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In-Depth Scrap Recycling Case Studies
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Paper Recycling: Packing Suppliers Case Study
A Wide Range of Insulation Types
A supplier approached us with scrap from wire insulation after the metal was removed. We began work with a customer that had a unique filtration problem. We tested various grades of the insulation media and developed a solution that saved the customer money while preventing the insulation materials from being land filled. With this new supply of media, the customer was able to better manage their cost by sticking with one consistent media product.
Capacity Management at its Best
A paper mill was faced with the loss of a key customer late in their production planning process. We surveyed our various customer networks and were able to provide an order that temporarily absorbed the excess capacity for an interim period, allowing the supplier to maintain efficient production while not interfering with their normal customer markets.
A Zero-Landfill Initiative
A supplier needed to find a way to dispose of the wood products resulting from returns of merchandise-without sending any material to landfill. Ramblin Corp was able to create a solution that resulted in a new fuel source, providing the supplier with a truly green outlet for their scrap products and, at the same time, developing a cost effective raw material for the customer.
The Right Recycling Equipment
A supplier that was working with a major scrap company came to us because they were getting low value for their recycled materials while at the same time incurring extra labor cost due to the size and configuration of their scrap materials. Donco was able to network through one of our key equipment suppliers and create a solution that allowed the customer to significantly improve labor efficiency. This new equipment allowed them to reduce staff from three full-time personnel to one, while at the same time increasing the value received for their scrap products.
Reversing the Status Quo
A safety equipment manufacturer approached us with a scrap stream of extremely high temperature-resistant polymer that they had been landfilling since the founding of their business. In addition to creating a profitable market for the material, Donco was able to dramatically improve their material handling process by streamlining movement of scrap through their plant. Cost avoidance, revenue creation and reduced labor all in one solution!
Creating a Tighter Bond
A manufacturer of multi-lamination packaging films was having problems with their clients. Every time one of their sales reps visited a client's plant, they were confronted with complaints about the cost of landfilling the residual "skeletons" after the packages were die cut from the master rolls. Poly Recyclers was brought in to create both a market for the scrap as well as a solution for handling scrap material for their clients. Both were achieved, and the film manufacturer was able to solidify its relationships with its clients.
Saving Green
A manufacturer of alternative fuels approached the Donco family to help identify a cost-effective, organic source of raw material that would work as a binder with the end product. Not only were we able to create the source of supply, allowing the manufacturer to both "green-up" their product and eliminate petrochemicals from their manufacturing process, but we lowered their cost as well.
Freeing Up Connections
A multi-national consumer products company had a campus of manufacturing facilities, but no efficient way to consolidate and recycle the various materials generated by their seven production plants. Further, corporate headquarters would take years to approve capital for the required baling system. Donco created markets for a wide range of the company's scrap - from coated papers to mixed plastics - and financed a $150,000 baling system with a ROI in under 10 months for this consumer products company.
No Money Wasted
The head of a pharmaceutical distribution company contacted Donco with interest in starting a recycling program. The facility was spending $1,500 each week on landfill costs. By identifying the individual materials in the scrap stream and creating a streamlined material handling process through their plant, the Donco team was able to reduce their landfill costs to $500 per week (a $52,000 per year savings), and create a revenue stream of $40,000 per year. With over $90,000 per year falling to the bottom line without any capital outlay, the company is having the Donco team perform magic at their other distribution centers.
Reduce, Reuse, Revenue... and Communication
One of the nationwide coffee chains required all of its suppliers to participate in a "green program" calling for a 100% recycling rate, including shrink wrap, plastic banding, metals, paper cores, etc. Our reply was to accept the challenge and help a packaging supplier achieve the goal. This required specialized processing equipment, specialized transportation, creation of new markets and communication 7 days a week to ensure the movement of scrap was smooth and easy. Needless to say, the fact that Donco has a live person manning the telephones 24 hours a day, seven days a week helped make this project a success. Further, the reduction of landfill costs and the creation of new revenue streams could pay for a round of coffee for the whole team... extra large of course!!