Professional Documents
Culture Documents
Stretch Wrap Recycling
Stretch Wrap Recycling
Stretch Wrap
Recycling
A How-To Guide
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Table of
Contents
1 INTRODUCTION
Why Recycle Stretch Wrap?
Getting Started
14 CASE STUDIES
Stretch Wrap Recycling at Pepsi-Cola Allied Bottlers, Inc.
Stretch Wrap Recycling at Target Stores
Stretch Wrap Recycling at Anheuser-Busch, Inc.
Stretch Wrap Recycling at Spartan Stores, Inc.
T
he purpose of this guide is
on the bottom line.
to encourage and promote
the recycling of a product
Recycling stretch wrap offers an attractive alter-
commonly used by distributors
native to disposal. There are ready markets for
in a wide variety of industries —
clean material and many firms are especially
stretch wrap.
interested in working with businesses. Also,
stretch wrap is relatively easy to identify and
Stretch wrap is most commonly made of linear
recover. It arrives at the dock in a fairly clean,
low density polyethylene, or LLDPE. Most of us
uncontaminated state. If kept that way, it has real
know it as the material that secures pallets of
market value. In fact, pound for pound, stretch
individual containers. Pallet stretch wrap is
wrap may be the most valuable scrap material a
used by product manufacturers and distributors
W/DC can recover.
to bind shipping cartons to pallets going to a
warehouse/distribution center (W/DC). It is
also used at the W/DC to wrap pallets sent to
outlets/customers.
The guide is targeted primarily to firms with one • Design a collection and handling system
or more W/DCs where products are received tailored to your operation.
from manufacturers and then distributed to
downstream outlets/customers. The fundamen- • Educate program participants.
tals should assist any location receiving and
unwrapping stretch film from pallets in develop- • Implement a quality control program.
ing a viable stretch wrap recovery program. Four
case studies have been provided to demonstrate
how a stretch wrap recycling program can be
adapted to meet the needs of a given organiza-
tion.
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Locating a Market
There are currently more than 280 firms in
the United States that accept LDPE/LLDPE
film, although only a handful of these com-
panies are able to process the large amounts
of stretch wrap recovered by large-scale
distribution operations.
T
he first step in developing a
stretch wrap recycling pro - The American Plastics Council maintains a
gram is finding a market that national database of post-consumer plastics
will purchase or accept the handlers and reclaimers that is accessible
recovered material. The through a toll-free hot-line — 1-800-243-
market will dictate the price 5790. This service is designed to network
paid for recovered stretch wrap and the buyers and sellers of recovered plastics and is
material specifications. Those two factors — continually updated as the business of plastics
price and specifications — will shape the recycling grows.
recovery program.
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Markets
• a handler — an intermediate
scrap processor that will sort,
bale and/or shred material;
• an end-product manufacturer
— a company that manufactures
a finished product from post-
consumer plastic.
Stretch Wrap Generic modified 12/12/97 8:28 PM Page 5
O
nce a market is located and
stretch wrap recovery program. Ask your
the material specifications
vendors to keep tape and labels off the
are understood, a system
stretch wrap, and not to use tinted film.
for collecting and process-
This will simplify recovery and increase the
ing stretch wrap can be
value of the material considerably. Just as
put into place. The most
important is letting vendors know how
efficient stretch wrap recovery operations
successful your stretch wrap recycling
are integrated with the recovery of other
program is and that you appreciate the
materials, such as corrugated cardboard and
important role they play in its success.
wooden pallets.
Warehouse/Distribution
Diagram A
Stretch Wrap Recycling Flow Chart Center
Vendors Collection Containers
Collection containers for stretch wrap should
Pallet Stretch Wrap on Shipments be clearly labeled and conveniently located in
the W/DC to accommodate warehouse oper -
ations.
Pallet Stretch
Warehouse/Distribution Wrap on • Stretch wrap may be removed from incom-
Center Shipments ing pallets of goods near the receiving area.
In this case, special containers for stretch
Cleaned wrap should be located near the receiving
Recycling Recovered
Area/Center Outlets/ area.
Stretch
Customers
Wrap from
Pallets • Wrapped pallets may be moved to other
Baled Recovered areas immediately. The stretch wrap can be
Stretch Wrap removed later, when the pallets are broken
down. To recover this film, collection
containers must be appropriately located
Reclaimer throughout the W/DC.
Products
Pelletized LDPE with • Also, roll-ends and trim scrap may be
End-User Recycled recovered at the shipping area where stock is
from Stretch Wrap
Content palletized and wrapped in stretch film for
shipment to outlets.
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Shipping Personnel
Employees responsible for assembling pallet
loads may also be stripping stretch wrap. This
may take place throughout the W/DC, so
containers for stretch wrap must be distrib-
uted accordingly. Remove the contents of
these containers regularly to avoid overflow.
Again, it is far more efficient to remove tape
and, if necessary, paper labels as pallets are
broken down, rather than waiting until after
the film has been bundled up and mixed with
other stretch wrap.
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Participation
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Troubleshooting
If a multi-material baler is used, it should be
cleaned out when changing over from corru- The recycling center is the
gated cardboard to stretch wrap. Care must final opportunity for quality
be taken to keep the baler free of dirt and
other materials so that clean stretch wrap will control. Stretch wrap that is
not be contaminated. highly contaminated or cannot
Segregated stretch wrap must be inspected be easily cleaned should not
and the contamination removed prior to be sent on to your market. It
baling. Contamination not removed previ-
ously must be removed by the baler operator is very important that sources
prior to baling the film.
of contaminated stretch wrap,
One of the best quality-control mechanisms i.e., loads from a particular
is a conscientious baler operator who inspects
the film as it goes into the baler. Remember,
area of the W/DC, be identi-
clean material will receive the highest price. fied as quickly as possible.
Tape, strapping, labels and other contami-
nants must be removed whenever possible.
This will assure that a glitch
in the system can be fixed
Bales should be stored indoors on pallets or
concrete pads to keep them clean and dry.
before it becomes a serious
Bales stored outdoors should be placed on problem and that the quality
concrete pads and covered with tarps to pre-
vent moisture accumulation and degradation
of the material sent to your
caused by exposure to ultraviolet light. market remains consistently
high.
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The Economics of
Stretch Wrap Recycling
T
he economics of stretch wrap As a rule, however, markets will not accept
recycling can be divided into poor-quality material at any price.
two broad areas: (1) costs and
revenues associated with If your location already has a recycling pro-
recovering the material and gram, many of the costs involved in stretch
(2) the cost savings attribut - wrap recovery will be incremental costs of
able to avoided disposal. In some areas, the adding a material to an existing program.
recovery of stretch wrap is not economical Start-up costs may include the purchase of
unless cost savings from avoided disposal are new collection containers, signage and the
included. development of an employee training pro-
gram. (Table 1 lists major cost items. ) In
calculating the annual cost of recovering
Table 1 stretch wrap, both the incremental costs and
Cost Elements of a Stretch Wrap Recycling Program the start-up costs should be spread over the
amount of material recovered. The cost of
Cost Element Comment some items, such as containers, can be spread
Employee training Includes meetings, signage over their useful life. The more stretch wrap
Special containers $45/container; 3-yr life recovered, of course, the lower the per
Baling labor and wire $7.50/bale incremental cost pound cost of recovery.
Transport to market Usually paid by the buyer
Collection labor costs 1 Depend on program efficiency
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P
sixteen-ounce, twenty-ounce and one-liter bot -
Latham, NY: tles) are backhauled from the satellite warehous-
An Overview es to Latham. In addition, any recyclables, such
PepsiCo, Inc. is involved through various divi- as cardboard or stretch wrap that a satellite
sions and subsidiaries in businesses relating to warehouse cannot market locally can be back-
beverages, snack foods and restaurants, both hauled to Latham as well. Table 2 shows the
domestically and overseas. PepsiCo’s beverage materials recycled by Pepsi-Allied (Latham, NY)
business consists of Pepsi-Cola North America in 1995.
(“Pepsi-Cola”) and Pepsi-Cola International
Based on the current tipping fee of $85 per ton
(“PCI”). Pepsi-Cola manufactures and sells
at the Colonie, NY landfill, the avoided cost
beverages, primarily soft drinks and soft drink
savings of recycling 702 tons of solid waste were
concentrates, to licensed independent and
approximately $59,700 in 1995. Therefore, in
company-owned bottlers. Worldwide sales of
addition to the materials shown in Table 2, alu-
Pepsi-Cola beverages totaled $32 billion in 1995.
minum cans and PET bottles were recovered by
Pepsi-Cola Allied Bottlers, Inc. (“Pepsi-Allied”) is Pepsi-Allied.
a licensed independent Pepsi-Cola bottler with
nine facilities in New York, Connecticut and
Massachusetts. Pepsi-Allied has been producing
Pepsi, Diet Pepsi, 7UP and Schweppes bever-
ages at its facility in Latham, NY since 1982. Stretch Wrap Recycling
These beverages are packaged in aluminum
cans, PET bottles and transfer tanks (five-gallon
metal containers used in commercial sales of
soft drinks). The products are shipped by truck Collection
to Pepsi-Allied’s eight satellite warehouses. In Pepsi-Allied’s Receiving Department receives
1995, Pepsi-Allied produced and shipped approximately 20 to 30 truckloads of containers
approximately 24 million cases of beverages. and other materials per day. Most of these goods
arrive on pallets, and the type of packaging
materials used to secure goods to pallets varies.
Approximately 95 percent of the stretch wrap
recovered was used to secure empty PET bottles
Pepsi-Allied and aluminum cans to pallets. The remaining 5
Recycling Program percent of recovered stretch wrap was used to
secure miscellaneous other products received.
Personnel at the receiving dock strip the stretch
Recycling at Pepsi-Allied began in 1991 as
wrap from the pallets, removing any paper labels,
landfill tipping fees in New York State began to
string and other contaminants. Most of the
increase dramatically. Up to that time, Pepsi-
incoming stretch wrap is relatively clean, due to
Allied had been recovering some corrugated
a special effort that Pepsi-Allied has made to get
cardboard, bottles and cans. In 1991, Pepsi-
its suppliers to eliminate these contaminants. As
Allied began to recycle office paper, plastic
a result, contamination levels are low and quality
strapping and stretch wrap.
control does not seem to be a serious problem.
The goal of Pepsi-Allied’s recycling program
The stretch wrap is placed in gaylord containers
was to take environmentally sound measures to
near the receiving dock. Although these contain-
reduce the amount of waste being landfilled from
ers are not clearly labeled, workers recognize
their Latham, NY facility. As a result of the
that they are to be used for stretch wrap. The
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Case Study
Stretch Wrap Recycling at
Target Stores
arget Stores,
T Dayton-Hudson Corporation:
An Overview
Target Stores (“Target”) is a part of the Dayton-
Target Recycling Program
Table 3
Materials Recycled at Target’s Indianapolis W/DC (1995)
Material Amount (tons) Stretch Wrap Recycling
Old Corrugated Cardboard
W/DC 2,325
Stores 5,584
Aluminum Cans 1 Collection
Office Paper 2 The W/DC operates two ten-hour shifts per day,
Stretch Wrap 123 seven days per week. The facility’s 82 receiving
Scrap Metal 3 docks receive approximately 150 to 160 truck-
Pallets 4 loads of merchandise per day. Incoming
Garment Hangers 5 merchandise is secured to pallets with stretch
wrap and strapping. Products delivered to the
1 No figures are available for aluminum cans from soda machines. W/DC are directed to one of two areas. “Flow-
Proceeds from sale of aluminum cans are donated to charity. through” merchandise is received, repacked and
2 No figures are available. sent directly to stores. “Pool stock” is held at the
3 A small amount of scrap metal is taken by a local scrap metal W/DC for shipment to stores at a later time.
dealer. No cash reimbursement. No figures are available. Personnel at the receiving dock strip the stretch
4 Wooden pallets are re-used or repaired through an outside wrap from the “flow-through” merchandise. The
contractor. No figures are available. stretch wrap is placed in appropriately labeled
5 Garment hangers are reused or recycled through an outside con- containers. When the containers are full, they are
tractor. No figures are available taken by forklift to the baler.
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Pallets with merchandise that is to be held in The price Poly-America pays for stretch wrap
“pool stock” are generally not unwrapped when depends on the level of contamination of the
received. The pallets are immediately moved to stretch wrap and current market conditions.
the appropriate section of the warehouse for
storage. When this merchandise is needed, it is
unpacked for shipment to stores. The stretch
wrap is removed and placed in containers located
throughout the W/DC. When these containers are
The Economics of Stretch Wrap
full, they are taken by forklift to the baler. Recycling at Target
Processing
When the stretch wrap recycling program was Target’s recycling program is driven by Target’s
begun, an attempt was made to train receiving desire to be environmentally responsible and to
personnel to eliminate paper labels and other keep operating costs as low as possible. Accor-
contaminants before placing the stretch wrap in ding to Target, the revenues it received for the
containers. However, this training effort proved sale of its stretch wrap exceeded its operating
awkward and complicated and was discontinued. costs. It also benefited from lower disposal costs.
At the present time, all stretch wrap is baled on
the second shift and the baler operator has Target’s costs for solid waste disposal for 1995
responsibility for checking for contaminants. This consisted of an $11.00 per ton hauling charge
is the only quality check done on the stretch and a tipping fee of $19.50 per ton. Total dispos-
wrap. Because stretch wrap in the containers has al costs were $30.50 per ton. The cost savings of
been rolled together or “bunched,” it is difficult recycling 123 tons of stretch wrap were $3,750.
to see contaminants.
For more information, contact:
The stretch wrap coming from the receiving
docks and other areas is baled in a vertical Cram- Target Stores
A-Lot baler made by J.V. Manufacturing Co. of Mr. Jim Boesch
Springdale, AR. The bales of stretch wrap, weigh- Environmental Manager
ing approximately 1,000 lbs, are shipped by trac- Dept. CC-20E
tor/trailer, 38 bales per trailer, to the market. 33 South 6th Street
Minneapolis, MN 55402
Marketing (612) 304-8499
Target sells its stretch wrap to Poly-America.
In 1992, when Poly-America agreed to purchase
Target’s stretch wrap, Poly-America sent a
representative to Target’s W/DC to explain and
demonstrate to Target personnel the quality of
stretch wrap Poly-America expected.
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Case Study
Stretch Wrap Recycling at
Anheuser-Busch Companies, Inc.
nheuser-Busch Companies, Inc., operates at three shifts per day, six days a week,
A Merrimack, NH:
An Overview
Anheuser-Busch Companies, Inc. is the parent
throughout the year. Production of beer at the
Merrimack Brewery is approximately 65,000
barrels per week.
company to Anheuser-Busch, Inc., the largest
beer brewer in the world, and is the parent com-
pany to a number of subsidiaries that conduct
other business operations, including those related
to the manufacture of metal beverage containers,
Anheuser-Busch
the recycling of metal and glass beverage con- Recycling Program
tainers, and the operation of nine theme parks.
Anheuser-Busch Companies, Inc. reported total
1995 sales of 12 billion dollars. Anheuser-Busch Recycling at the Merrimack Plant is carried out
breweries produced 87.5 million barrels of beer in in both the Brewhouse and the Packaging and
1995 in 12 plants across the United States, more Shipping Department. Recycling in the Brew-
than double that of its largest competitor. house is supervised by the Brewmaster and his
staff. The primary materials recovered in the
The Merrimack, NH brewery, built in 1970, Brewhouse are spent grain from the brewing
includes the Brewhouse, where beer is brewed, process and alcohol-bearing wastes, which are
and the Packaging and Shipping Department, distilled into ethanol and sold as automotive fuel.
where the beer is packaged in glass bottles,
aluminum cans and kegs and is then shipped to The Packaging and Shipping Department handles
18 beverage wholesalers in New Hampshire, deliveries from 130 trucks per day, bringing
Maine, Vermont and Massachusetts. The brewery bottles, cans, labels and other supplies. In
general, the materials recovered are generated
in two areas of operation:
Table 4
Materials Recycled at Anheuser-Busch (Merrimack, NH) • the receiving docks — pallets, stretch wrap,
Material Amount (tons) PET strapping, corrugated cardboard; and
Export Grade Fiber 1,725
#1 Kraft Board 530 • the packaging lines — glass, aluminum,
Office Paper 12 PET strapping, stretch wrap and corrugated
PET Strapping 44 cardboard.
Aluminum Cans 51
Stretch Wrap 20 Materials recycled at the receiving dock are
Spent Grain 86,000 handled by receiving personnel and materials
Glass 4,194 recycled on the packaging lines are handled by
Wooden Pallets1 14 the line service personnel.
Beechwood Chips 70
Clydesdale Straw 272
Alcohol-Bearing Wastes 5502
Total 93,482
1 1,100 wooden pallets; 1 pallet = 25.5 lbs.
2 164,000 gallons; 1 gallon = 6.7 lbs; recovered as ethanol.
Source: Anheuser-Busch
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The recycling program is supported by the stretch wrap off the pallets delivered to the line
Nashua, New Hampshire plant of Anheuser- and place it in gaylord containers. When these
Busch Recycling Corporation, a subsidiary that containers are full, they are taken by forklift to
processes aluminum, steel, and glass containers, the recycling dock, where the stretch wrap
plastic, paper goods, and sorts re-usable glass is baled.
bottles.
Processing
Table 4 shows the amounts of materials recycled Incoming stretch wrap contains small amounts
in the Merrimack Plant in 1995. of paper labels, string and other materials.
Individuals collecting the stretch wrap — either
personnel on the receiving dock or line service
personnel — are trained to remove these conta-
minants before placing the film in the collection
Stretch Wrap Recycling containers. Because employee turnover in the
brewery is quite low, training costs are minimal.
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In order to ensure that the stretch wrap met Line service personnel, who already move
Rubbermaid’s quality standards, a representative materials to and from the packaging lines, simply
from Rubbermaid visited the Merrimack Brewery put the recovered stretch wrap in different con-
to review and critique collection and processing tainers. Similarly, the receiving personnel, who
procedures and to inspect samples of the recov- previously would have placed pallet wrap in a
ered stretch wrap. Samples were taken back to trash barrel, now place it in a recycling bin. The
Rubbermaid’s manufacturing plant to be sure cost of additional containers and signage are
they met the necessary quality specifications. assumed to be small. The baler used for stretch
Rubbermaid also provided a pamphlet describing wrap is the same one used for corrugated card-
the quality standards for recovered stretch wrap, board. Anheuser-Busch regards the incremental
including the materials regarded as contami- cost of baling stretch wrap as reasonable. Efforts
nants. The stretch wrap currently recovered by to quantify the exact costs of recycling are now
the Packaging and Shipping Department is very under way.
clean.
It has already been pointed out that the firm
Rubbermaid products made from the recovered receives $0.08/lb for its stretch wrap and
stretch wrap include mop buckets and trash received an estimated $3,200 in revenues in
cans. These are now being purchased by the 1995. In addition, the savings of diverting the
brewery’s Packaging and Shipping Department, stretch wrap from the landfill, based on a tipping
thus “closing the loop” on stretch wrap fee of $65/ton, were approximately $1,300.
recycling. Therefore, the total economic benefit was $4,500.
Anheuser-Busch, Inc.
The Economics of Stretch Wrap Mr. Doug Proulx
Recycling at Anheuser-Busch Environmental Quality Coordinator
221 Daniel Webster Highway
Merrimack, NH 03054
The recycling program at the Merrimack Brewery (603) 889-6631
is driven by a desire to be environmentally
responsible by helping to conserve resources
and preserve the town of Merrimack’s landfill
space. The program was not promoted as a way
to cut costs or generate revenues. In fact, the
exact costs of the recycling program have not
been calculated.
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Case Study
Stretch Wrap Recycling at
Giant Food
Spartan Stores, Inc.
of grocery and related products in the United • distribution services for dry grocery items, pro-
States, with fiscal year 1995 sales of $2.5 billion. duce, meats, dairy products and frozen foods;
Spartan distributes to approximately 525 affiliat-
• reclamation services for damaged items;
ed retail grocers and 8,600 convenience stores
serving Michigan, Ohio, Indiana, Illinois, • recycling services for corrugated cardboard
(OCC), plastic film, stretch wrap and polystyrene
(PS) foam;
• private label brands of many products; and
Diagram B
Stretch Wrap Recycling at Spartan Stores • support services of various kinds.
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The heart of Spartan’s recycling program is its As the incoming pallet loads are broken down for
Reclamation Center, located in Charlotte. The distribution to retail stores, the stretch wrap is
Reclamation Center has two functions. First, it stripped off and placed in bins (usually gaylord
receives and processes damaged food items boxes) located throughout the W/DCs.
from the W/DC and retail stores. It also receives Employees are urged to remove tape and paper
and processes recyclable materials from the labels, the primary contaminants of stretch wrap,
W/DC, retail stores and the city of Charlotte. before placing the film in the bins. The film is
collected in the bins and trucked to the SSRC for
A summary of materials recovered by Spartan in processing.
1995 is presented in Table 5 above. Table 5 does
The second, and smaller, source of stretch wrap
not include recyclables delivered by the City of
is retail stores. Each store receives pallets from
Charlotte, white paper from headquarters, oil and
Spartan’s W/DCs that are covered in stretch
freon from the transportation facility or materials
wrap. In addition, the store also receives prod-
that retail stores may have recovered and mar- ucts directly from vendors, such as soft drink
keted independently.
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By Spartan’s own estimate, it costs the company Table 6 shows Spartan’s avoided cost savings
$0.065 per pound to collect and handle stretch for stretch wrap recovery based on the assump-
wrap, while it receives $0.05 per pound from tion that stretch wrap weighs approximately 150
Trex. Spartan is cognizant, however, that there pounds per cubic yard when compacted.
are avoided disposal cost savings realized by the
program. Table 7 summarizes the costs and revenues,
including the cost savings from avoided disposal
The current tipping fee at the Kent County of the Spartan stretch wrap recycling program.
Resource Recovery Facility is $36.40 per ton.
At the Grand Rapids W/DC, trash is collected in While Spartan benefits from recycling stretch
40 yard compactors. The cost each time a com- wrap, economics are not the main reason why
pactor is hauled is $110.10. Spartan recycles. Spartan assumes the recycling
program, of which stretch wrap recycling is a
part, contributes significantly to customer and
Table 6 community goodwill.
Avoided Cost Savings for Stretch Wrap Recycling
For more information, contact:
Weight of Volume of Savings Savings
Stretch Wrap Stretch Wrap Hauling Tipping Total Spartan Stores
Recovered Recovered Costs 1 Fees 2 Savings
Mr. Ron Bell
1995 Logistics Service Manager
550,000 lbs 3,667 yd3 $10,093 $9,900 $19,993 1055 Mikesell Road
($0.036/lb) Charlotte, MI 48813
1 Assumed to be $110.10 per 40-cubic-yard compactor load. (517) 543-5972
2 Assumed to be $36/ton in 1995.
Table 7
Summary of Economic Benefit of Recovering Stretch Wrap
Avoided Cost Net
Savings Revenues Costs Benefit
$0.036/lb + $0.050/lb - $0.065/lb = $0.021/lb
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A Joint Initiative
with The Society of the
Plastics Industry, Inc.