drive material innovation at industrial scale.

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

By diversifying feedstock sources and establishing strategic partnerships with renewable energy suppliers, LEGO is building a procurement framework designed to withstand market fluctuations whilst advancing environmental objectives.