Case Studies
Transforming Spent Foundry Sand into Sustainable Resources
The Challenge
Our client, a leading metal foundry, relies on various types of sand to create molds for casting molten metal. However, once the sand reaches the end of its useful life, it has traditionally been disposed of in landfills, creating both environmental and economic burdens.
The Solution
At Waste Optima, we identified two landfill-diversion solutions that not only eliminate waste but also repurpose the sand into valuable industrial applications:
1. Cement Production – The spent foundry sand is blended with raw materials in the manufacturing of Portland cement, contributing to a more sustainable supply chain in the construction industry.
2. Road Base Material – The sand is repurposed as sub-base material for road construction, helping to create durable and stable foundations for infrastructure projects.
The Impact
• Zero Landfill Disposal: The foundry has successfully diverted 100% of its spent sand away from landfills.
• Environmental Benefits: Reduces the extraction of virgin materials, conserving natural resources.
• Cost Savings: The client now avoids landfill tipping fees while contributing to a circular economy.
• Industry Adoption: These solutions set a precedent for other foundries looking to reduce waste and improve sustainability.
Conclusion
This case study showcases how innovative waste solutions can turn by-products into resources, benefiting both the environment and industry. At Waste Optima, we specialize in finding sustainable alternatives for manufacturing waste, creating value where others see waste.
Case Study: Maximizing Recycling Efficiency for a National Envelope Manufacturer
The Challenge
A leading paper envelope manufacturer with multiple production plants across the U.S. generates a significant amount of off-spec products and manufacturing waste. Previously, this material was considered unsellable waste, and their recycling efforts were not as efficient as they could be, leading to higher logistics costs and lost revenue opportunities.
The Solution
At Waste Optima, we developed a customized recycling program tailored to the manufacturer’s operations, ensuring their waste materials are efficiently collected, processed, and monetized for their benefit. Our approach includes:
1. Direct-to-Mill Recycling – We have direct relationships with paper mills closest to each plant, eliminating unnecessary intermediaries and reducing transportation costs.
2. Maximized Rebates – By optimizing logistics and going direct to mill, we secured better financial returns for the client on their recycled paper and cardboard.
3. Multi-Plant Integration – We are in the process of creating a cohesive, company-wide recycling program with consistent processes and cost efficiencies, so that the client has a “one stop shop” to call for the entire U.S.
The Impact
✅ Lower Transportation Costs – Shipping waste directly to the nearest mill reduced logistics expenses.
✅ Higher Rebates for Recycled Material – The manufacturer now receives increased revenue from their recyclables.
✅ Improved Sustainability – Diverting paper waste from landfills enhances their environmental footprint and aligns with corporate sustainability goals.
✅ Expansion into Other Waste Streams – We are currently developing a proposal to manage all waste streams, including plastics, so the manufacturer can consolidate their recycling efforts under one provider—simplifying operations and maximizing efficiency.
Conclusion
By leveraging Waste Optima’s expertise, this manufacturer transformed what was once a costly waste stream into a revenue-generating, sustainable solution. Our strategic recycling partnerships ensure that valuable materials are kept in circulation, benefiting both the environment and the client’s bottom line.