SpecialFocus

by IAPD Recycling Task Force

he IAPD Recycling Task Force formed in 2021 to identify ways in which we can approach recycling as an industry. The task force found that most IAPD members are handling materials responsibly: Manufacturers with zero-waste policies capture trim and shavings, returning it to the beginning of their processes. Many distributors and fabricators manage their scrap carefully and are able to send it back to their manufacturer partners. The task force agreed to collect best practices used by the companies that have mature programs that others can use to start a program of their own or make improvements to their current practices.

Benefits of recycling

The task force identified the following benefits for implementing a recycling program, whether it is company-wide or at an individual distributor location:

• Financial Benefit: The scrap you produce has value, demand is increasing and supply is limited. Furthermore, recycling reduces landfill costs.
• Support Your Customers’ Initiatives: Provides solutions to help meet customer sustainability goals, branding requirements or meet their customers’ requirements/goals. Support customers growth in a changing market.
• Environmental Impact: Contributes to a circular economy, sustainability and the greater good.
• Branding: Promote the value of your recycling program in your community and industry marketing.
• Risk Mitigation: Taking the time to build systems that keep plastics out of landfills and minimizes regulatory and legislative pressures on our industry and livelihoods.

Plus, it’s the right thing to do. The task force agreed that a recycling program might not be a source of revenue. In many cases, the best that can be hoped for is a net neutral outcome. However, there are high-level goals to consider, such as:

• Meet growing customer and market requirements.
• Create a net-positive financial impact by attracting new business opportunities.
• Promote your program in the marketplace to improve your brand and generate goodwill.
• Cost reduction potential.

Getting started

The first step in developing a program is to determine the most common polymers that are going into your dumpster or you are sending to a landfill. Begin your program by focusing on the lowest hanging fruit first; that is, your largest polymers by volume. Then identify recyclers in your area for those polymers.

Next, you will want to define how you will measure your goals; that is, set key performance indicators (KPIs). For example:

1. Recycle 80% of your top 5 polymers.
2. Reduce landfill costs by 75%.
3. Create your own goals — this is your program to measure!

Material collection

To maximize the amount of money you can get for scrap materials, care must be taken when collecting the scrap. Start by establishing a dedicated collection space. In this space, set up well-labeled containers for each type of polymer you plan to recycle. Effective polymer segregation and controlling contamination is critical for several reasons. First, if any other materials are mixed in with the polymers, it could damage the (large, expensive) machinery that the recycler uses. In addition, if a different polymer is added to the container — for example, PVC added to a PC collection bin — not only will it damage the recycler’s equipment, but it’s also possible that chemical reactions will create an unsafe, dangerous environment. In fact, if more than the intended one polymer or any contamination is introduced into a bulk silo system creating a failure, the entire silo must be cleaned and all of the material is sent to a landfill, defeating the purpose of having a recycling program. Finally, even when blended polymers are accepted, they will be much less financially valuable. The bottom line is that clean, segregated materials will fetch a better price from recyclers.

PVC ready to be sent to a recycler. Notice the packaging ensures the most density possible. The label follows best practices: It details what is being recycled, the gross weight and the net weight (without packaging).

Your collection space should be organized, clean and in a well-lit location with clear signage. Make it obvious that these containers are for recycling, not trash. Since many companies have space considerations, ask your recyclers for advice about which polymers can be stored outside vs. inside.

The task force shared these tips:

• Benchmark your existing safety programs for ideas on recycling program discipline.
• Keep polymers stored inside your facility away from saws, routers and truck dock doors to avoid cross-contamination.
• Create a wheeled pallet as a dolly to move gaylords around easily, allowing them to be placed where they are needed for collection and then moved back to the segregation area. No forklift needed!

Packaging

Once you’ve collected your materials, identify and secure the appropriate collection and packaging supplies. Again, the company taking this material from you can give you some guidance about how they want the material. For example, recyclers will detail specific packaging and volumes required for collection and prepaid freight. Ask if they provide the collection supplies, such as gaylords, totes, pallets, etc. Recyclers also might have guidelines that cover the following:

• Masked or demasked
• Lay flat vs scraps in gaylord
• Labeling requirements
• Weights per package, etc.

Training

For a recycling program to be successful, you must train your team on your recycling program and why it matters! You need to earn their buy-in by engaging and educating the team about the program’s value proposition. Company managers and leadership must lead by example and embrace the recycling program. Highlight the financial benefits of properly maintaining segregated materials. Better yet, create an incentive program that allows your team to share in the financial benefits, such as using a portion of the proceeds from the recycled materials to purchase a perk that your team will appreciate.

During your training, be sure to cover how to identify polymers for recycling. For example, see-through polymers are visually similar, but recycle very differently. Mixing polycarbonate, PETG and acrylic can cause equipment damage if recycled together. Also, discuss how and why to segregate based on your recycler’s requirements. And be sure to detail the risks associated with contamination, as outlined above.

Review these guidelines during your regular team meetings so the information is top-of-mind for employees. Training is so important that it cannot be a one-and-done activity.

Shipping considerations

As we know all too well, freight is a major consideration. Be sure to discuss freight costs with your recycler to maximize the value of your return or qualify for prepaid freight. When working with a manufacturer, ask about backhauls when receiving regular inventory to minimize freight costs.

With freight costs being what they are, package density is critical. Some suggestions for more efficient packaging include:

• Cut down larger shapes and stack them flat to increase package density and scrap value.
• Put a top on your gaylord to allow double stacking in the truck.
• Limit your pallet sizes to standard sizes to avoid surcharges.
• Use a bailer to compress lightweight/hollow materials and films.
• Program your router for exit cuts that minimize skeleton/trim size.

Label your shipments properly. For example, be sure the label is visible and easy to read — printed is better than handwritten. Include gross weight of the packaging and contents as well as the net weight of the polymer being returned. Be specific about the polymer in the package. For example, if you are recycling clear acrylic sheet, indicate whether it is cast, continuous cast or extruded. Include the color of the polymer on the package’s label. Number your pallets and gaylords to correspond with a master packing list and be sure to include your company name, address and contact information. Include a packing list of what is being returned to itemize and tracking purposes.

Can’t find a recycler?

What happens if you can’t find a recycler? Before giving up on recycling, here are some tips from the task force. If your company has multiple branch locations, try negotiating multiple pick-ups between locations with your recycler. You can also use internal transfer activity to aggregate material in a centralized location. If recycling just isn’t possible, explore other options, such as waste-to-energy. Waste-to-energy companies will often take comingled and/or contaminated materials.

You can also consider upcycling. For example, if you are creating larger drops, sell those drops to fabricators creating smaller parts or inventory for future jobs. Advertise scrap materials to your local community; chances are good that there’s a hobbyist looking for materials that you are trying to get rid of. If you just want it gone and don’t think you’ll be able to make any money from the material, you can have a box of free material available for your local customers, or consider donating it to a school, Scout troop or other local nonprofit organization.

Closer to closed loop

As an industry, it is imperative that we handle our scrap materials responsibly. The tips in this article can help you ensure that your scrap becomes something else that someone, somewhere will value. If you can make a profit while doing the right thing, even better.

Download the best practices document

Click on the QR code to download a PDF of the Recycling Best Practices document to share in your organization: