Zero Waste to the Landfill Unifi s Experience. April 2014

Transcription

1 Zero Waste to the Landfill Unifi s Experience April 2014

2 Background on Solid Waste Reduction Strong history of recycling and minimizing waste to the landfill Dedicated company recycling facility (Topsider) Based on recycled quantities through Topsider (primarily corrugated, paper and plastics) and quantities pulled to the landfills, in % of our solid waste streams were being recovered (650 tons/ mo.) Spending approximately $160K per year on landfill tipping fees, hauling fees, and equipment rentals (excluding recycling facility moves & equipment)

3 Drivers for Sustainability Improvement & Zero Waste to the Landfill Growing our Repreve branded family of recycled products. Evaluating what steps to take to further reduce our internal environmental footprint Text Leading companies in sustainability communicate not just externally, Txt but do more to get employees engaged and incorporate sustainability into internal communications Sustainability Text becoming a non-negotiable part of everyone s job, like safety and quality Focus on sustainability attracts the best people, Text enhances brand value, and builds trust with customers and other stakeholders Text Achieving good results on reducing our energy intensity and associated carbon footprint. Wanted to take solid waste reduction to the next level

4 Diving into the Solid Waste Reduction Challenge In 2010 teamed with Sonoco, our major paper tube supplier and the largest purchaser from our recycling facility Dumpster Dives! Found 20% to as high as 80% recoverable material in dives, including some surprises. Averaging 105 tons per month to the landfill Increased management attention on waste streams

5 Next Step - Landfill Free Reduced landfill volumes to 61 tons per month in 2011 Approached by ICE Recycling: Industrial Conservation Engineering Headquartered in Lake City, SC Clients include Highland and Glen Raven ICE Recycling Mission: To reduce a customer s waste handling/landfill costs, reduce carbon footprint, re-use any salvageable waste, and create a positive sustainable position from what was once an expense. Model is to offer a set margin on the value achieved from the waste streams, securing their raw material source. Full-time ICE employee(s) at each site to manage waste streams segregation & maximizing shipping density Any non-recoverable waste streams are incinerated for energy - $0.25/lb. Kicked off the effort to achieve zero waste to the landfill at our Reidsville, NC plant in August 11

6 Landfill Free by August 2012 Reidsville: Aug 11 - Apr 12 9 mos. Madison: Sept 11 - May 12 9 mos. Yadkinville: Jan 12 - June 12 Greensboro: Mar 12 - Aug 12 6 mos. 6 mos. Typically takes 6-12 months from kicking off the effort to achieving landfill free

7 Training for every employee Show & Tell on products made from the recycled streams Replaced black trash bags with clear ones Big trash cans became small trash cans From many trash cans/few recycle bins to many recycle bins/few trash cans Recycle bins in every office. Recycle bins closer than trash cans Trash and recycle bin audits How We Did It Key Learnings

8 Key Learnings - continued Employees asking to bring recyclables from home bins placed at employee entrances Color coded, consistent recycling containers Eventually locked the trash compactors Resolve any issues with existing waste stream customers Identify outlets for more challenging items Educate and work with on-site contractors Hybrid approach for lower volume corporate office

9 2013 Recovered Material Benefits Equivalent Units Quantity Energy Saved KW Hours 33,940,245 Fuels Saved Gallons 5,068,285 Labor Saved Hours 4,728,864 GHG Saved Pounds 10,129,506 Trees Saved Trees 135,945 What was once a cost now generates income every month! Only 2.2% of recovered volumes incinerated for energy

10 Sustainment & Continuous Improvement Periodic communications to maintain awareness Champion at each site - Review monthly summary reports from ICE Recycling Best practice sharing between sites Synergies with ICE Recycling Composting food waste in Yadkinville Recycling paper towels in Madison Implemented a sustainability assessment for our major suppliers Increased focus on reducing our water intensity

11 Internal Awareness Communications

12 Questions?