Page 435 - Solid Waste Analysis and Minimization a Systems Approach

CASE STUDY 413

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 lb/week to 1000 lb every 3 weeks.
Transferring resin pellets to production areas often resulted in losses before the
waste reduction efforts began. STARTEX’s waste reduction team found that approxi-
mately 248,500 lb 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 systems were 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 were then used for making lower-grade
packaging.
To implement the changes in handling resin pellets, the waste reduction team doc-
umented procedures for cleaning up pellets and provided training to employees.
STARTEX continues to receive virgin pellets in 1000-lb 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 would purchase the boxes for reuse, if they are properly broken down. STARTEX
received approximately $36,000 annually from the sale of its used boxes.
Plastic sheeting produced at STARTEX is shipped out on solid paper cores. Cores
were purchased in 12-ft lengths and were cut to fit the various widths of plastic prod-
ucts. STARTEX generated approximately 5000 to 6000 lb of paper core waste every
3 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 require-
ment 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 $8000, which were used exclu-
sively to collect and store the waste cores.
In terms of results and cost savings, STARTEX had disposed of approximately 2500
tons of solid waste at a cost of $90,000 ($35 per ton). After implementing the