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Zero Waste to Landfill. Wilson NC April 2014. Who we are…. 1 st tire built on March 1,1974 Current size – 60 acres under roof Parking lots – 10 acres. What we do…. Recycling 100% of plant waste ~58,700 lbs of waste/day 350 acre Wildlife Habitat. 40th Year of operation
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Zero Waste to Landfill Wilson NC April 2014
Who we are… 1st tire built on March 1,1974 Current size – 60 acres under roof Parking lots – 10 acres
What we do… Recycling 100% of plant waste ~58,700 lbs of waste/day 350 acre Wildlife Habitat 40th Year of operation ~$160 Million annual payroll No Layoffs! Union Free! 378,148,558 tires built so far 7 sizes (15-22”) 33,800 tires per day 2,125 team members Large contributor to the United Way of Wilson County Multiple Community Awards Only Run Flat Capable Plant in North America 11 OE Customers
What we have accomplished… • ISO 14001 - Environmental Management System • ESI - Environmental Stewardship Initiative • WLH - Wildlife Habitat • ISO 50001 - Energy Management • SEP-Silver - Energy Performance • ULE - “ZWLF” Underwriter Laboratories Environment
Bridgestone Freedom Wildlife Habitat Certified by the US Wildlife Habitat Council as “Corporate Lands for Learning” since 2006 (recertification every three years) and as “Wildlife at Work Site” (recertification every two years) Approximately 350 acres of habitat Freedom Wildlife Habitat & Refuge
Our Commitment to the Environment Value Natural Resources In Harmony with Nature Reduce C02 Emissions • Reduce the overall weight of our tires and the resources needed to produce them while maintaining performance • Promote retreading, which requires fewer resources to manufacture a tire • All scrap material from manufacturing and 98% of scrap tires from our 2,200 retail stores nationwide are recycled or find other valuable end use • Researching new, renewable sources for natural rubber • The company maintains nine wildlife habitats and learning centers certified by the Wildlife Habitat Council (WHC) • The Bridgestone Environmental Education Classroom and Habitat (BEECH) was named the 2010 Corporate Habitat of the Year by WHC • Reduce CO2 from entire products lifecycle by 35% per sales • Improve tire rolling efficiency by 25%, resulting in less fuel use and CO2 emissions while driving
What ZWLF means to us… • Zero means nothing goes to Landfill • 100% of waste is diverted from landfill • All materials (waste) that are generated onsite will be recycled/repurposed to build something else or will be used to generate energy (WTE) visits Bridgestone November 2013 for ESI Meeting NCDENR Secretary John Skvarla
Some material we recycle/repurpose • Uncured rubber • Cure rubber, rubber with wire • Sludge • Pigments and carbon black • Wood • Metal • Plastics • Packing materials (super sacks, waxed paper, shrink plastic, cardboard, plastic belts, etc) • Lamps and ballast • Batteries • Cafeteria and restrooms waste
Our Journey to ZWLF 2011 to 2013 • Identified the need to recycle • Created a plan • Identified / selected opportunities for recycle • Established a team – internal and external members • Defined responsibilities at all levels including key areas for start -up (environmental engineer, plant manager, onsite waste management service, communication department, etc.) weekly meetings • Communicated the program • Asked for HELP from everyone, all the time • Continuous communication including pictures • Show what we are looking for and why
Hands on • Dumpster Dive by implementation team • Determine recycling containers needed and provide them • Define roles and responsibilities • Eliminate or reduce trash/waste where possible • Provide training and visual aids with color coding recycling containers • Monitor containers (take pictures and share them) • Conduct assessment • Share results monthly Employees meeting (including contractors)
Tracking systems 2011 Approximately 36% of our waste was sent to landfill
Hands on • Efforts were focused on highest numbers (from tracking system -volume and cost such as: Rubber, pinvents, bladders, plastics ) • Continuous conversation with areas where major volume of materials were generating, some Kaizen projects were developed in order to reduce generation and to help recycling process “pinvents” capture high volume
Employee Involvement • TV monitors communicate information • Internal news letter • Monthly meetings to share results . Teammates were more aware and open to change when they understood the benefits. (cost, revenue, and recycle %)
Sharing results 2010 to 2012 Recycle % monthly tracking system Revenue is better while recycle volumes increased
Sharing ideas • Final inspection dust collection • IT and electronics materials needed a special container
Outside conditions • Good clean-up of metal helped us generate more revenue and improved the look and safety of outside and storage areas • Weekly monitoring to insure no return to bad habits
Outside cleanup Special equipment to handle materials Ready to recycle
Better view of storage areas Before After
Tracking system 2nd half of 2012 90% Recycle
Sharing results 2010 to 2013 Recycle % monthly tracking system Revenue doing even better while increasing recycle volume Cost of Service - after revenue
Decision for WTE • On January 2013 we decided to use WTE option for the last part 6.5% of waste (trash compactor ) and sent the waste to Wheelabrator and Colvanta facilities • Landfill = $57 / Ton • WTE = $75+ (Trash) $265 (Rubber) • We generated some work opportunities, hiring 8 people to sort trash containers and make sure that we do not send anything inappropriate to the WTE facilities or miss any recycling opportunities • Got involved/participated with local recycle committees
Bumps and Headaches • Current vendors who buy or take large volumes of rubber, may have problems too and may call and say “Sorry but we can not take any more of your materials” • Pricing is subject to commodity market • Not only for rubber but with wood, plastics, & other materials • Always try to have more than one option for all materials
Recycle • Be a good corporate citizen – Do the right thing – Recycle!
Thank you… Thank you!