Landfill Free

The Armour-Eckrich, Peru, Indiana Experience

• 18 Operating Facilities;

• 9,800 employees

• $3.7 Billion in sales per year (FY2011)

• Decrease waste disposal to landfill by 10% in

FY2016 as compared to FY2008 on a production weighted basis;

• One Zero Landfill facility per IOC by 2018.

JMFG: 10% less waste to landfill in FY2011 as

compared to FY2008 (production weighted);

FY2008: 39,129 tons (6.47 lbs/cwt)

FY2011: 33,700 tons (5.82 lbs/cwt)

Waste Elimination/Source Reduction; Reuse; Recycle (including compost) Waste to Energy; Landfill

Zero waste shipped to a landfill for a 12 month

continuous period; The percent of waste reused or recycled must be

at least 50% of the total generated; Incineration without energy recovery is limited to

legally required disposal (hazardous and medical wastes);

Stabilized and landfilled hazardous waste limited to 0.1% of the total waste generated.

The total waste management cost must not exceed 5% above the baseline waste management cost.

FY2008 = 999 tons/year FY2011 = 440 tons/year FY2012 = 252 tons/year FY2013 = <25 tons/year (goal)

We don’t anticipate any additional loads to the landfill beyond early May 2012, so by June 2013, we should meet the Smithfield Foods definition of landfill free.

Precooked Bacon Plant, so lots of grease!

White Grease: 4,134 tons/year Brown Grease: 1,403 tons/year Total Amount: 5,527 tons/year

Very profitable: Revenue – White Grease: $3,854,152/year Revenue – Brown Grease: $ 392,253/year Revenue – Total: $4,246,405/year

If it was easy, we’d all be there:

What’s in there? Plastic sleeves and liners; dirty plastics; paper towels; ear plugs; “dirty” plastics; old corrugated cardboard; wax coated cardboard; wooden pallet scraps; scrap metals; barrels; aluminum cans; paper; used oven belts; ingredient bags; fibers; food waste from employee lunch breaks, etc.

What’s acceptable for recycling?

Step by Step Process:

Establish BHAG;Form Cross-Functional Team;Designate Team Leader: Ed Schmaltz, Transportation ManagerTop Management Support: Mike Fritz, Plant ManagerBuy-in from all Facility Team MembersPartner with Recycling Firm that will take almost EVERYTHING

Step by Step Process:

Color coded bags for improved sorting:Black bags for plasticsTan for trashClear for paper

Lock Trash Compactor!

Covanta: Waste-to-Energy Facility in Indianapolis for food scraps

A Place for Everything:

Cardboard Baler: Boxes, Combos, Paper, Film CoresPlastic Baler: Film, Stretch Wrap, Aprons, Sleeves, Rain Suites and Coats, BandingPlastic Combo: Bottles, Buckets, Tubs, Squeegees, HelmetsPaper Baler: Coated Paper, Copy Paper, Newspaper, Labels, Pallet Tickets, Paper Towels, Ingredient Bags, Glove BoxesMetals Container: Blades, Pipe, Edge Metals, Fuses with Metal Ends, Cans, Air Filters, Lids and Bands from Drums, WiringRubber Combo: Boots, Hoses, Transfer Wheels, Green GlovesTrash: Food Waste, Wood Scraps, Ear Plugs, Hair Nets, Misc.

Educate, Reinforce New Waste Disposal

Protocols, Update on Progress:

Daily Plant Employee MeetingsReviewed with the EHS Committee (composed of

operations, maintenance, wastewater, QA)  Town Hall meeting/CookoutReview of material retrieved from trash compactor

This involvement helped employees improve their habits and inspired them to take pride in their contributions.

Recycled/Diverted Amounts & RevenueCardboard: 304 Tons/year $32,000/yearPlastic: 384 Tons/year ----Paper: 58.5 Tons/year ----Metal: 25.7 Tons/year $5,275/yearRubber: 3.6 Tons/year ----Mixed Plastic: 1.2 Tons/year ----Aluminum: 1.0 Tons/year $1,004/yearPallets: 121.5 Tons/year $4,800/yearWaste-to-Energy: 48 Tons/year

TOTALS: 947.5 Tons/year $43,079

Net Annual Savings:

Recycling Revenue $43,079/yearLandfill Cost Avoidance: $31,000/yearCompactor Lease Avoidance: $ 4,800/yearWaste to Energy Costs: ($2,880)/yearTransportation Costs: ($2,800)/year

TOTAL: $73,199/year

Saratoga Food Specialties:

Decreased solid waste to landfill by 43% from FY2008 to FY2011 (production weighted).

Big push recently:FY2011 Average: 16.1 tons/monthCY2012 (YTD Avg): 11.4 tons/month

Working with suppliers to get raw materials only

in containers that can be recycled; Labeled bins for all types of waste, right at point

of use; Top management leadership and support Buy in from front line production managers Four balers: cardboard; plastics; woven fiber

totes; bags; Other: wax label paper; pallet stretch wrap;

paper slip sheets; pallet wrapping straps; plastic drums; office paper; aluminum cans.

FY2008: 4,152 tons (11% of total 39,129 tons) FY2011: 3,615 tons (11% of total 33,700 tons)

Cellulose Casings and Dewatered DAF sludge = 70% of total landfill material

Composting could is a viable alternative to landfill and is less expensive.

FY2008: 24,542 tons (63% of total 39,129 tons) FY2011: 21,093 tons (63% of total 33,700 tons)

Wastewater Sludges = 80% of total landfill material

Land application of Sioux Falls wastewater sludges would reduce our total JMFG landfill amounts by over 16,800 tons/year (50% decrease overall).

Environmental Land Management or Terra Renewal