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Waste Reduction Guide for the Plastic Industry |
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ABOUT THIS GUIDE
This guide is designed to help managers of plastic products
manufacturing plants increase solid waste reduction and
recycling. Smart organizations know that waste reduction
is simply good business because it directly improves your
bottom line by cutting materials and waste disposal costs.
Waste reduction also helps you achieve: Efficiency improvements in manufacturing, Whether your company already has a waste reduction program or wants to start one, this guide's practical techniques and examples will benefit you. Plastic products manufacturing represents a large, diverse and highly competitive group of industries along the U.S.-Mexico border. Many manufacturers continually change their product lines to respond to consumer preferences. For instance, in the toy industry, each year as many as 70% of products are new lines. Many companies, both large and small, have embraced waste reduction as part of their total quality management and continuous improvement programs in order to efficiently respond to market changes. Although this guide is intended to help plastic product
manufacturers, many of the waste reduction strategies and
techniques apply to all manufacturers.
Improving your bottom
line through waste
reduction.
Hasbro's toy plant in
Tijuana earned over
$230,000 in 1995 by
selling scrap plastic
from their
manufacturing
processes.
Border Waste Wi$e
This guide is part of the Border Waste Wi$e Project, a solid waste reduction and recycling effort in the border region. The project is funded through the U.S. Environmental Protection Agency's (EPA) Environmental Technology Initiative, with substantial in-kind contributions by each project partner. Border Waste Wi$e focuses on providing technical assistance (e.g., assessments) and training to U.S.,Maquiladora and Mexican National companies in the Tijuana, Baja California and the San Diego, California border region in order to help them take advantage of the economic and environmental benefits of solid waste reduction. Participation in this program is completely voluntary and non regulatory. Fact sheets, recyclers directories, industry case studies and other information that complement this guide are available from Border Waste Wi$e's Internet site (http://www.borderwastewise.org). Appendix A is a list of project partner contacts. Review this guide and compare it to your program. If
your company is not taking full advantage of the
suggestions presented here, start implementing some
simple changes. We guarantee that you will find
opportunities to improve your company's bottom line,
image and local environment.
Border Waste Wi$e
Partnership
City of San Diego Products, Processes and Wastes
There are many industries that produce plastic products or components including toys, consumer goods, medical products and housings for electronics products. Plastic products manufacturing includes a wide array of processes specific to the products produced. Injection molding is the primary manufacturing technology. This involves injecting molten plastic resins into injection molding machines that form the products. Then products are packaged and shipped to market. Manufacturing products generally follows these six steps: 1) Materials are received, stored and prepared. Plastic resins in pellet form are stored in Gaylord containers or silos. Subparts, including metals or other plastic components, are preassembled. 2) Molten plastic resins are piped or transferred via a vacuum pump system to injection molding machines. Types of resins include styrene, polyethylene, polypropylene, poly vinyl chloride, urethane, and others. Dyes used to color the plastics are also pumped to the molding machines. This process is usually controlled by a computer that measures quantities of plastic and dyes needed for each batch. 3) The injection molding machines mold the resins and then use noncontact water to cool the products. Some plants separate off-spec parts and purgings, grind them and reuse them in the molding process. The products often need cleaning to remove residual mold release agents and other unwanted materials. 4) Other components may be assembled with the product. The product may also be painted and/or stamped. 5) Products are visually inspected. 6) Products are packaged, stored and shipped to market. Solid wastes generated from these processes include purged plastic from the molding process, off-spec or rejected parts, waste paint, dye and ink, waste plastic and dye containers, cleanup rags, general office waste, white and colored paper, packing and packaging materials (includes polystyrene, cardboard, paperboard, wood pallets, and plastic bags, bubble-wrap, shrink wrap), scrap labels, and label backing paper. Plants that have cafeterias or food service/break areas also generate food wastes, glass and plastic containers and other wastes
typically associated with serving food. Food wastes are a
large percentage total waste by weight at plants that have
full-service cafeterias. Facilities that have landscaping also
generate green wastes (e.g., grass clippings, trimmings).
Examples of solid wastes Waste Reduction Techniques
You have opportunities to improve waste reduction
throughout your plant. While some techniques may be
company-specific, many apply to all plastic product
manufacturers. Evaluate these techniques in terms of
payback, annual savings and impact on your operations to
select the ones to implement. More ideas on steps to
improve your program are provided at the end of this
guide. Waste reduction
includes waste
prevention, material
reuse, recycling,
composting practices,
and buying products
with recycled content.
Product Design and Manufacturing
Use "just-in-time (JIT)" inventory control systems to reduce over buying materials that may become wastes (e.g., when product line change abruptly) and to cut storage needs and costs. Employ computerized process control systems to reduce purgings and off-spec pieces. Use "air molding" to make certain plastic components (e.g., housings), reducing plastic use by as much as 40%. Employ integral molding process and snap-in designs to eliminate the need for welding and gluing. Improve quality assurance for packaging and display products in order to reduce rejects. Enhance product "recyclability" by minimizing the number of plastic resins used (e.g., it is difficult to find recyclers for various styrenes because each has a different melting temperature) and by avoiding compound materials. Consider making or purchasing non-cosmetic parts (e.g., internal components, subparts bags) with a high percentage of post-consumer resin (PCR). Evaluate the cost effectiveness of redesigning outdated product molds to reduce reject rate. Although these design changes and process improvements
may be costly, they often cut overall production costs per
unit by a significant amount due to fewer materials and
faster assembly. Moreover, consumers respond well to
green products.
Mattel's large toy
factory in Tijuana uses
an advanced "just in
time" inventory control
system that saved $4.5
million dollars in costs
between 1990 and 1994.
Materials Reuse and Recycling
Grind off-spec parts and purgings (if possible) and reuse them in the injection molding process. Recycle materials from production processes, such as waste plastic that can not be reground and used again in the molding process. Implement a plastics recycling program by properly segregating waste plastics by type of resin and color in order to receive higher prices for these post-production resins. Many border manufacturers, such as Nypro and Hasbro, have implemented cost-effective methods to segregate these materials in production lines. Dismantle inoperable products and reuse subparts (e.g., metals, fabrics) in the manufacturing process. Reuse wire and shrink-wrap spools onsite or return them to the vendor. Launder and reuse shop towels and rags. Kodak's Tijuana plant saves $20,000/year by contracting with an industrial laundry. Reuse, refurbish and recycle wood pallets. Make recycling convenient. Provide bins in all areas where materials are generated. Bins are available from many different vendors or can be fabricated onsite using empty drums, crates, or boxes. The bins should be colorful, easy to use (i.e., no heavy lids or tools required to open), and clearly marked to indicate the appropriate materials to be disposed in each. Schedule regular collections. Recyclable materials must be collected and transferred before the collection bins get full. By doing so, sufficient space will always be available for properly segregating and storing the materials. Establish contracts with local recycling companies for regular removal of recyclables. In some instances, it may be more profitable for a facility to haul its own materials to a recycler than to pay for the pickup service. Periodically review market values to ensure you are getting the best value for recyclables. Verify that you are receiving the best prices for high-value materials and minimizing costs on others. Ask workstation operators to control materials segregation. Try to allocate recycling revenues by cost center in order to provide incentives for production managers. Also provide incentives, such as bonuses, for production workers. Use online waste exchanges, such as the Chicago Board
of Trade's system and the State of California's
CalMax/CalMex exchange to sell or find a use for
materials. Go to Border Waste Wi$e Online
(www.borderwastewise.org) to access these exchanges.
Kyomex, which has a
plant in Tijuana that
manufacturers
television, computer and
printer housings, grinds
off-spec pieces for reuse
in the injection molding
process.
Packaging Reduction
Reduce product packaging. Review all packaging specifications for redundancy and develop a policy that recommends or requires review of potential solid waste impacts of packaging requirements. Use reusable packaging. Determine the cost-benefit of replacing single-use corrugated boxes in certain shipping operations with durable distribution packaging that can be reused hundreds of times. Several large manufacturers have established closed-loop distribution systems to reduce packaging, labor and waste disposal costs. Reuse materials and packaging. Reuse packaging materials (e.g., cardboard boxes) internally or donate these materials for reuse by others. The decisions you make on packaging size and type, as
well as shipping specifications, impact waste generation at
wholesalers, retailers and consumers. Your customers also
want to reduce waste disposal costs. Consider this when
making packaging decisions.
Nypro's San Diego
plant, which
manufacturers products
for the health care and
consumer products
industries (e.g., medical
supplies and flashlight
casings), has an
aggressive plastic
segregation program and
ships certain products to
wholesalers and retailers
in reusable, returnable
pails.
Mattel's toy
manufacturing facility in
Tijuana donates some
off-spec (i.e., products
close to quality
standards) toys to
disadvantaged children.
Toys are shipped
without packaging to
reduce wastes.
Purchasing
Modify supplier/vendor contracts by adding "packaging reduction," "recycled content," and "design for recycling" requirements. Develop a facility "buy recycled" program to increase purchasing of recycled-content products, such as cardboard and white paper. Also, research and consider experimenting with using post-consumer resins in your products. Buying products or materials made with recycled content (known as "closing the loop") is the best way to expand markets and raise prices for scrap plastic and other recyclables. Manufacture products with less or non-toxic materials, such as water-based paint and non-toxic glues. Some manufacturers, such as toy companies, are required by the government (e.g., Federal Food and Drug Administration (FDA) in the U.S.) to ensure that their products are non-toxic. Order supplies by voice-mail or electronic-mail, and
order in bulk and concentrated form to reduce excess
packaging (e.g. janitorial supplies and cleaning
materials).
Office Paper Use
Implement two-sided photocopying with copiers that have this capability. Reuse one-sided copies by using the clean side for note pads, distribution lists, fax cover sheets, and laser printer drafts. Maximize the use of electronic messages. Review and maintain documents on computer disks rather than printing out multiple hard copies. Eliminate unnecessary forms. Redesign them to fit on a half sheet. Reuse envelopes or use two-way envelopes.
Cafeterias/Break and Rest Rooms
Switch from disposable styrofoam plates and plastic utensils to washable hard plastic plates and cups and stainless steel or reusable plastic utensils. This investment will pay off quickly. Many border facilities have implemented these waste reduction measures and are saving money. Inform employees that these improvements will reduce waste and increase savings based on reduced disposal costs and the cost of purchasing disposables. Recycle cardboard, steel, aluminum, glass, wood crates and other materials generated in cafeterias and break rooms. Compost organic materials onsite for use in gardens or send offsite. Food accounts for a large percentage of wastes (by weight) at manufacturers that have cafeterias. Install hot air hand dryers in restrooms to eliminate
paper towels. By installing hand dryers, a Sony
facility in Tijuana saved annually an estimated $3,000
and reduced paper towel waste by approximately 5 tons
a year.
Corporation Asahi, a
business that refurbishes
telephone answering
machines, took Border
Waste Wi$e's suggestion
and has started a food
composting program.
Waste Reduction Training
Communicate the benefits and successes of waste reduction to upper management, administrative staff and production employees. Expand communications and training programs to enhance waste prevention, reuse and recycling. Inform management, employees, vendors and clients of your waste reduction efforts, successes, challenges, and newly established targets and goals. Train employees to identify and segregate all recyclable materials before they enter solid waste bins or the solid waste dumpster. Incorporate recycling training in new employee orientations, health and safety meetings, and department meetings. It is also very important to provide training for employees who work on off-peak, nighttime and graveyard shifts. Conduct periodic assessments of your facility to
identify new waste reduction opportunities and to
evaluate current measures to reduce waste. Also,
perform a facility walk-through to evaluate where the
waste reduction opportunities suggested in this report
could be incorporated. Evaluate the operations and
waste generation rates during each work shift (e.g.
night shifts). A form to assist you in conducting a
facility waste reduction assessment is included in
Appendix B.
Enhance Your Waste Reduction Program
Communicate existing or new corporate environmental and/or waste reduction policies or waste reduction policy statement to management and staff, If these policies don't exist, encourage the corporation to develop them. (e.g., encourage waste reduction to reduce facility costs and impacts on environment). Identify specific goals and objectives. For example, implement a paper recycling program by December 1997, require the use of reusable plates, cups and utensils in the cafeteria when the next cafeteria contract is up for renewal, and implement activities to buy products with recycled content throughout the facility by November 1997. Select waste reduction projects that meet your objectives. For example, purchase bins and post signs to implement a paper recycling program. Budget and schedule implementation of selected waste reduction projects. Provide incentives to employees based on returns from recycling, reduced disposal, and material procurement costs. Effective incentives can be in the form of cash bonuses, or funding for company sponsored events, parties or sports teams. Solicit employees' opinions about current operations and potential waste reduction opportunities. Employees' input will help management identify specific waste reduction opportunities they may have overlooked, and will give employees a sense of accomplishment in helping to develop waste reduction activities and procedures. Integrate waste reduction into your overall
environmental and total quality management (TQM)
programs (e.g. ISO 9000 and ISO 14000)
Kyomex, whose Tijuana plant makes plastic housings for
several electronics products, implemented a continuous
improvement program in each department that focuses on
training. One of its stated objectives is to save money
and generate revenue from waste reduction.
Many Border
companies, including
Panasonic, are actively
incorporating solid
waste reduction and
recycled products
procurement as part of
their ISO 14010
certification process.
Waste reduction and
other preventive
measures are the factors
weighed most heavily in
an ISO 14010 audit
score.
Giuntini, Ron, and Tom Andel. "Track the Comings and Goings, & Costs of Returnables." Transportation and Distribution. v35, n7 (July 1994) 55. Ottman, Jacquelyn A. "Four Strategies for Success in the Green Packaging Era." American Marketplace. v15, n23 (November 17, 1994). Saphire, David, "Delivering the Goods, Benefits of Reusable Shipping Containers." Inform, Inc., 1994. The Fabricated Metal Products Industry. Guides to Pollution Prevention, EPA/625/7-90/006, U.S. EPA Office of Research and Development, Washington DC, July 1990. Pollution Prevention in the Electronics Industry. U.S. EPA/SEDESOL Pollution Prevention Workshop (English and Spanish), May 1996. Profile of the Electronics and Computer Industry. EPA Office of Compliance Sector Notebook Project, EPA/310-R-95-002, September 1995. Profile of the Fabricated Metal Products Industry. EPA
Office of Compliance Sector Notebook Project,
EPA/310-R-95-007, September 1995.
Ms. Rochelle Monroe
Ms. Adriana Howard
Public Services Department
US/Mexico Border Team
Regulatory Affairs Manager/Ombudsman
Senior Program Manager Facultad Internacional de Economía* Dr. Paul Ganster Use this worksheet to identify and record the different waste-generating activities and equipment in your facility, the types of waste produced, and any current waste reduction efforts. In addition, identify all materials that could be targeted by your waste reduction program and brainstorm ways to reduce, recycle, or compost these materials. The information needed to complete this worksheet can be obtained by conducting a walk-through of targeted functional areas of your entire facility. The walk-through entails carefully observing waste-generating activities and equipment, examining the contents of waste containers, and interviewing supervisors and employees. Be sure to pay close attention to areas and operations that tend to generate the largest amounts of waste, such as shipping and receiving departments, copying areas, cafeterias, assembly lines, and offices. Remember to include a review of the grounds maintenance operations. While conducting the walk-through, watch closely for activities and equipment that generate waste unnecessarily, as well as waste reduction efforts that are already in place. Before the walk-through begins, contact department managers to inform them of the visit and the possibility of short interviews with department staff. (More involved interviews should be scheduled separately.) You may also want to interview custodial workers and operations staff. If possible, schedule the walk-through just before trash pickups to allow a sufficient amount of waste to accumulate. Avoid scheduling it on or around holidays, company parties, or other special events that would produce wastes not representative of a normal workday. During the walk-through, ask questions about variations in daily waste generation. For example, periodic deliveries may result in more discards on the delivery day. In addition, ask about any recent or upcoming changes within the department, such as new equipment or procedures, that could alter the types or amounts of waste generated. Larger companies may want to record information gathered on the walk-through by
department, copying this worksheet as needed.
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