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Hy-Capacity Green Team |
Hy-Capacity utilized FABA programs in their efforts to become a Zero-Landfill facility. The company received a Solid Waste Alternatives Program (SWAP) forgivable loan for the purchase of a vertical baler to expand its recycling program to include polyurethane and cushion foam. The Iowa Waste Exchange (IWE) facilitated an agreement between Hy-Capacity and Foam Rubber Products in Muscatine to receive the baled materials.
Hy-Capacity's team approach to production efficiency, recycling, waste reduction, and the family atmosphere within the plant serve as a model for private companies. With a commitment to the environment and a partnership with FABA, a facility can reduce waste and energy usage while becoming more productive and profitable at the same time.
Hy-Capacity, Inc., is a family-owned corporation that manufactures and refurbishes various tractor components such as pumps, pressure plates, clutches, engine components and hose assemblies at its Humboldt facility. Another plant in Dayton manufactures complete replacement tractor cab kits. The company employs approximately 100 people.
Hy-Capacity has a history of environmental stewardship: since the early 1990s the company has recycled paper and corrugated cardboard; in 2002 a grinder was purchased to grind scrap PVC flooring and cushion foam into packing material.
In 2008 the company undertook the Lean Manufacturing program to identify potential production efficiency opportunities through management and employee teamwork. The Lean process recommended eliminating the transportation of cardboard from Dayton to Humboldt to be baled and also suggested identifying markets for plastics recycling.
As a result of the Lean process, Hy-Capacity formed a Green Team and set the goal of becoming a Zero-Landfill company. Their first priority was the five tons of foam packing material the company generates each month. Cindy Danielson, the Humboldt Plant Manager, contacted the vendor of the material, Insta-Pak, which agreed to take back the packing material if baled. The company purchased a baler for the Dayton plant for plastics and cardboard, eliminating the need to transport the materials to Humboldt. A SWAP grant funded the purchase of another baler for the foam material, and IWE representative Fred Kesten coordinated with a company in Muscatine to receive the baled PVC materials from Hy-Capacity.
The Hy-Capacity Green Team also designed a recycling program for the plant, placing recycling containers for plastic, paper, bottles and cans at various locations in the facility. Old parts carts were cleaned and repainted to carry the containers and steel cages were built for corrugated cardboard and plastics.
As a result of these efforts, the 40 cubic-yard trash compactor has been replaced with a 1.5 cubic-yard dumpster. The remaining waste consists of food and paper towel waste. The company purchased a composter in July 2009 to further reduce the organic waste disposed of in the dumpster.
As of August 1, 2009, two semi truck loads of 400-pound PVC and Insta-Pak bales have shipped for recycling. The company is collecting rainwater for parts-washing and is working to find a market for the seven barrels of blaster dust and grinding sludge they generate each month.
Hy-Capacity's efforts will prevent approximately 88.8 tons of plastic from ending up in a landfill each year, saving the company $16,200 in pull fees and $17,108 in transportation costs. Fuel usage will be reduced by 978 gallons annually.
The company has been recognized for its environmental programs: in December, 2008 the company was featured in the Humboldt Independent for its efforts to become a Zero-Landfill facility; in July, 2009, Hy-Capacity was honored with the Iowa Farm Bureau's ReNew Rural Iowa award on WHO Radio for its efforts to grow the agricultural economy while implementing best practices in recycling and environmental protection.
Submitted by Fred Kesten, Iowa Waste Exchange
Thanks to Cindy Danielson, Ken Brantland, Karen Skoglund and Molly Varangkounh at Hy-Capacity.
Resources:
Iowa Waste Exchange
Solid Waste Alternatives Program
FABA Programs
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Visitors to the DNR Building at the 2009 Iowa State Fair once again showed that recycling is important to them. The amount of plastic and aluminum beverage containers collected in the special recycling bins located around the DNR Building exceeded the amount collected in previous years. To visualize the number of beverage containers collected, if stacked end to end they would reach the top of the Capitol's golden dome (275 feet) nearly 10 times.
"DNR Building visitors that participated in the beverage container recycling program did an excellent job in separating their beverage containers from leftover food, paper, and other waste. The recycling bags held very few contaminants which will help project partners agree to participate next year," said Tom Anderson, DNR Environmental Specialist. Recycling containers were placed next to garbage cans at the DNR Building to make it as easy as possible to separate beverage containers for recycling from trash.
"Many thanks go to Metro Waste Authority for loaning the DNR the recycling containers and MidAmerica Recycling for accepting the recyclables from the Fair and thanks to all the fair goers that participated in the program," said Anderson.
For more information on recycling, click here.
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Twenty-four upper level engineering students from various Iowa colleges and universities participated in the 2009 Iowa Pollution Prevention Intern Program. Interns were placed at selected host facilities to analyze their waste stream and research alternative processes or technologies before making recommendations that will save the company money while reducing their environmental footprint. Since 2001, host companies have saved more than $58.6 million in implemented intern projects.
For more information on the Pollution Prevention Intern Program and details on the 2009 results, click here.
With the assistance of an EPA grant, the program recently purchased an infrared camera that can identify sources of radiant energy loss at a facility. Locating these sources and recommending corrective changes and improvements will assist companies in decreasing their energy costs and equipment downtime. The 2009 Pollution Prevention Intern Program sent an engineering student to a number of Iowa facilities to use the camera to provide analysis and recommendations.
For more information on Pollution Prevention, click here.
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Household Hazardous Materials (HHM) Regional Collection Centers are the first of the solid waste permitting programs to implement electronic reporting for standard forms. The electronic reporting program began with the September 1, 2009 submittal and coordinated with the beginning of the 2009 reimbursement period. Submitting required reports via the internet reduces the amount of data entry and significantly reduces paper use. As a result, reimbursement for disposal costs will be more accurate and timely and potential errors will be reduced in the annual HHM program legislative report and other data queries.
For more information on HHMs, click here.
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House File 826 created the Comprehensive Recycling Task Force to develop a report and present findings and recommendations related to creating and enhancing comprehensive sustainable recycling programs in the state that address wastes generated from the residential, commercial and industrial sectors.
Click here to visit the Comprehensive Recycling Task Force web page for more information.
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The DNR's TV Recycling marketing campaign wrapped up at the end of June. The campaign featured newspaper and radio advertisements encouraging Iowans to recycle their unwanted TVs. Staff fielded more than 250 phone calls from 51 Iowa counties and visits to the TV Recycling information web page totaled more than 3,600 for the month of June alone. Data for the number of recycled TVs is still being gathered, but it is safe to say that Iowans received the message.
More Information:
TV Recycling
E-Waste
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