How to - Using more waste materials in your manufacturing process

Enhancing waste utilisation in your manufacturing process is pivotal for fostering a circular economy and promoting sustainable manufacturing. Let's delve deeper into each step:

1. Conduct Waste Audits:

This initial step allows you to understand the quantity and type of waste generated by your operation. Toyota, a leading automobile manufacturer, is well-known for its rigorous waste audits. They identify and classify every waste stream in their facilities, helping them spot opportunities for reuse and recycling. Toyota's efforts in waste auditing are part of their broader circular economy strategy, aiming for zero waste to landfill.

2. Implement Waste Segregation:

Segregation makes waste management easier and aids recycling. Tech giant HP enforces strict waste segregation practices at all their manufacturing sites. By separating waste into distinct categories (metals, plastics, paper, etc.), HP facilitates efficient recycling and contributes to reducing landfill waste. These efforts are central to HP's commitment to sustainable manufacturing.

3. Encourage Waste Minimisation:

Adopting waste minimisation strategies, such as lean manufacturing, can help reduce the volume of waste generated. General Motors, a prominent player in the auto industry, employs lean manufacturing techniques to cut down on production waste. By doing so, they have managed to divert 90% of their manufacturing waste from landfill, a significant contribution to their sustainable manufacturing initiatives.

4. Utilise Industrial Symbiosis:

Forming partnerships where waste from your company becomes a resource for another fosters a circular economy. A prime example is the Kalundborg Symbiosis in Denmark, a network of companies that exchange waste and by-products. For example, waste steam from a power plant is used by a nearby pharmaceutical company, while surplus yeast from a bioethanol producer is used as fish feed.

5. Explore Waste-to-Energy Opportunities:

Converting waste into energy can significantly reduce waste volumes. BMW Group, for instance, captures biogas from organic waste in its production process to generate heat and electricity. This waste-to-energy initiative contributes to BMW's sustainable operations and circular economy strategies.

6. Invest in Waste Processing Technologies:

Advanced technologies can turn waste into valuable resources. IKEA, the home furnishings retailer, invests in recycling technologies to transform waste from its manufacturing process into raw materials for new products. This approach is fundamental to IKEA's circular economy strategy and its ambition to become a fully circular business by 2030.

7. Develop New Products from Waste:

Creating new products from waste materials promotes a circular economy. Nike's Flyleather material, for example, is made from 50% recycled leather fibres, utilising waste from the company's own manufacturing process. By doing so, Nike not only reduces waste but also creates a high-quality material that enhances its sustainable manufacturing practices.

8. Collaborate with Supply Chain Partners:

Collaborating with supply chain partners can unearth further opportunities for waste utilisation. Cisco, the technology conglomerate, has established partnerships to manage electronic waste, transforming it into valuable materials for reuse in the production process. This forms a significant part of Cisco's sustainable operations and its circular economy initiatives.

9. Seek Certifications:

Certifications such as Zero Waste to Landfill can validate your waste management efforts. Bridgestone, the tyre and rubber company, has achieved Zero Waste to Landfill certification in many of its facilities, demonstrating its firm commitment to sustainable manufacturing and waste reduction.

10. Create a Waste Management Culture:

Encouraging all employees to partake in waste reduction and recycling fosters a culture of sustainability within the organisation. 3M, for instance, has integrated waste management into its corporate culture. Through initiatives like their "Pollution Prevention Pays" program, they've engaged employees across departments in waste reduction efforts. Their proactive approach has led to a significant reduction in waste generation, aiding their shift towards a circular economy.

By effectively utilising waste from your manufacturing process, you not only contribute towards environmental conservation but also uncover new opportunities for cost savings and innovation, driving your circular economy and sustainable manufacturing initiatives forward.