Bodine Aluminum Inc. Zero Landfill Roger Nekula - Facilities Manager November 15, 2011
The Goal • Reduce 95% of all Production related waste going to Landfill • Achieve Goal with zero net disposal cost increase
Plan, Do, Check, Act • Plan – What are the waste streams – How to minimize • Do – Set up procedures, vendors, transportation – Establish recycle centers • Check – Verify stream segregation – Verify actual to target • Act – Refine / modify as required
Plan Step 1. Preparation • Establish waste classifications & profiles • Determine waste disposal methods • Recycling Activity (Best Practice) • Waste Cost Summary – Handling (Equipment) – Disposal – Transportation
Waste Classifications Haz Waste, 3% Paper/Cardboard, 21% Plastic, 18% Scrap Metal, 8% Food Waste, 12% Wood, 32% Paint Waste, 2% Light Bulbs, 4%
Total Waste Cost Incineration Cost Handling Transportation Landfill Cost Fuels Blend & Other Cost Recycle Cost
Waste Disposal Landfill Cost dictated by location Other Disposal Cost
Plan cont’d Step 2. Zero Cost Increase & 5Rs • Disposal Cost Reductions (Landfill Cost Offset) – Transportation (Maximize load/ Bulking/ Contract Reviews) – Disposal Cost (Corporate Rates/Consolidation/Waste ID) – Handling (Contractor Cost Reviews/Segregation) • The 5Rs – Reduce (Reduce or Eliminate) – Reuse ( Returnable Packaging, Compost) – Recycle (Plastic, Metal, Paper) – Refine (Identify Wastes, Set up Recycle Procedure, Handling) – Recover ( Energy , Raw material)
Do SEGREGATION @ PROCESS Non-Hazardous Waste Segregation Line side Recycling Centre
Office station – receives recyclables from desks
Plant side and Cafeteria Examples Key Points: Labels 3D Examples Minimized “Trash” Opportunities Standardized
Check 1. Establish a check system Waste being segregated? Waste being disposed of properly? 2. Report performance
Act • Review plan – Adjust as required • Revise recycling or disposal contracts • Reduce incoming materials
Key to Maintain • Make it Visible (Location, Color, Result) • Make it Easy to do (Lineside) • Top Management / Company Support • Continuous Improvement
Questions?
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