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study |
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Plastics Manufacturer Reduces Waste
through Good Housekeeping and Recycling
Company:
Startex;
Lakeville, Minnesota; employs 200 people and produces
60 million pounds of product annually
Industry:
Manufactures plastic sheeting and extruded plastic packaging
for commercial medical, food construction and agricultural
Waste:
Various wastes: polyfilm scrap, resin pellets, cardboard
boxes and paper cores.
Change:
Implemented techniques to reduce or reuse wastes.
Cost:
$8,000 for wire cages to contain paper core waste.
Results:
Reduced total volume of solid wastes by 88 percent,
saving $72,000 annually in disposal costs and generating
$36,000 annually from resale of used gaylord boxes.
Background
STARTEX manufactures
a variety of plastic packaging for commercial medical,
food, construction and agricultural products. It produces
multi-layered plastic film sheeting and uses a blow-film
extrusion process to manufacture approximately 60 million
pounds of packaging materials annually.
In 1988, STARTEX disposed
of approximately 16 to 20 tons (two or more 40-yard
dumpsters) of solid waste weekly. The waste consisted
of polyfilm scrap (extruded plastic waste), resin pellets
and cardboard (from gaylord boxes and paper cores).
As production increased, the waste volume increased
to three 40-yard dumpsters weekly, or approximately
1,150 tons annually. In addition, disposal costs were
increasing by approximately $3 per ton annually.
As part of its commitment
to continuous process improvement, STARTEX addressed
the growing waste problem by establishing a waste reduction
team. The team consisted of five to eight employees
who worked to identify the types, amounts and sources
of solid waste generated, and to find ways to reduce
this waste.
Waste Reduction
Initiatives
To
start the waste reduction process, the Waste Reduction
Team held early morning "dumpster dives," during
which team members would sort and document the types and
volumes of solid wastes being disposed of in dumpsters
at STARTEX.After
collecting this initial data, the team developed a strategy
for reducing solid wastes, which included:
- Focus the first waste reduction
efforts on a waste that could be greatly and quickly
reduced to show results that would stimulate employee
participation.
- Review and evaluate the process(es)
generating a waste to determine how it can be modified
to reduce or eliminate the waste.
- Explore possibilities for reusing
or recycling wastes that cannot be reduced.
A critical part of implementing
the waste reduction strategy was to provide training to
employees on waste reduction techniques, and encouragement
and motivation to participate in the overall effort.
Waste
Reduction Techniques
The most successful
waste reduction technique used at STARTEX was, and is,
good housekeeping. By preventing spills and raw material
contamination, waste generation was greatly reduced.
The four primary wastes reduced at STARTEX and the techniques
used to reduce or eliminate these wastes are detailed
below.
Polyfilm Scrap.
Polyfilm scrap (extruded plastic waste from the manufacturing
process) contributed to over 50 percent of the total waste
generated at STARTEX. In 1988, approximately eight tons
of scrap were generated weekly. Because this scrap was
the largest contributor to STARTEX's waste volume, it
was the focus of the first waste reduction project. By
showing quick and large reductions of this waste, the
Waste Reduction Team speculated that STARTEX employees
would see the results of their efforts and be more likely
to accept and contribute to the overall waste reduction
process.
After
comparing purchasing data with waste volume data, the
Waste Reduction Team found that only 80 to 90 percent
of the virgin polysheeting fed into the extrusion equipment
became product. After evaluating reuse options, the
Team determined that polyfilm scrap could be fed directly
back into the extrusion process along with virgin material
to produce lower-grade packaging (not medical or food
packaging).
The
Waste Reduction Team documented procedures on how to
reuse scrap in the extrusion process and provided training
to employees.
By reusing polyfilm
scrap, STARTEX reduced the amount of scrap it disposed
of by 97 percent from
approximately 16,000 pounds per week to 1,000 pounds every
three weeks.
Resin Pellets.
Transferring resin pellets to production areas often
resulted in losses before the waste reduction efforts
began. STARTEX's Waste Reduction Team found that in
1992, approximately 248,500 pounds of resin pellets
fell onto the floor while being loaded into process
equipment, and were subsequently disposed of.
The
Team evaluated ways to prevent pellet loss and implemented
the following changes. First, the conveyor system was
improved to convey the pellets directly into the processing
area. Second, after it was found that up to 5 percent
of all resin pellets used remained inside the cardboard
gaylord boxes (caught under the flaps), the boxes were
replaced with steel tanks. Since steel tanks had no
edges or flaps, pellets could be completely removed.
Next,
the Team determined that spillage, however minimal,
would continue to occur. The alternative to disposal
was to collect the pellets and send them off site to
be washed and reprocessed at a cost that was significantly
lower than the purchase cost of virgin pellets. These
reprocessed pellets are now used for making lower-grade
packaging.
To
implement the changes in handling resin pellets, the
Waste Reduction Team documented procedures for cleaning
up pellets and provided training to employees.
Cardboard Gaylord
Boxes. STARTEX continues to receive virgin pellets
in 1,000-pound quantity
cardboard gaylord boxes, which are then emptied into
steel tanks. The boxes cannot be recycled, however,
because they are contaminated with resin pellets that
are difficult to completely remove. After exploring
alternative disposal options, STARTEX found numerous
companies that will purchase the boxes for reuse, if
they are properly broken down. STARTEX currently receives
approximately $36,000 annually from the sale of its
used boxes.
Paper Cores. Plastic sheeting
produced at STARTEX is shipped out on solid paper cores.
Cores are purchased in 12-foot lengths and must be cut
to fit the various widths of plastic products. STARTEX
generated approximately 5,000-6,000 pounds of paper core
waste every three weeks and was anxious to find a recycling
market for this material. However, the Waste Reduction
Team was unable to find a recycler who would accept the
cores. STARTEX staff contacted the supplier of the paper
cores and found that it shredded and reused its core waste.
Since the supplier was only a few miles away, STARTEX
worked out an agreement with the supplier to take back
the waste cores. One requirement of the supplier was that
the cores be free of plastic waste. To help employees
keep the cores clean and to prevent accidental contamination
from other wastes, STARTEX purchased open-wire cages for
a total of $8,000, which are used exclusively to collect
and store the waste cores.
Results
Cost Savings. In 1988,
STARTEX disposed of approximately 2,500 tons of solid
waste at a cost of $90,000 ($35 per ton). In 1994, it
disposed of approximately 290 tons at a cost of $18,000
($62 per ton). This is a savings of $72,000 annually
(not including the increase in disposal costs per ton)
and an 88 percent reduction in total waste volume.
In addition to reduced
disposal costs, selling the used gaylord boxes generates
approximately $36,000 annually in additional income.
Employee Satisfaction.
Since employees have seen the results of their efforts,
most are committed to STARTEX's continuous process improvement
efforts to reduce waste. A monthly newsletter to employees
includes articles from the new Material Conservation
Team (formerly the Waste Reduction Team) that highlights
overall waste reduction successes. The articles also
show amounts and disposal costs of wastes still produced,
and encourage employees to find solutions to waste problems.
Customer Satisfaction.
Customers have reacted very positively to the "clean
shop" appearance resulting from the waste reduction
efforts and good housekeeping practices at STARTEX.
Customers from the medical industry who must audit STARTEX's
operation are particularly pleased with the clean results.
Keys
to Success
The most significant factors
contributing to the waste reduction success at STARTEX
are:
- Forming a team, composed of employees
from throughout the operation, to focus on waste reduction.
- Training employees.
- Communicating to employees through
an in-house monthly newsletter that provides:
- updates on waste reduction
efforts.
- recognition of company-wide
accomplishments in reducing waste.
- encouragement to employees
to be ever mindful about reducing wastes, cutting
costs, and keeping a clean shop.
Future
Goals
STARTEX's
goals are to continue to encourage employee involvement,
retain employee enthusiasm for waste reduction, and
reduce solid waste disposal from 290 tons per year to
8 tons, or one 40-yard dumpster per year.
For More Information
MnTAP has a variety of technical assistance services available to help Minnesota businesses implement industry-tailored solutions that maximize resource efficiency, prevent pollution, increase energy efficiency, and reduce costs.Our information resources are available online. Or, call MnTAP at 612.624.1300 or 800.247.0015 from greater Minnesota for personal assistance.
Acknowledgements:
This case study was prepared with assistance from Roger
Anderson of STARTEX.
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