Challenge

A global consumer products company sought to decrease landfill usage and increase the by-product recycling rate at one of its plants. The plant separated the by-products into bins, then consolidated them into two compactors – one for non-salable products and one for waste – on the dock. Recyclables were often mixed with the waste streams and sent to the landfill, and there was no accountability that the non-salable products were destroyed.

Solution

A Greener Solution restructured the internal logistics of by-product collection without using any additional space, creating centralized collection points featuring clearly labeled containers for each different type of material. Balers were also located at the collection points. Employees were thoroughly educated on the goals of the revised workflow process and trained on proper separation techniques that enhanced the value of recyclables as well as the volume. Technology was employed to process the non-salable materials and convert them into revenue-producing recyclable material.

Results

Within three months, the plant reached its goal, increasing its recycling rate from 24% to 90%. At the same time, recycling rebates increased by 300% and solid waste costs decreased, fueling momentum and support for the program. The centralized collection and baling enabled the plant to eliminate both compactors, freeing up valuable dock space. The overall economic impact annually has been more than $250,000.

A Greener Solution continued to educate employees and refine the workflow process, bringing the recycling rate up to 99% within the next three months. Employees appreciated the clearly defined separation procedures, the user-friendly containers on wheels and the ability to see the impact their efforts made on the environment via “The Green Sheet” posted throughout the plant. “The Green Sheet” details the trees, electricity, oil and water saved as well as pounds diverted from landfills as a result of the program.

Employees have recommended several ideas which have been implemented to further improve the program, reflecting a positive change in plant culture.

Challenge

A Fortune 50 company utilized large quantities of highly concentrated sulfuric acid to manufacture one of its industrial products. To remediate the sulfuric acid, the company annually generated close to 100,000 tons of synthetic agricultural grade gypsum (calcium sulfate). Dissatisfied with the outsourced management of the gypsum production site, as well as the return received on the material, the company turned to A Greener Solution for help.

Solution

We redesigned and reorganized the gypsum production site, with two primary objectives. One was to improve drainage and prevent storm water run-off into the nearby James River. The second was to improve the efficiency of the site. This included hiring a new crew and providing intensive training, instituting new operating and safety procedures, and recommending the purchase of the proper equipment for the weighing, screening, loading and storing of the material.

To enhance revenue from the gypsum by-product, we trademarked the product under the name Cal-Max™, then launched an extensive campaign to market the gypsum in agricultural and industrial markets.

Results

In less than one year, sales revenue from gypsum increased by 35%. The site consistently passed all internal environmental inspections, and the number of trucks loaded per day increased significantly. Monthly reports to management documented sales, shipments and other key metrics.

Challenge

A Fortune 500 manufacturer of feminine products sought to reduce its waste streams and increase its 20% recycling rate. The company’s goals included reducing landfill usage to save money and maximizing its rating on the soon-to-be-introduced Wal-Mart Sustainability Product Index. To make the by-product recyclable, however, it first had to be separated into its two component materials.

Solution

After designing a method to separate the individually recyclable product components, A Greener Solution implemented an in-plant collection system, as well as set up a recycling area staffed with on-site labor. We also instituted and monitored secure destruction procedures, essential for the FDA-approved product.

Results

The manufacturer increased its recycling rate to 90% and doubled its recycling revenues. Our solution also reduced costs by enabling the plant to eliminate the four trash compactors previously required.

Challenge

A manufacturer of plastic dispensers for the health and beauty market sought to reduce its waste streams and decrease trash management costs. To handle its current needs, the plant required two trash compactors.

Solution

By instituting a program to recycle additional material beyond the 40% the plant already recycled, A Greener Solution eliminated the need for one compactor. Compactor pulls were reduced by 50% on the remaining compactor by installing a One Plus Waste Edge wireless monitoring system to accurately determine and report container levels. In addition, we renegotiated favorable rates with the manufacturer’s waste disposal vendor.

Results

Our solution cut waste disposal costs in half while doubling the company’s recycling rate to more than 80%. Also, the plant gained the use of a loading dock with the elimination of the trash compactor.

Challenge

A leading global medical technology company wanted to increase its recycling revenue and help its 30 manufacturing facilities achieve the company’s landfill-free goal. The plants manufacture medical devices in a clean room environment, limiting the types of containers that can be used. Under existing procedures, by-products were collected in bins located at specific points along the manufacturing line. The bins were then emptied into gaylords near each machine, cross-contaminating the material and reducing its value. Recycling was not a high priority because of strict regulations, severely limited space and concern by busy employees that recycling created additional work. And due to the variety of materials and packaging, many non-salable assembled parts and finished goods were discarded.

Solution

Seeking to minimize space and keep the program as simple as possible, A Greener Solution lined all the bins with bags. When the bags were full, employees knotted them and put them in a gaylord outside the clean room which both prevented contamination and allowed commingling of the bagged material from all the gaylords in collection trailers.

Signage was added to clearly explain which material should be collected in which bins outside the clean room, and employees were educated on how to best separate material to maximize recycling and reduce waste. A Greener Solution processed all the recyclables, providing critical chain of custody monitoring and secure destruction. In addition, A Greener Solution’s comprehensive reporting enabled each plant to track its progress toward achieving landfill-free status.

Results

The new process securely destroys and recycles 99% of the assembled parts and finished goods which were previously either landfilled or disposed of as medical waste. The first plant achieved landfill-free status goal within six months, and 90% of the plants are expected to reach this goal within a year.

In the first facility, the bag program increased recycling revenue by avoiding contamination and therefore improving value of the recyclables. Each clean room now needed only one or two gaylords rather than one by each machine, opening up more of the limited space.

At the same time, the volume of recyclables collected outside the clean room increased, saving money by lowering waste collection costs. And by commingling the bagged recyclables, the plant was able to reduce its collection trailers from four to one, freeing up valuable dock spaces.