Solid Waste Solutions

This Waste Minimisation Project presents a unique opportunity for Australian Industry to work Cooperatively on Waste Issues. The collaborative nature of the Project extends to a commitment by member companies, of disseminating Case Studies that will benefit Industry as a whole. The following Case Studies represent a series that showcase successful projects, undertaken by companies committed to Environmental Waste Management.

Case Study 1:

Background
Abbott Australasia is a pharmaceutical company based in Kurnell. They manufacture and distribute a range of products to supermarkets, pharmacies and hospitals.

The Initiative
One of their product lines involves being imported from the US. Due to the nature of the product and the quality standards required it needs to be sent in special packaging that keeps it at a low temperature. To achieve this the packaging system used comprises of an expanded polystyrene box with a lid and rigid plastic ice bricks.

The packaging has been reviewed and alternatives are not available that do not compromise the temperature requirements or increase the costs and environmental impact through a higher weight per pack which impacts on the transportation.

Up until recently the company has been stockpiling these components, investigations for alternative methods of disposal turned to a search for options for reuse.

Reducing Waste to Landfill
A local solution to the problem occurred when an arrangement was made with a local fish market who have agreed to take the complete EPS boxes as well as the ice bricks. To date they have received the equivalent of 3 truck loads of the boxes as well as 400 of the rigid plastic containers which equates to 2 cubic meters.

Within the Pharmaceutical Waste Minimisation Group meetings discussions around options for the potential uses of the individual segments of EPS that have been stockpiled. These are not suitable for the fish market and currently Abbotts has 25 pallet loads. The company is currently exploring sending these to Reverse Garbage which was a suggestion from the last group meeting.

These arrangements will now continue on a permanent basis.

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Case Study 2:

Background
GlaxoSmithKline is one of Australia's largest manufacturers of Toothpaste. The manufacture of toothpaste involves two main stages. In the first step raw materials are dispensed into large tanks, where the product is mixed, then pumped into holding tanks. The next step involves filling of the toothpaste tubes on automated filling and packaging lines.

Wastage of toothpaste can occur through factors like overfilling of tubes, damaged product, incomplete emptying of storage containers and cleaning of the system between product changes. Disposal of the waste toothpaste placed significant demands on the company's treatment plants and required significant quantities to be sent to landfill.

The Initiative
GlaxoSmithKline was already seriously attempting to find innovative solutions - eg. Exploring if there are other companies who could use the waste product for practical purposes?

Clearly the best solution was to reduce the amount of waste being generated, and a project was initiated targeting approximately 50% reduction in wastage. This equates to approximately $50,000pa cost saving.

A team was put together from Finance, IT, Operators and facilitator, Production Planner and EH&S. The project was lead by Natalie Chung from finance.

Some Good Ideas Implemented
Some of the achievements included:
· Improved process control to reduce overfilling of tubes.
· Increased awareness of waste reduction as a key issue, and the cost of such waste.
· Reduced cleaning losses through improved campaign runs.
· Improved techniques to minimise residue in filling tanks

Achievements and Savings.

Year Waste Quantity ( Tonnes)
1999 199
2000 140
2001 60YTD- August

The financial impact at August YTD is savings of $32,000, and the target of $50,000pa should be achieved.

A major additional benefit was the reduced load on the waste treatment plant, which meant the current plant did not need replacement.

Interestingly the quantity of waste has now reduced by so much that the quantity to be disposed of may now be to small to be of interest to a potential "reuser".

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Further Information on the AMC Industry Waste Minimisation Program and Additional Case Studies may be obtained by:

Phone: (02) 9209 4051
Fax: (02) 9209 4470