How Do Manufacturers Recycle Waste Materials?

Waste in manufacturing is an unfortunate reality. However, manufacturers can actively mitigate the effects of waste by recycling. 

Even the leanest manufacturing facilities create waste. Companies, families, and individuals all play a role in the buildup of waste. 

However, that doesn’t mean we should give up and let the waste go to the landfill. 

Recycling industrial waste is an opportunity to redeem useful metals, glass, and other materials from the scrap produced during manufacturing. 

Learn more about how to recycle industrial waste and how NRTC Automation can help below. 

Recycling in manufacturing 

Source of industrial waste  

Industrial waste is produced by manufacturing companies, construction sites, and production and power plants. The waste can be a by-product of manufacturing, like raw materials such as metals, or it may be broken and defective equipment that cannot be repaired.  

When a company finishes a project and completes a tear out of their facility, there is a huge opportunity for recycling materials. Recyclable industrial waste is also produced on a day-to-day basis as production occurs and scrap material is left over.  

What is tear out waste?  

Tear out waste is any material that is not part of the company’s valuable equipment or resources.  

Waste can be anything from scraps of manufacturing material to profitable materials like copper, or even remnants from lunch break. It’s important to identify waste production to prevent future debris and to save money and materials. Perhaps it is even more important to identify how to correctly manage waste so that resources are used and energy is saved.  

Defining the end-state  

One of the most important parts of decommissioning a project is defining the end-state. The end-state is the goal of the project: a broom-ready facility prepared to take on a new project. Defining the actions that need to happen to get to the end-state will outline our strategy for completing a tear out.  

The end-state is also necessary for considering how we deal with tear out waste. In order to achieve a broom-ready facility, we will need to manage waste in a way that is both efficient and environmentally responsible. 

Common recycled industrial materials  

A few of the common industrial materials that are recyclable include:  

• Scrap metals (copper, iron, aluminum, etc.)  

• Glass  

• Plastics  

• Scrap tires  

• Chemicals  

• Digital waste  

Most manufacturing by-product can be recycled, which makes it even more important for manufacturers to take action and recycle their waste. 

Chemical waste in particular is necessary to recycle, or at least dispose of responsibly, because of the risk of contaminating groundwater and other resources. 

Recycling process  

Recycling is a standardized step-by-step process from picking up the waste to presenting repurposed materials to be used for new products.  

• Once the materials have arrived at the processing center, they are dumped and sorted. The sorting process may be done by hand or with automated lines.   

• The waste will then be processed once it has been accumulated into groups. Waste can be broken down, melted, or separated by parts and reused.  

• Finally, the waste is transformed into a useable product and can be sold to companies that utilize recycled materials to create new products and be reintroduced to the market.  

Repurposed products  

Recycled materials can be reused to create repurposed products, such as:   

• building materials  

• industrial equipment and storage  

• glass products  

• cables  

Using repurposed products are cost-effective and marketable for being sustainable.  

Let your customers know your green habits! They may be more loyal customers if they know you are doing your part to improve the sustainability of your company. 

Prevent waste by recycling usable materials.  

You can contribute to the movement toward a sustainable world by recycling viable industrial waste.  

Conforming to the Superfund law and keeping waste out of landfills will allow materials to be repurposed, preventing more pollution and litter from soiling the planet.   

DO YOU NEED PROFESSIONAL SERVICES TO DECOMMISSION YOUR FACTORY?  

NRTC Automation is renowned for our decommissioning and tear out services. We provide tear outs for all industries in factories and manufacturing facilities around the world. With our dedication to complete the project on your time requirements, our strategic planning process, and our team’s commitment to your project, it’s no wonder that we are trusted by the world’s top automobile manufacturers.  

Contact NRTC Automation today to discuss how we will decommission your factory according to your standards. 

The Biggest Problem with Your Manufacturing Line, And How You Can Fix It

By being prepared and proactive, manufacturers can prevent their companies from sinking under financial stress. 

Manufacturers should be flexible, aware, and ready to take action at any point during the production process. 

Without these crucial qualities, they may struggle to fix the biggest problem in almost every manufacturing line. 

Learn more about this pervasive issue and how to fix it below. 

Overcoming the biggest problem in manufacturing 

What is the biggest problem in manufacturing? 

When working toward improved manufacturing processes, the inclination is to take away excess rather than add on. Like the French writer and aviator Antoine de Saint-Exupér wrote, “Perfection is achieved, not when there is nothing more to add, but when there is nothing left to take away.” 

What is excess? Waste. 

Waste is the biggest problem in manufacturing because it is always present. No matter how efficient production becomes, there will always be some form of waste present that results in financial loss. 

However, that doesn’t mean manufacturers shouldn’t aim for low-waste production. In fact, it should be a priority. 

Cost of waste in manufacturing 

The amount of waste that a company produces during manufacturing can make or break its bottom line. 

Waste comes in many forms, including: 

• Product 

• Time 

• Energy 

• Motion 

• Employee talent 

Globally, 20 percent of each dollar is wasted in manufacturing due to inefficient systems and processes. That comes out to $8 trillion dollars wasted due to poor manufacturing practices. 

Clearly, the manufacturing industry needs significant improvements to meet lean manufacturing standards and sustainability. 

To increase productivity, reduce lead time, and improve cost savings, getting a hold on waste is necessary. Manufacturers will see gradual—or even immediate—benefits once they take steps to reduce overall waste. 

Steps to reduce waste 

1. AUTOMATE 

The best way to reduce waste is through automation. 

Industrial automation can create more products in a shorter amount of time, eliminate human error, and produce near-identical products time after time. All three of these perks add up to major cost savings.  

In fact, across the United States, industrial robots can save up to 22% on labor costs, even if they are only performing 25 percent of the tasks they could complete. 

Are you interested in automating your production line, but don’t know where to start? Consider adding an all-in-one robotic work cell to your facility with NRTC Automation. This turnkey solution will transform your production line; for example, our customers have seen a 200 percent increase in throughput since implementing our custom work cells into their manufacturing process. 

Visit our Automation Services to learn more about robotic work cells. We also offer financing for manufacturers who want to start improving their bottom line without the upfront investment. 

2. TRAIN YOUR EMPLOYEES 

Waste can come in the form of unfulfilled employee talent. 

Companies with well-trained staff avoid costly errors caused by inexperienced and unknowledgeable employees. When employees understand their jobs, feel secure in the workplace, and have confidence in their work output, they make fewer mistakes and are more productive. 

All of these benefits are a result of training. Train your facility personnel in robotics to ensure that production is as efficient as possible. Humans are as much a part of manufacturing as robots, so including everyone in the process for improvement is the best way to meet your production goals. 

We offer Robotic Training Services for companies who want to be competitive in their industry. Visit our website to learn more. 

3. STUDY PRODUCTION DATA 

A great way to find and eliminate waste is by studying production data. 

With all the IoT and connected equipment of today’s manufacturing warehouses, getting the details of production is easier than ever. Use human-machine interfaces or programmable logic controllers to view data as your machines are working and save reports to study and compare later on. 

4. USE ENERGY-SAVING MACHINERY 

Energy can become a huge drain on manufacturers’ finances. In 2019, the average energy bill in the United States came out to nearly $6,000 a month! 

Become proactive in your energy plan by implementing energy-saving equipment, such as: 

• Waste heat recovery systems 

• Servo motors 

• Automatic blowdown control systems 

• Switchgear 

Other, small-impact ways to reduce energy usage are to install LED lighting and encourage employees to turn off lights and equipment when they are not being used. 

5. RECONDITION YOUR EQUIPMENT 

Finally, recondition your industrial equipment to reduce the need for repairs and replacements. 

By reconditioning your equipment (cleaning out dust and old grease, replacing parts, regreasing joints, and more), you can get the most out of the equipment you currently have. 

NRTC Automation offers Industrial Robot Refurbishing Services. With three tiers of service to choose from, you can recondition your robots on your terms. Save thousands of dollars by extending the life of your equipment and delaying the need to purchase new equipment. 

Get on top of waste – before it’s too late 

As you can see, waste is in every part of the production line, from human employees to the lights lining the ceiling in the warehouse. 

Letting waste get out of control can lead to unmanageable financial losses. Instead of turning a blind eye to waste, choose to actively reduce waste with our tips above to remain competitive and improve your company’s bottom line. 

AUTOMATE WITH NRTC 

NRTC Automation is dedicated to providing high-value industrial automation and manufacturing equipment solutions to all its customers.  

From decommissioning and tear out to industrial robotic training services to custom flexible work cells, NRTC is the key to integrate your workplace. With personalized training and custom-built designs, NRTC Automation is the destination for all your industrial automation and manufacturing equipment services. 

Schedule a free consultation with us today to get the best automation plan for your company’s production needs. 

Here's What Happens to Recycled Industrial Materials

In 2017, the U.S. produced about 7.6 billion tons of industrial waste, and only 30% of all industrial waste is recycled.

Recycling is important for two reasons, and the first one that comes to mind is sustainability. Who wouldn’t want to contribute to a cleaner, greener world? Recycling waste materials lowers pollution rates, lessens production’s harmful impact on animals and marine life, improves standards for human health, and eliminates the addition of one more product in a landfill. 

The second reason is liability, as industrial waste can potentially be dangerous. Violating waste regulations is expensive and may have negative consequences for employees and the company. The Superfund law is reinforced by the EPA to keep companies responsible for their waste, encouraging them to take action against unlawful dumping. 

Thankfully, recycling is becoming easier as technologies develop and more recycling companies enter the market. Read more about the source and types of industrial waste and how they are recycled below. 

Recycling Industrial Materials 

Source of industrial waste 

Industrial waste is produced by manufacturing companies, construction sites, and production and power plants. The waste can be a by-product of manufacturing, like raw materials such as metals, or it may be broken and defective equipment that cannot be repaired. 

When a company finishes a project and completes a tear out of their facility, there is a huge opportunity for recycling materials. Recyclable industrial waste is also produced on a day-to-day basis as production occurs and scrap material is left over. 

COMMON RECYCLED INDUSTRIAL MATERIALS 

A few of the common industrial materials that are recyclable include: 

• Scrap metals (copper, iron, aluminum, etc.) 

• Glass 

• Plastics 

• Scrap tires 

• Chemicals 

• Digital waste 

There is a different process for each of these materials, which will be explained below. 

Transportation of materials 

The logistics of transporting waste materials is important for two reasons: 

• There will likely be a lot of waste, especially after a tear out, that will be sent for recycling. 

• These materials could be potentially hazardous (like chemicals) or dangerous (like glass), so proper transportation is necessary for safety. 

Materials are typically loaded into a roll-off container, ranging in size from 20-yards for heavy materials to 40-yards or more for large industrial equipment. They are then transported by a truck. Compactors may also be used to condense like materials for easier transportation. 

Waste transportation can be costly, which is why NRTC Automation covers the bill during a decommissioning project. We will ensure that your facility is broom-ready by shipping off recyclable materials and prevent any surprise costs associated with transportation. 

Recycling process 

Recycling is a standardized step-by-step process from picking up the waste to presenting repurposed materials to be used for new products. 

Once the materials have arrived at the processing center, they will be dumped and sorted. The sorting process may be done by hand or with automated lines.  

The waste will then be processed once it has been accumulated into groups. Waste can be broken down, melted, or separated by parts and reused. 

Now the waste is transformed into a useable product and can be sold to companies that utilize recycled materials to create new products and be reintroduced to the market. 

REPURPOSED PRODUCTS 

Recycled materials can be reused to create repurposed products, such as:  

• building materials 

• industrial equipment, storage 

• glass products 

• cables 

The benefits of using repurposed products are that they are cost-effective and marketable for being sustainable. 

Prevent waste by recycling usable materials. 

You can contribute to the movement toward a sustainable world by recycling viable industrial waste. Conforming to the Superfund law and keeping waste out of landfills will allow materials to be repurposed, preventing more pollution and litter from soiling the planet.  

CONTACT NRTC AUTOMATION FOR YOUR TEAR OUT. 

NRTC Automation will provide a customized solution for the decommissioning and tear out of your manufacturing and industrial assets. Our focus is on minimizing disruption and downtime in the work area while emphasizing safety, speed and efficiency. We also provide additional services to help ensure full adoption of automation solutions and a seamless integration into your workplace. 

Contact NRTC Automation today for more information on how we can personalize our solutions for your company. 

What Do We Do with Tear Out Waste?

In manufacturing facilities, tear out waste is the remainder of material after industrial robots and manufacturing equipment have been removed. 

Waste is a reality of manufacturing, but with proper care and methodology, we can reduce the amount of waste that goes to the landfill and repurpose it for future projects. 

What is tear out waste? 

Tear out waste is any material that is not part of the company’s valuable equipment or resources. 

Waste can be anything from scraps of manufacturing material to profitable materials like copper, or even remnants from lunch break. It’s important to identify waste production to prevent future debris and to save money and materials. Perhaps it is even more important to identify how to correctly manage waste so that resources are used and energy is saved. 

Defining the end-state 

One of the most important parts of decommissioning a project is defining the end-state. The end-state is the goal of the project: a broom-ready facility prepared to take on a new project. Defining the actions that need to happen to get to the end-state will outline our strategy for completing a tear out. 

The end-state is also necessary for considering how we deal with tear out waste. In order to achieve a broom-ready facility, we will need to manage waste in a way that is both efficient and environmentally responsible. 

What do we do with tear out waste? 

Clean material (that is, non-hazardous solid waste) is available for disposal, recycling, or refurbishment. The amount of waste created depends on the type of company and the size of the project. 

When the tear out portion of the decommissioning project is complete, we will break up the waste into three groups: waste to be sent to disposal, waste that can be recycled, and parts that can be refurbished. 

IF IT’S UNSALVAGEABLE, WE DISPOSE OF IT. 

Any material that cannot be recycled or restored will be disposed of. We use trash gondolas to organize and transport materials to construction size dumpsters that will be relocated to a landfill. 

The goal is to reduce the amount of waste that goes to a landfill. In order to do this, we determine what materials can be salvaged and where to send them next. 

IF IT CAN BE REPURPOSED, WE SENT IT TO A RECYCLING CENTER. 

Waste that can be recycled will be sent to the nearest recycling center for repurposing. Some examples of materials that can be recycled include batteries, transformers, large containers, and oil filters. 

There are a few different methods of recycling, and they all make use of materials and gases to create new products or energy: waste can be melted into a homogenous substance and reused, broken down in recyclable parts, or heated to create thermal energy. There are even more methods to recycle depending on the type of waste and the new technologies that become available to recycling centers. 

Recycling is the second-best option for managing waste. Read our next point to find out the best option for managing tear out waste! 

WASTE THAT CAN BE RESTORED WILL BE SOLD TO ORGANIZATIONS THAT REFURBISH WASTE MATERIALS. 

Materials that contain valuables like copper, aluminum, and steel will be sold to an organization that provides the best value. Once a deal is made, the buyer will restore the materials into new equipment for future projects. 

Refurbishing materials is the most environmentally friendly option for managing waste after a tear out. It takes less energy than recycling to reuse materials and it keeps garbage out of landfills. 

There’s more to decommissioning after the equipment is removed. 

Once NRTC Automation completes the tear out portion of the decommissioning project, the next step is to manage the waste from the project. We create a detailed plan for every step of the decommissioning project to ensure that the facility is broom-ready for another project. Once we have delineated waste into the categories above, we distribute the materials to the landfill, a recycling center, or to an organization that will refurbish the waste. 

After the waste is managed, then we can prepare the facility for the next project by creating a smooth surface and performing a walkthrough with a dedicated project manager. 

DO YOU NEED PROFESSIONAL SERVICES TO DECOMMISSION YOUR FACTORY? 

NRTC Automation is renowned for our decommissioning and tear out services. We provide tear outs for all industries in factories and manufacturing facilities around the world. With our dedication to complete the project on your time requirements, our strategic planning process, and our team’s commitment to your project, it’s no wonder that we are trusted by the world’s top automobile manufacturers. 

Contact NRTC Automation today to discuss how we will decommission your factory according to your standards.