Landfill Free The Armour-Eckrich, Peru, Indiana Experience.
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Transcript of Landfill Free The Armour-Eckrich, Peru, Indiana Experience.
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Landfill Free
The Armour-Eckrich, Peru, Indiana Experience
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• 18 Operating Facilities;
• 9,800 employees
• $3.7 Billion in sales per year (FY2011)
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• Decrease waste disposal to landfill by 10% in
FY2016 as compared to FY2008 on a production weighted basis;
• One Zero Landfill facility per IOC by 2018.
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JMFG: 10% less waste to landfill in FY2011 as
compared to FY2008 (production weighted);
FY2008: 39,129 tons (6.47 lbs/cwt)
FY2011: 33,700 tons (5.82 lbs/cwt)
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Waste Elimination/Source Reduction; Reuse; Recycle (including compost) Waste to Energy; Landfill
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Zero waste shipped to a landfill for a 12 month
continuous period; The percent of waste reused or recycled must be
at least 50% of the total generated; Incineration without energy recovery is limited to
legally required disposal (hazardous and medical wastes);
Stabilized and landfilled hazardous waste limited to 0.1% of the total waste generated.
The total waste management cost must not exceed 5% above the baseline waste management cost.
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FY2008 = 999 tons/year FY2011 = 440 tons/year FY2012 = 252 tons/year FY2013 = <25 tons/year (goal)
We don’t anticipate any additional loads to the landfill beyond early May 2012, so by June 2013, we should meet the Smithfield Foods definition of landfill free.
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Precooked Bacon Plant, so lots of grease!
White Grease: 4,134 tons/year Brown Grease: 1,403 tons/year Total Amount: 5,527 tons/year
Very profitable: Revenue – White Grease: $3,854,152/year Revenue – Brown Grease: $ 392,253/year Revenue – Total: $4,246,405/year
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If it was easy, we’d all be there:
What’s in there? Plastic sleeves and liners; dirty plastics; paper towels; ear plugs; “dirty” plastics; old corrugated cardboard; wax coated cardboard; wooden pallet scraps; scrap metals; barrels; aluminum cans; paper; used oven belts; ingredient bags; fibers; food waste from employee lunch breaks, etc.
What’s acceptable for recycling?
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Step by Step Process:
Establish BHAG;Form Cross-Functional Team;Designate Team Leader: Ed Schmaltz, Transportation ManagerTop Management Support: Mike Fritz, Plant ManagerBuy-in from all Facility Team MembersPartner with Recycling Firm that will take almost EVERYTHING
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Step by Step Process:
Color coded bags for improved sorting:Black bags for plasticsTan for trashClear for paper
Lock Trash Compactor!
Covanta: Waste-to-Energy Facility in Indianapolis for food scraps
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A Place for Everything:
Cardboard Baler: Boxes, Combos, Paper, Film CoresPlastic Baler: Film, Stretch Wrap, Aprons, Sleeves, Rain Suites and Coats, BandingPlastic Combo: Bottles, Buckets, Tubs, Squeegees, HelmetsPaper Baler: Coated Paper, Copy Paper, Newspaper, Labels, Pallet Tickets, Paper Towels, Ingredient Bags, Glove BoxesMetals Container: Blades, Pipe, Edge Metals, Fuses with Metal Ends, Cans, Air Filters, Lids and Bands from Drums, WiringRubber Combo: Boots, Hoses, Transfer Wheels, Green GlovesTrash: Food Waste, Wood Scraps, Ear Plugs, Hair Nets, Misc.
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Educate, Reinforce New Waste Disposal
Protocols, Update on Progress:
Daily Plant Employee MeetingsReviewed with the EHS Committee (composed of
operations, maintenance, wastewater, QA) Town Hall meeting/CookoutReview of material retrieved from trash compactor
This involvement helped employees improve their habits and inspired them to take pride in their contributions.
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Recycled/Diverted Amounts & RevenueCardboard: 304 Tons/year $32,000/yearPlastic: 384 Tons/year ----Paper: 58.5 Tons/year ----Metal: 25.7 Tons/year $5,275/yearRubber: 3.6 Tons/year ----Mixed Plastic: 1.2 Tons/year ----Aluminum: 1.0 Tons/year $1,004/yearPallets: 121.5 Tons/year $4,800/yearWaste-to-Energy: 48 Tons/year
TOTALS: 947.5 Tons/year $43,079
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Net Annual Savings:
Recycling Revenue $43,079/yearLandfill Cost Avoidance: $31,000/yearCompactor Lease Avoidance: $ 4,800/yearWaste to Energy Costs: ($2,880)/yearTransportation Costs: ($2,800)/year
TOTAL: $73,199/year
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Saratoga Food Specialties:
Decreased solid waste to landfill by 43% from FY2008 to FY2011 (production weighted).
Big push recently:FY2011 Average: 16.1 tons/monthCY2012 (YTD Avg): 11.4 tons/month
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Working with suppliers to get raw materials only
in containers that can be recycled; Labeled bins for all types of waste, right at point
of use; Top management leadership and support Buy in from front line production managers Four balers: cardboard; plastics; woven fiber
totes; bags; Other: wax label paper; pallet stretch wrap;
paper slip sheets; pallet wrapping straps; plastic drums; office paper; aluminum cans.
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FY2008: 4,152 tons (11% of total 39,129 tons) FY2011: 3,615 tons (11% of total 33,700 tons)
Cellulose Casings and Dewatered DAF sludge = 70% of total landfill material
Composting could is a viable alternative to landfill and is less expensive.
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FY2008: 24,542 tons (63% of total 39,129 tons) FY2011: 21,093 tons (63% of total 33,700 tons)
Wastewater Sludges = 80% of total landfill material
Land application of Sioux Falls wastewater sludges would reduce our total JMFG landfill amounts by over 16,800 tons/year (50% decrease overall).
Environmental Land Management or Terra Renewal