Page 434 - Solid Waste Analysis and Minimization a Systems Approach

412 PLASTIC AND RUBBER MANUFACTURING

31.5 Case Study

STARTEX produced multilayered plastic film sheeting and used a blow-film extrusion
process to make plastic packaging for commercial, medical, food, construction, and
agricultural products. It manufactured about 60 million pounds of packaging materials
annually.
STARTEX was disposing of approximately 16 to 20 tons (two or more 40-yd dump-
sters) of solid waste weekly. This waste consisted of polyethylene film scrap (extruded
plastic waste), resin pellets, and cardboard (from Gaylord boxes and paper cores). As
production increased, the waste volume increased to three 40-yd dumpsters weekly, or
approximately 1150 tons annually. In addition, disposal costs were increasing by
approximately $3 per ton annually.
STARTEX addressed its 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.
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 reused.
■ 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.

The most successful waste reduction technique used at STARTEX was good house-
keeping. 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 (extruded plastic waste from the manufacturing process) contributed
to over 50 percent of the total waste generated at STARTEX. Approximately 8 tons of
scrap was 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