Page 417 - Solid Waste Analysis and Minimization a Systems Approach

EXEMPLARY PERFORMERS—INCREASING RECYCLED CONTENT IN PUBLISHING 395

■ Increase recycling levels
■ Reduce operating costs
■ Improve waste materials flows and staging within the facility

The facility was rebuilt in 1974 after a major fire; in addition, printing machine and
computer upgrades had rendered the layout obsolete. The team conducted a waste
audit and determined that the facility produced 7500 tons of solid waste per year and
paid about $52,000 in waste removal costs. Under current practices about 15 percent
or 1100 tons were recycled in the form of papers and the company was not generating
any revenue form the sale of these recyclable materials.
The team conducted a value stream analysis for the key processes and determined
that many intersecting and inefficient process flows existed. Limited standardization
was in place and few checks and balances were in place to ensure that recyclable mate-
rial was transported to the correct spot on the dock. The team recommended that the
facility improve and standardize the flows including dedicated space for staging and
clear transportation lanes. The staging areas and lanes were clearly labeled and train-
ing was provided to facility personnel regarding the new system. The recommended
flows were outlined using a computer-aided design template. In addition, an economic
justification of a baler was conducted based on the amount of paper and cardboard
generated. The company was able to justify the purchase of a baler with a payback
period of 3.2 years and a return on investment (ROI) of 17 percent working with a
commodity broker for the baled paper in Detroit, Michigan. The waste hauler contract
was also renegotiated to reduce the amount of pulls by switching to an on-call system
versus regularly schedule collection routes. As a result of the changes, the company
increased its recycling level from 15 to 62 percent and achieved cost avoidance/
additional revenue of nearly $31,000.

29.7 Exemplary Performers—

Increasing Recycled Content

in Publishing

Random House, the publishing company owned by Bertelsmann, the German media
giant, announced in 2008 that it would increase the proportion of recycled paper it
buys for its books to at least 30 percent by 2010, from 3 percent now.
The company currently buys 110,000 tons of uncoated paper to publish books each
year. When it reaches its target of purchasing 33,000 tons of recycled content paper by
2010, it believes that will be equivalent to saving more than 550,000 trees a year and
removing 8000 cars from the nation’s roads, because of the resulting reduction in
greenhouse gas emissions.
“We believe our new paper policy is the right thing for us to do and now is the right
time to do it,” Peter W. Olson, chairman and chief executive of Random House, said
in a statement.