to my loving family and friends who inspired me always
TRANSCRIPT
AN ANALYSIS OF GREEN PRODUCT MANUFACTURER RESPONSIBLE MATERIALS CYCLE STRATEGIES
By
SAHIL MOTWANI
A THESIS PRESENTED TO THE GRADUATE SCHOOL
OF THE UNIVERSITY OF FLORIDA IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE OF
MASTER OF SCIENCE IN CONSTRUCTION MANAGEMENET
UNIVERSITY OF FLORIDA
2018
© 2018 Sahil Motwani
To my loving family and friends who inspired me always
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ACKNOWLEDGMENTS
I would like to thank Dr. Charles J. Kibert for guiding and supporting me through-
out my journey at University of Florida. You have set an example of excellence as a
researcher, mentor, instructor, and role model. I would also like to thank Dr. James
Sullivan and Dr. Ravi Srinivasan for their guidance and mentoring me through this
process.
My sincere thanks also to the entire Walt Disney World Family and Friends for
offering me the internship opportunity and resources for this research. I would also like
to thank Knoll, Inc. family for giving me an opportunity to visit the Knoll manufacturing
plant in Philadelphia.
Additionally, I would like to thank my entire family for providing me an opportunity
to study at the University of Florida. I would like to thank all my friends at Powell Center
for Construction and Environment for helping in my journey at Rinker School of
Construction Management.
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TABLE OF CONTENTS page
ACKNOWLEDGMENTS .................................................................................................. 4
LIST OF TABLES ............................................................................................................ 8
LIST OF FIGURES .......................................................................................................... 9
LIST OF ABBREVIATIONS ........................................................................................... 10
ABSTRACT ................................................................................................................... 12
CHAPTER
1 INTRODUCTION .................................................................................................... 14
1.1 Significance of Managing Waste ....................................................................... 14
1.2 Objective of the Study ....................................................................................... 15 1.3 Research Methodology ..................................................................................... 16 1.4 Organization of the Study ................................................................................. 17
2 LITERATURE REVIEW .......................................................................................... 18
2.1 Overview ........................................................................................................... 18
2.2 Importance of Waste Management ................................................................... 18
2.3 Industrial Waste ................................................................................................ 21
2.4 Waste Management Practices Followed by Furniture Manufacturing Industries ............................................................................................................. 23
2.4.1 Knoll, Inc. ................................................................................................. 23
2.4.1.1 Knoll studio .................................................................................... 24 2.4.1.2 Knoll coverings ............................................................................... 25
2.4.1.3 Knoll and sustainability ................................................................... 25 2.4.2 Herman Miller .......................................................................................... 26
2.4.2.1 Packaging ...................................................................................... 27
2.4.2.2 Materials and resources ................................................................. 27 2.4.2.3 Repurpose program ....................................................................... 27 2.4.2.4 Circular economy ........................................................................... 27
2.4.3 IKEA ........................................................................................................ 28
2.4.3.1 Third-party initiatives ...................................................................... 28 2.4.3.2 Products ......................................................................................... 28 2.4.3.3 Working together with suppliers ..................................................... 29 2.4.3.4 Circular economy ........................................................................... 29 2.4.3.4 Owning a forest .............................................................................. 29
2.4.3.5 Packaging ...................................................................................... 30 2.4.3.6 Chemicals ...................................................................................... 30
2.4.3.7 Innovation ...................................................................................... 30
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2.4.3.8 Energy models ............................................................................... 30
2.4.3.9 Product transport ........................................................................... 30 2.4.3.10 Waste ........................................................................................... 31
2.4.4 Steelcase ................................................................................................. 31 2.4.4.1 Repurpose ..................................................................................... 31 2.4.4.2 Renewable source of energy ......................................................... 31 2.4.4.3 Scrap fabric .................................................................................... 31 2.4.4.4 Thinking backward ......................................................................... 32
2.4.4.5 Partnership with research institutes ............................................... 32 2.4.4.6 Waste ............................................................................................. 32 2.4.4.7 Planked veneer .............................................................................. 32 2.4.4.8 Melamine pallets ............................................................................ 32
2.4.5 Haworth ................................................................................................... 33
2.4.5.1 Zero-Waste title .............................................................................. 33 2.4.5.2 Updated sustainability standards: femb attestations and google
portico ..................................................................................................... 33
2.4.5.3 Carbon-offsetting projects .............................................................. 33 2.4.5.4 Packaging ...................................................................................... 33 2.4.5.5 Project clarity ................................................................................. 34
2.4.5.6 Materials ........................................................................................ 34 2.5 Waste Management Practices Followed in Europe........................................... 34
2.5.1 Introduction .............................................................................................. 34 2.5.2 EU Waste Management Policy ................................................................ 35 2.5.3 Automobile Industry ................................................................................. 35
2.5.3.1 General Motors (GM) ..................................................................... 35 2.5.3.2 Audi ................................................................................................ 36
2.5.3.3 Mercedes-Benz .............................................................................. 36 2.5.3.4 BMW .............................................................................................. 37
2.5.3.5 Rolls Royce .................................................................................... 37 2.6 Waste Management Not Practiced by Company Around the World: ................ 38
3 METHODOLOGY ................................................................................................... 45
3.1 Overview ........................................................................................................... 45 3.2 Interview Questionnaire Design ........................................................................ 46
3.2.1 Past ......................................................................................................... 46 3.2.2 Present .................................................................................................... 46 3.2.3 Future ...................................................................................................... 47
4 DISCUSSION AND ANALYSIS .............................................................................. 48
4.1 Overview ........................................................................................................... 48 4.2 Design and Supply Chain ................................................................................. 50
4.2.1 Working Closely with Suppliers ............................................................... 50
4.2.2 Updating Sustainability Standards ........................................................... 50 4.2.3 Suppliers’ Code of Conduct ..................................................................... 51
4.2.4 Involvement In Different Programs .......................................................... 51
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4.2.5 Annual Sustainability Reports .................................................................. 52
4.3 Manufacturing and Showrooms ........................................................................ 52 4.4 Client Supports and Performance ..................................................................... 52
4.4.1 Innovation ................................................................................................ 53 4.4.2 New Updated Sustainability Standards ................................................... 53
4.5 End of Life Cycle ............................................................................................... 54 4.5.1 Circular Economy .................................................................................... 54 4.5.2 Embodied Energy .................................................................................... 55
4.6 Recycle Centers................................................................................................ 55
5 CONCLUSION AND RECOMMENDATION ............................................................ 57
5.1 Waste Management Practices .......................................................................... 57 5.2 Future Scope of Study ...................................................................................... 58
APPENDIX
A UNIVERSITY OF FLORIDA INSTITUTIONAL REVIEW BOARD EXEMPT APPROVAL ............................................................................................................ 59
B INTERVIEW CONSENT FORM .............................................................................. 61
C QUESTIONNAIRE FORM ....................................................................................... 63
LIST OF REFERENCES ............................................................................................... 64
BIOGRAPHICAL SKETCH ............................................................................................ 67
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LIST OF TABLES
Table page 2-1 Table below shows involvement on different furniture manufacturing
industries in different categories. ........................................................................ 44
4-1 Table below displays different issues which are being addressed by the LEED and the Green Globes in recent versions. ................................................ 56
4-2 Table below displays the embodied energy of aluminum and steel in its virgin and recycled form. .............................................................................................. 56
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LIST OF FIGURES
Figure page 2-1 Figure shows the amount of industrial waste generated in 2011 ........................ 39
2-2 MSW generation rates from year 1960 to 2014 .................................................. 39
2-3 Management of MSW in the United States in the year 2014 .............................. 40
2-4 MSW recycling rates from the year 1960 to 2014 ............................................... 40
2-5 The figure displaying example of IKEA group working together with the suppliers ............................................................................................................. 41
2-6 The figure displaying example of IKEA group working closely with the suppliers in India to improve resource-efficiency ................................................ 41
2-7 The figure displaying example of IKEA group working closely with the suppliers in China ............................................................................................... 42
2-8 The figure displaying quantity of different Mercedes-Benz vehicle parts which were re-used in the year 2016 ............................................................................ 43
4-1 The figure compiles different materials cycle strategies manufacturing industries can follow at 5 steps and their respective performance check .......... 55
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LIST OF ABBREVIATIONS
ANEW Asset Network for Education Worldwide
BCI Better Cotton Initiative
BIFMA Business and Institutional Furniture Manufacturers Association
BMW Bayerische Motoren Werke
CAP Center for American Progress
CH4 Methane
COD Chemical Oxygen Demand
CO2 Carbon Di Oxide
DfE Design for Environment
EfW Energy from Waste
EPA Environmental Protection Agency
EPS Expanded polystyrene
EU European Union
FABSCRAP Fabric Scrap
FEMB European Federation for Office Furniture Associations
FSC Forest Stewardship Council
GDP Gross Domestic Product
GFA Green Freight Asia
GM General Motors
INC. Incorporated
LCA Life Cycle Assessment
LED Light Emitting Diode
LEED Leadership in Energy and Environmental Design
IKEA Ingvar Kamprad Elmtaryd Agunnaryd
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IPCC Intergovernmental Panel on Climate Change
ISO International Organization for Standardization
MI Michigan
MSW Municipal Solid Waste
MW Megawatts
NeoCon Neoconservatism
OECD Organization for Economic Co-operation and Development (OECD
OEM Original Equipment Manufacturer
OSHA Occupational Safety and Health Administration
PA Pennsylvania
PET Polyethylene terephthalate
S&P Standard and Poor
SMaRT Sustainle Materials Rating Technology
SMM Sustainable Material Management
SRP Short-rotation plants
UFIRB University of Florida Institutional Review Board
US United States
VOC Volatile Organic Compounds
VPP Voluntary Protection Program
WMS Waste Management System
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Abstract of Thesis Presented to the Graduate School of the University of Florida in Partial Fulfillment of the
Requirements for the Degree of Master of Science in Construction Management
AN ANALYSIS OF GREEN PRODUCT MANUFACTURER RESPONSIBLE MATERIALS CYCLE STRATEGIES
By
Sahil Motwani
May 2018
Chair: Charles J. Kibert Major: Construction Management – Sustainable Construction
Waste is generated at every step starting from procurement, process, use, and
disposal of material. New products for the residential and commercial uses – laptops,
materials, paints and colors, plastics - often produce toxic waste, including poisonous
chemicals, which are released into nature. The increasing population combined with
economic growth in the cities results in higher demand for goods, prompting steady
consumption of natural resources is driving to a questionable future. To avoid this
increased consumption of worldwide resources, sustainable waste management
practices would be necessary. The aim of this thesis is to investigate the state-of-the-art
sustainable waste management practices in an industrial scale focusing on sustainable
practices followed by a green product manufacturing company. This research will
investigate the diverse steps taken by a global manufacturing company in managing
different types of waste.
The annual sustainable waste management reports from various manufacturing
companies help in gaining an in-depth knowledge about the latest innovations and how
they manage the diversity of waste they produce. An Interview was conducted to collect
data at Knoll’s Philadelphia manufacturing plant to understand the manufacturing
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processes, manufacturing systems, and use of sustainable tools practices to achieve
zero waste sent to landfill award. This study reveals that waste management system
ensures efficient use of resources thereby mitigating the harmful environmental impacts
together with increasing number of landfills. In summary, the results obtained indicate
the strategies of a “circular economy”, “working closely with suppliers”, “involvement in
different sustainability initiatives”, and “working closely with the suppliers” as the best
waste management practices. However, there is still significant change that need to
take place to find one-stop solution for managing waste in a best possible way.
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CHAPTER 1 INTRODUCTION
It is believed that the term sustainability gained popularity early in 1987 as a
result of the Brundtland report. The Brundtland report mainly discusses the two worries
that ought to be accommodated: the environment and development. One can also think
in terms of supply versus demand, or as short-term versus long-term goals. Over the
years, the term sustainability has changed and now includes 3 major aspects: social,
economic and environmental (Kuhlman & Farrington, 2010). There can be no single
definition of sustainability. This can be seen in the definition of sustainability embraced
by the United Nations:
“Development is a multidimensional undertaking to achieve a higher quality of life
for all people. Economic development, social development and environmental protection
are independent and mutually reinforcing components of sustainable development.”
(Kuhlman & Farrington, 2010)
Human beings depend on many things on the environment to satisfy their various
needs. In the process of such development, they tend to produce some things that have
no use for humans own purpose of production, transformation or consumption, and
which they discard, or intend or are required to discard.
1.1 Significance of Managing Waste
Industrial and mining operation has been a problem since the industrial
revolution. Such operations have been successful in generating waste which might be
poisonous, destructive and/or reactive which holds unsafe conditions for both human
well-being and ecology. Manufacturing industries have been successful in increasing
the amount of waste generated from 4.5 million tons per year after world war II to 57
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million tons per year by the year 1975 to 265 million tons per year by the year 1990
(Mifflin, 1994; Petulla, 1988; United States Government Printing Office, 1981). It is
estimated that the amount of Industrial waste generated by the year 2011 has reached
to 914 million ton per year (Frost, 2012).
Waste generation has serious bearings on human wellbeing and the
environment. It causes pollution, epidemic diseases and disruption in daily lives. Waste
generally ends up in either a landfill or on water bodies or are incinerated. Specifically,
waste produces many ozone-depleting substances such as methane (CH4), which is
the most critical issue in global climate change. As indicated by the Intergovernmental
Panel on Climate Change (IPCC), the surface temperature is expected to increase by
4.8° Celsius and ocean levels are anticipated to rise by 0.82 m by 2100. (Lee, Kim, &
Chong, 2016)
According to Lee et. al., (2016) approximately 1.3 billion tons of global municipal
solid waste is generated annually, which is expected to rise to 2.2 billion tons annually
by 2025. The United States produces the most waste per capita among all OECD
nations. The United States also leads to the greatest harm to the ozone layer among all
nations.
Waste management system ensures efficient use of resources thereby mitigating
the harmful environmental impacts together with increasing number of landfills. Material
resource efficiency counts for an economical and efficient approach to reducing the
harmful effect on ecology.
1.2 Objective of the Study
This thesis focuses on sustainable waste management systems which ensures
an effective use of resources thereby mitigating the harmful environmental impacts
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together with increasing number of landfills. Material resource efficiency counts for an
economical and efficient approach to reducing the harmful effect on ecology. The
objectives of this research are:
To study the current waste generation in the United States.
To study the responsible materials cycles strategies of green product manufacturers.
The current challenges faced by green product manufacturing companies in achieving their sustainability goals.
The research also aims at answering the following questions: “what methods a
company implements in achieving ‘zero waste to landfill’?” as well as, “what drives
sustainability in a company?”
1.3 Research Methodology
The research methodology is divided into three steps. The first step consists of
review of the literature. The first step focuses on importance of waste management and
industrial waste generated globally. This step also briefly describes different waste
management practices followed by green product manufacturers around the world. The
second step involves conducting an interview at a Knoll, Inc. - green product
manufacturing company. Knoll has been selected because Knoll committed to
environmental sustainability from the year 1978. Since then the Knoll developed new
processes, tools, and philosophies over the years to be more sustainable. The third step
analyzes the responses from the interview conducted at Knoll and reviewing annual
sustainability reports from different global automobile and furniture manufacturer
companies. The research also focuses on waste management practices and
involvement of different million-dollar global manufacturing companies towards
sustainability.
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1.4 Organization of the Study
This thesis is structured in five sections. This chapter defines the need for this
research and defines the objective of the study. Chapter 2 presents the concept of
sustainable waste management and summaries the early insights in various research
papers and reports. Chapter 3 present the research methodology. Chapter 4 briefly
describes the about the best waste management practices followed globally by various
companies. Chapter 5 summarize the research through a conclusion and presents
future scope in the research.
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CHAPTER 2 LITERATURE REVIEW
2.1 Overview
The literature review is divided into two parts. The first section talks about the
importance of waste management and current trends of industrial waste generation
globally. The first section also provides information about the different green
certifications and special certifications under the sustainability. These certifications help
manufacturing companies achieve their sustainability goals. The second section of the
literature review covers the current trends of waste management practices followed by
million-dollar manufacturing companies around the world. The second section focuses
more on how the industrial waste is managed at a different level and in different
countries. It is important to examine different factors that are responsible for the waste
handling. The later part of this chapter also focuses on company who still do not take
part in waste management but is successful globally.
2.2 Importance of Waste Management
According to a report by the United Nations, the world’s urban populace
increased from 746 million in 1950 to 3.9 billion in 2014. More than half of the world
population resides in urban areas. The increasing population combined with economic
growth in the cities results in higher demand for goods, prompting high pressure on
municipal solid waste management systems (WMS) (World urbanization prospects the
2014 revision highlights.2014). In a report by Hoornweg & Bhada-Tata, (2012) an urban
resident generates approximately 1.2 kg of MSW per person per day, which has
doubled in the past 10 years (0.64 kg per person per day).
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According to Hoornweg & Bhada-Tata, (2012) the worldwide annual volume of
MSW would double by 2025 and would amount to 2.2 billion tons from 1.3 billion tons in
2012. The immediate result of the annual increase of MSW would increase the solid
waste management costs in low-income countries by five times and middle-income
countries by four times. It is anticipated that global solid waste management costs
would reach $375.5 billion in 2025 from $205.4 in the current year (Hoornweg & Bhada-
Tata, 2012). In a report by Chanhthamixay et. al., (2017) the average waste collection
falls under 50% to 90% only. In addition, 30% to 60% of waste is not collected, and bad
practices of waste management system are adopted. See Figure 2-1.
Such practices include burning of waste in an open atmosphere and dumping of
waste in landfills. Hence, sustainable waste management solutions play an important
role.
Many different waste items compose a city’s municipal waste stream. Usually,
products in a city’s waste stream travel through different nations and go through
innumerable manufacturing plants and autonomous producers. Some wastes are easier
to manage than others. For example, cardboard and organic (food) waste are easier to
manage than electronic waste or industrial waste. MSW incorporates different types of
waste categorized according to the source.
The MSW of a city normally falls under the local government jurisdiction and is
a single budget expense that provides employment to people in large numbers. It is
difficult for a city to manage complex services such as transportation or health if it
cannot handle its waste management system effectively. The inadequate waste
management system of a city has an adverse effect on health, local environment, and
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economy. It also results in higher downstream costs than what it would have cost to
handle the waste at an initial stage. MSW has an especially significant impact in
contaminating water, soil, air, and climate change.
Burning of waste and landfilling contribute to harmful greenhouse gas emissions
when carried through waste collection vehicles. Waste that is not properly managed
offers breeding space and food in some cases to different animals. Greenhouse gas
emissions, land use planning, and labor are some of the issues that must be considered
to effectively manage waste. Solid waste management has financial, social, and
environmental problems attached to it. These problems can vary at different levels in
countries with different income levels.
Uncalled MSW management practices—for example, dumping waste in a landfill,
mixing different types of waste, and burning of waste—result atmospheric pollution by
releasing harmful greenhouse gases (Chanhthamixay et al., 2017). Greenhouse gases
are highly responsible for depleting the ozone layer. For instance, in Asia, governments
spend approximately USD 25 billion every year on MSW management, and this figure is
expected to double by 2025 (Chanhthamixay et al., 2017).
According to a report in Advancing sustainable materials management (2017),
the United States generated approximately 258 million tons of waste in 2014. See
Figure 2-2. Approximately 34.6% of waste was recycled, totaling 89 million tons.
However, 136 million tons of waste was diverted to landfills, and 33 million tons of MSW
was combusted into energy. The recycled waste helped in an annual reduction of 181
million metric tons of carbon dioxide (Advancing sustainable materials management
2017). See Figure 2-3 and Figure 2-4..
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In Advancing sustainable materials management: 2014 fact sheet, 2017 report
the EPA lays emphasis not only on waste but also on sustainable material management
(SMM). Sustainable material management refers to the utilization and reuse of materials
in the most gainful and feasible route over their complete lifespan. SMM would help in
conserving resources, reducing waste, and slowing climate change, thereby minimizing
the impact on the environment by using resources efficiently.
2.3 Industrial Waste
Industrial solid waste envelops an extensive variety of materials with varying
environmental toxicity—example, packaging materials, oils, paints, leather, wood. The
absence of a consistent up-to-date database of industrial solid waste makes it more
difficult to track the rates of generation. Industrial solid waste varies at different levels
for different countries at various advancement levels. For example, a developed country
such as China has a ratio of municipal to industrial solid waste of 1:3. However,
developing countries such as Bangladesh, Sri Lanka, and Pakistan have much lower
ratios. Moreover, for developed countries with high incomes such as Australia and
Japan, the ratio becomes 1:8. The global average is 1900 million tons per year for
industrial solid waste generation. With the increase in urbanization, growth rate, and
Gross domestic product (GDP), this figure is expected to double in under 20 years.
Industrial solid waste will become a severe threat due to inadequate processing,
handling, and transferring and a lagging database.
Municipal solid waste comprises only 5% of the total waste in the United States.
The other 95% of waste generated in the United States comprises agricultural, mining
or industrial waste. Industrial activity in the United States produces and disposes of 7.6
billion tons each year, which composes 40% of the total waste generated each year.
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Only 1% of all plastic and aluminum products in the United States are recycled each
year. According to studies by Ho et al., (2012) and Huysman et. al., (2017), Europe
generates approximately 26 million of plastic waste each year.
Harmful effects on the environment due to industrial discharge. According
to a detailed study by Ho et al., (2012) of various textile industries, paper production
industries, meat production, metal fabrications, etc., all industrial waste or byproducts
discharged from factories carry toxic substances. This industrial waste or byproduct is
directly related to the nature of work. For example, tannery industry waste discharges
contain a high amount of cadmium, which was adopted during the Industrial Revolution,
and textile industry waste discharge contains high chemical oxygen demand (COD) and
color point. Due to the presence of high amounts of toxic substances, it has a high
impact on the environment and the health of living beings.
For many developing countries, groundwater is still considered as the largest
supply of drinkable water and a major source for a country’s domestic, industrial and
agricultural sectors. For example, according to a report by (Singh et al., 2009)
groundwater acts as the largest reservoir for India by meeting the needs of irrigation by
50% and drinking water by 80%. It is assumed that roughly 33% of the world’s
population consider groundwater as a source of drinking water. Thus, contamination of
groundwater due to practices followed by different industries around the world is a major
issue (Vasanthavigar et. al., 2012).
A study by Govil et al., (2008) of an industrial zone with 300 various types of
industries ranging from chemical to metal alloys to plastic products found that the land
around an industrial zone was highly contaminated by arsenic, lead, and zinc. Lead is a
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harmful metal and accumulates in the brain, kidneys, and liver. Zinc plays a very
important role in human and plant life.
Reports from the World Bank suggests the noteworthy increment of per capita
waste from 1.2 kg per day per person to 1.42 kg per day per person for the next 15
years (Kumar & Kumar, 2014). These estimates are not intended to be gauges of a
troubling future. Rather, they underline the motivations for reusing, recycling,
conservation, and opting for less harmful materials. Through direct ways or indirect
ways, all activities involved in the construction industry in the United States account for
54% of the United States energy consumption (Augenbroe et. al., 1998).
2.4 Waste Management Practices Followed by Furniture Manufacturing Industries
Sustainable waste management practices bring innovative and creative solutions
for dealing waste by diverting waste from landfills. The later part focuses on different
furniture manufacturing industries which have their presence throughout the world. The
thesis objectives include analyzing the state-of-the-art sustainable waste management
practices followed by different furniture manufacturing industries by factory visit and
annual sustainability reports. See Table 2-1.
2.4.1 Knoll, Inc.
Knoll, Inc., founded in 1938 by Hans and Florence Knoll, is a leading designer
and manufacturer of textiles, leather, and furnishings for commercial and residential
spaces. Knoll is among the world’s top 10 commercial manufacturing companies. Knoll
works very closely with architects and the designers to deliver best-in-class products.
Some of the Knoll’s products are exhibited in the art museums around the world. Knoll
currently operates on 3,978 (in thousands) square feet of space which includes
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showrooms, offices, studios and manufacturing plants. The Knoll manufacturing plants
located across the globe are shown below:
East Greenville, Pennsylvania – 735,000 Square feet
Grand Rapids, Michigan – 534,000 Square feet
Muskegon, Michigan – 367,000 Square feet
Chicago, Illinois – 34,000 Square feet
Dallas, Texas – 30,000 Square feet
Toronto, Canada – 386,000 Square feet
Foligno, Italy and – 259,000 Square feet
Graffignana, Italy – 108,000 Square feet Knoll manages its products in three segment lines: office, studio, and coverings.
The Knoll office segment includes a wide range of work desks, tables, and seating
options. The Knoll studio offers state-of-the-art products for lounge seating, barstools,
dining, and café seating. Knoll coverings include a collection of Knoll textile, felt, and
leather products.
Knoll studio
Florence Knoll learned principles of architecture and design at Cranbrook
Academy of art from architects Eero Saarinen and Mies van der Rohe. She pioneered
the idea of “total design”—marrying furniture and architecture. She designed the
architectural spaces that were needed to make the room work. To achieve this goal, she
started a “planning unit” where she practiced space planning for the building and the
furniture that complements the space and fit the architecture. Knoll has a rich history of
working with different architects, designers and art lovers from across the globe. A few
of them are Ludwig Mies van der Rohe, Eero Saarinen, Herry Bertoia, Frank Gehry,
Herbert Matter, Richard Schultz, etc.
“For 20 years, Mrs. Knoll was the ‘eye’ of the knoll.” – The New York Times, 1983
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Knoll coverings
Florence Knoll invented the sampling system that continues to be the industry
standard. She tried out different samplings, swatches and sample kits. Florence was
influential in creating a fine line between the classic/traditional ideas and took it to next
level as a clean/modern design. Texture and color always played an important role in
design for Florence. Florence always made sure that the textile accorded to the space
and respected the integrity of the design. She pioneered the concept of integrated
fabrics for modern interiors. Some of the noted and celebrated aspects of Knoll studio
fabrics selected by Florence at that time belonged to men’s suiting but were selected for
furniture.
“A good fabric has to relate to the person, the object and the atmosphere.” –
Florence Knoll
Knoll and sustainability
Knoll implemented sustainable solutions when the term sustainability was at its
initial stage. To reduce harmful effluents, Knoll hired a full-time environmental engineer
in 1978 and redesigned the wastewater treatment plant at East Greenville, PA.
Knoll aimed at eliminating VOCs from all its manufacturing units in 1984. Currently, all Knoll facilities are 95% VOC free.
In 1986, Knoll opened doors to a new manufacturing factory in East Greenville, PA, which received the LEED Gold rating in 2004.
In 1993, Knoll developed and manufacture its first chair using clean technology with even reusable packaging.
In 1998, Knoll met the ISO 14000 standard for Environmental Management Systems Certification, the first of its kind among United States OEMs.
In 2005, Knoll’s East Greenville plant was named an OSHA VPP star site for the first time.
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In 2006–2009, Knoll participated in the Clinton Global Initiative and invested more than $2 million of capital to reduce CO2 emissions by more than 10% each year.
In 2009, one Knoll product achieved SMaRT sustainable platinum certification.
In 2010, Knoll earned BIFMA level 3 certification for various products and became the first company to achieve such a goal.
Knoll made 2011 a remarkable year by establishing a Full Circle Program in partnership with ANEW, a nonprofit organization. The Full Circle program is a one-of-a-kind sustainable and end-of-life initiative in which Knoll takes care of the products that have reached the end of their lives by recycling, repurposing, reusing or converting waste to energy.
In 2014, Knoll’s East Greenville, PA facility achieved the 100% landfill-free award.
Following the trends of East Greenville, PA, the Grand Rapids, MI facility achieved a landfill-free division rate of 98%.
In 2016, following East Greenville, PA and the Grand Rapids, MI, the Toronto facility achieved a 98% landfill-free division rate.
Knoll aims at 10% reduction in energy consumption, waste production and water use by 2018 in comparison to 2017. Knoll also aims at calculating Life Cycle Assessments and Environmental Product Declarations for all its products by 2018.
Knoll has involvement in sustainable waste management practices from the year
1978. Knoll has worked closely with the local authorities and committees for diverging
waste and improve recycling. Due to early involvement in the field of sustainability they
are one of the leading furniture manufacturing company who treat waste as a valuable
resource.
2.4.2 Herman Miller
Herman Miller, a furniture manufacturing company, was founded in 1905 in
Michigan. The Herman Miller Company deeply believes in environmentally sustainable
business practices.
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Packaging
Herman Miller in coordination with Eagle Packaging invented a patented pallet
system called CorrLoc. Both companies wanted to provide a safe, healthy and
sustainable solution to its workers and guests by eliminating the wooden pallet system.
CorrLoc is a pallet system made entirely out of paper with corrugation. Hence, it is
lighter, durable, and reusable; reduces injury at the workplace; and can be moved
around easily. The CorrLoc pallet system can carry approximately 2.5 t of weight.
Materials and resources
Aeron, a Herman Miller chair, was redesigned based on sustainability. In the
process, the chair was made 3 pounds lighter and eliminated carcinogens, mutagens,
and reproductive toxins. The chair is up to 94% recyclable at the end of its useful life.
The Herman Miller Company also donates scrap fabrics to FABSCRAP, a non-
profit textile recycler based in New York. FABSCRAP diverts landfill waste and provides
fabric to artists and students.
Repurpose program
The Herman Miller Company started a repurpose program for products that have
reached their end of life or are of no use to divert the waste from landfill. The program,
launched in 2009 and currently active in more than 150 cities, has helped divert 27,000
tons of product from the landfill.
Circular economy
Herman Miller launched a Gift of Hope program in 2014 in which fabric scraps
are transported to Haiti instead of the landfill. The low-income mothers in Haiti make
totes and laptop bags out of this scrap fabric and ship them back to the United States,
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where these products are sold in Herman Millar gift shops. The money earned by these
women helps pay for food, rent and education for their kids. To date, 80,000 yards of
fabric has been diverted from landfills.
2.4.3 IKEA
IKEA is a multinational group based in Sweden that designs and sells furniture
and home appliance products. The company is the world’s largest home furnishing
retailer with 411 stores in 49 countries. The company’s sales were €36.4 billion in 2016.
IKEA is responsible for approximately 3% of the total global wood output, which is over
9 million m3 of wood consumption annually. IKEA aims at 90% of the waste generated
to be recycled or converted to energy by 2020.
Third-party initiatives
By participating in initiatives such as Global Lighting Challenge, IKEA aims at
selling 500 million LED bulbs from 2015 to 2020. The Global Lighting Challenge
initiative aims at selling 10 billion energy-efficient bulbs to fight for sustainability.
Products
In 2016, IKEA decided to replace all electric hobs with energy-efficient induction
hobs. IKEA is also looking for alternative solutions of wood. Tabletops, legs, and bench
products are a few products made of bamboo. IKEA believes in innovation and is
working closely with farmers in China to produce bamboo with increased efficiency and
quality.
IKEA consumed approximately 130,000 t of cotton in 2016, which constitutes 1%
of the world’s cotton. IKEA is a founding member of the Better Cotton Initiative (BCI),
which aims at motivating cotton producers to improve their yields and make cotton
production better for the environment.
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IKEA consumes approximately 3 million m3 of leather each year. The year 2016
was the first year in which IKEA used 100% leather made using a chrome-free process.
Sustainability product scorecards help in creating awareness about products
sustainability.
Working together with suppliers
Cotton is mostly sourced from countries that face water scarcity problems. IKEA,
in collaboration with suppliers in Hillong, generated a fiber dyeing technique commonly
called dope dyeing that reduces water consumption by 80% by eliminating steps in the
production. See Figure 2-5.
Circular economy
IKEA strives to achieve zero waste by minimizing or eliminating all kinds of waste
generated. Glass that is rejected due to the bubbles/cracks in the production of different
products is used to make vases with leftover paints. Waste plastic products are
converted into small spray bottles. IKEA also sells FSC certified kitchen front options
made of recycled wood.
Owning a forest
IKEA has its own forestry team, which works closely with growers and suppliers
regarding minimal requirements for wood and bamboo and audits them regularly. IKEA
believes in supporting local economies and responsible forestry. By 2015, IKEA will own
46,700 hectares of forest and will have received FSC certification. Four thousand
hectares of this land will be used for short-rotation plantations (SRPs), which help speed
up lightweight and strong wood production. See Figure 2-6 and 2-7.
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Packaging
IKEA used to consume expanded polystyrene (EPS) foam, a cheap, durable,
lightweight, easy-to-form oil-based product used for packaging. The new sustainable
solution is an innovative honeycomb structure made of fiber-based materials with the
same durable and lightweight properties.
Chemicals
IKEA believes in displaying increased information on chemical contents of
products for transparency. They assess chemical safety and aim at eliminating and
phasing out chemicals that could cause harm.
Innovation
IKEA aims at trying fuel cells in the coming year, which would help generate
electricity and store energy. Hydrogen fuel cells are effective in IKEA’s operations in
France for lifting goods by forklift.
Energy models
All IKEA stores and production facilities have an energy model, which helps track
energy, carbon dioxide, and water and carbon emissions. It also helps in designing the
next store to have greater efficiency than the previous one.
Product transport
IKEA, a founding member of Green Freight Asia (GFA), aims at the most
sustainable means of transportation by lowering shipping costs and carbon emissions.
Lithium-ion forklifts, vegetable-oil-powered trucks, diesel-hybrid vans and electric
shunting trucks are few more of IKEA’s steps toward reducing its environmental impact.
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Waste
The installation of baling machines at IKEA stores has helped cut the company’s
transportation impact by 80%. Baling machines compress waste packages into bales.
Repackaging of a product is a problem. Not every store has a repackaging facility for
returned or defective products.
2.4.4 Steelcase
Steelcase is a United States-based furniture manufacturing company founded in
1912 in Michigan. Steelcase participates in more than 20 third-party certification and
sustainability programs considering materials, products, and operations. Steelcase
achieved the “Clean Corporate Citizen” award in 2017 for displaying strong
environmental ethics and stewardship.
Repurpose
EcoServices is a repurposing and redeployment service started in 2008, which
works hand in hand with Steelcase to repurpose products in Europe, the Middle East
and Africa. Steelcase also joined hands with Societe Generale in France for the same
purpose. By 2017, 167,700 m3 of furniture was diverted from dumping in landfills.
Renewable source of energy
Steelcase started investing in clean energy in 2014. According to the EPA,
Steelcase is among the top 30 100% green power users in the United States.
Scrap fabric
In collaboration with fabric suppliers, Steelcase found a way to recover leftover
fabric and divert waste from landfills. The fabric is melted down and mixed with PET
recycled bottles to create yarn. This yarn is then dyed black and woven into new black
textiles. This collaboration received an innovation award at NeoCon 2016.
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Thinking backward
Steelcase has a different approach to its products. The conventional technique is
to develop a concept/design and later in the process struggle to eliminate
underperformance or meet goals. Consideration of engineering, materials,
sustainability, marketing and the global supply chain at an initial stage helped in
developing ergonomic, high-quality, aesthetically appealing, sustainable, price-efficient
and comfortable products. The Steelcase series 1 chair was developed in such a way.
Partnership with research institutes
In 2016, Steelcase partnered with the Biomimicry Institute in a joint research
project searching for ways to eliminate pervasive materials and their alternatives.
Waste
Steelcase aimed at reducing waste generation and water consumption by 25%
by 2020. So far, Steelcase has been successful in eliminating waste by 45% and water
consumption by 8% since 2010.
Planked veneer
When grains of wood did not match the desired product specifications, Steelcase
used the scrap wood and turned it into a prototype planked oak table, which met the
customer’s design aspirations perfectly.
Melamine pallets
The opportunity to find a use for excessive melamine at Steelcase inspired the
packaging team to develop melamine pallets to make the pallets stronger. The
packaging team was looking for improved support and additional protection for a
particular range of products.
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2.4.5 Haworth
Haworth Inc. is a manufacturing and design factory opened in Michigan in 1948,
which produces a wide range of products from workspaces, seating, and storage
furniture to movable walls. Haworth Inc. serves more than 120 countries with revenue of
$1.96 billion in 2016.
Zero-Waste title
In 2012, Haworth received the Zero Waste to Landfill award globally and
EcoVadis Gold status for excellence in corporate social responsibility.
Updated sustainability standards: femb attestations and Google portico
In 2014, the European Federation for Office Furniture Associations (FEMB) at
Europe’s largest contract furniture tradeshow launched updated sustainability
standards. Google also has its own healthy materials library reporting tool. In 2016,
Haworth received 4 product certifications under FEMB and 9 products eligible under
Google Portico.
Carbon-offsetting projects
Haworth focuses on improving the quality of air by following certain measures,
such as producing renewable energy through micro-hydro plants and generating
sustainable energy through a wastewater treatment plant in a starch plant.
Packaging
In 2015, the Haworth manufacturing facility changed its packaging method from
the conventional peanut method to the ExpandOS system. The new ExpandOS
technique cuts and folds sheets of paperboard materials into three-dimensional
triangular structures. The new technique is an environmentally friendly option and saves
approximately $0.75/ft3.
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Recycled plastic bags and the use of blankets for transportation have helped
Haworth achieve its goal of green transportation globally.
Project clarity
Haworth joined hands with more than 30 organizations in western Michigan and
various government agencies, organizations and businesses to restore 700 miles of
rivers and streams that drain into Lake Macatawa. Haworth donated 70.6 acres of land,
which will be converted to a wetland that would reduce the flow of fertilizers, sediments,
and bacteria into Lake Macatawa.
Materials
With the use of advanced technological software such as CutRite, Schelling and
3TEC Haworth have been successful in saving more than 262 t of wood per year. The
new software uses technology such as nesting that calculates the most efficient way to
cut designs from boards.
2.5 Waste Management Practices Followed in Europe
2.5.1 Introduction
Europe generates 360 million tons of waste from manufacturing activities, and
900 million tons of waste produced from construction activities annually. As indicated by
the Center for American Progress (CAP), 69% of waste generated in the United States
gets dumped in landfill which is 1% in contrast to nations like Belgium and Sweden.
Germany and Netherlands are a few cases of nations which are landfill-free, with 62%
of waste being reused or composted. The other 38 percent is converted into energy
from waste (EfW). The United States waste in EfW is merely 7 percent of total solid
waste generation in contrast to 40 percent of some European nations. Strict policies on
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waste output, numerous laws regarding recycling and waste processing are some major
reasons why Europe has high percentage of Energy from waste.
2.5.2 EU Waste Management Policy
Over the course of stringent environmental action plans and legislation has made
European Union waste policy an efficient waste management policy focusing on waste
prevention and management. The latest and EU’s Seventh Environment Action
Program (2013-2020) focuses on:
Packaging, vehicle and electronic waste streams
Industrial waste treatment and landfilling
Environmental performance of eco-design products,
Targets at 50% of municipal waste generated and 70% of construction waste generated to be recycled by the year 2020.
2.5.3 Automobile Industry
Aston Martin, Jaguar Land Rover and Toyota Motor Europe – three of the world’s
leading car manufacturers targeted in eliminating risks associated with the supply chain.
Achilles, supply chain management company developed an online portal which displays
supply chain information to the buyers and suppliers and also keeps as a ‘financial
health check’ on them.
General Motors (GM)
General motors currently operate 131 facilities throughout the world and 90
manufacturing sites which reuse, recycle more than 97 percent of their waste which are
landfill-free. In the year 2014 GM recycled or reused approximately 2.5 million metric
tons of waste which accounts for highest than any other automaker in the world. Today,
GM recycles or reuses 85%5 of the waste they generate worldwide. GM is the first
organization and to date only auto manufacturer who have been recognized on the
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United States EPA Waste Wise hall of Fame for its outstanding waste reduction
strategies.
Audi
Over 95 percent of waste is recycled at the Ingolstadt plant and less than 5
percent of waste is accumulated for disposal. All vehicles manufactured by Audi are
altogether recyclable. For instance, all functional aggregates in the Ingolstadt plant are
reconditioned. In case of a repair, clients can pick whether they need another starter
engine, another alternator or a reconditioned unit.
Mercedes-Benz
Taking sustainability principles into thought at an initial stage, contribution in
different recycling programs and most recent advancements the Mercedes Benz
contemplates sustainability. The managing guideline of “Design for Environment” (DfE)
is applied to the development of all-encompassing vehicle concepts, with the aim of
improving environmental compatibility in a way that can be objectively measured. The
use of state-of-the-art technologies such as water-based paints and water-based fillers
reduces solvent emissions, while continuous process improvements help us to save
energy.
MeRSy recycling management. In 1993, The “MeRSy Recycling Management”
system was introduced which provided an early foundation for the development of more
advanced recycling concepts. There are now more than 30 subsections, including tires,
car batteries, catalytic converters, coolant/brake fluid, aerosols, electronic scrap and
plastic parts. The recycling of materials takes precedence over the recovery of energy.
One of our objectives is to continue gradually increasing the proportion of
recycled materials used in new Mercedes models. The wheel arch linings, for example,
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are produced using a recycled material derived from reprocessed starter batteries and
bumper coverings. 3417 tons of batteries were recycled by Mercedes-Benz in the year
2016. Waste batteries are also recycled and turned into new headlamp housings. See
Figure 2-8.
Repurposing tires. A tire is made of rubber, steel and a textile element. The
textile residues, for example, are often used in insulation. The steel, once freed of
impurities and melted down, can be used again as new quality material. The category
most frequently encountered on an everyday basis is that comprising rubber elements.
These are used in the construction of sports grounds and playgrounds, mixed with
asphalt, or can be found in plastic containers and rubber seal.
BMW
BMW uses upto 20 percent of the thermoplastic materials which are entirely made from
recyclates and account for approximately 12 percent of the total vehicle weight. The
company also uses 50 % secondary aluminum in high strength cast aluminum parts.
BMW also focuses on replacing door trim panels with natural fibers and removing rare-
earth elements from engine fan.
End-of-life vehicle recovery and recycling. The BMW group offers
environmental friendly vehicle recycling programs for vehicles which have achieved or
are near its end-of-life vehicle in more than 30 countries across the globe. All BMW
vehicles after the year 2008 are 95 percent recyclable and 85 percent reusable and
material recyclable.
Rolls Royce
Every Rolls Royce manufacturing facilities, in over 100 locations around the
world, is part of our Revert program, where we recover, recycle and reuse waste metals
38
in manufacturing. These can then be melted and used again in new aerospace alloys.
We use over 20,000 tons of high value metal alloys each year, equivalent to two and a
half Eiffel Towers. That's why we work to reuse as much metal as we can through a
closed-loop recycling program we call Revert. This reduces our need for virgin
materials, the extraction of which is expensive and has a significant environmental
impact. Almost 95% of a used aero engine can now be recycled and around half of the
recovered material is of such high quality it can be safely used again to make a new
engine.
2.6 Waste Management Not Practiced by Company Around the World:
Amazon. Amazon is an American electronic commerce company based in
Seattle. Since its founding in 1994, Amazon has achieved tremendous growth over the
years. In 2016, Amazon had total assets exceeding $83 billion with a team of
approximately 542,000 employees. Due to continuous attempts to harm the Amazon
brand image by different environmental and sustainable leaders, in 2015, Amazon
decided to hire 4 individuals to form a sustainability team.
According to an article published in The Guardian, Amazon does not emphasize
environmental, workplace, diversity, charity, logistics, business ethics or sustainability
issues. The report also states that more than 80% of global S&P 500 companies take
part in the Carbon Disclosure Project. However, Amazon falls in the other 20% and
unlike Best Buy and Walmart does not take back its own electronic waste.
In an article by GreenBiz on Oct 3, 2017, Kara Hurst, Amazon’s director of
worldwide sustainability and social responsibility, said that Amazon aims at investing in
a renewable source of energy. Amazon plans to install solar panels at 50 fulfillment
centers by 2020. The system would generate a total output of 41 W.
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Figure 2-1. Figure shows the amount of industrial waste generated in 2011 (million tons)
adapted from Song et. Al., (2015)
Figure 2-2. MSW generation rates from year 1960 to 2014 adapted from (EPA, 2015)
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Figure 2-3. Management of MSW in the United States in the year 2014 adapted from (EPA, 2015)
Figure 2-4. MSW recycling rates from the year 1960 to 2014 adapted from (EPA, 2015).
41
Figure 2-5. The figure displaying example of IKEA group working together with the
suppliers adapted from IKEA group sustainability report (2017)
Figure 2-6. The figure displaying example of IKEA group working closely with the
suppliers in India to improve resource-efficiency adapted from IKEA group sustainability report (2017)
42
Figure 2-7. The figure displaying example of IKEA group working closely with the
suppliers in China adapted from IKEA group sustainability report (2017)
43
Figure 2-8. The figure displaying quantity of different Mercedes-Benz vehicle parts
which were re-used in the year 2016 adapted from Recycling Management Mercedes-Benz sustainability report (2017)
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Table 2-1. Table below shows involvement on different furniture manufacturing industries in different categories.
Company Category
Knoll Herman Miller IKEA Steelcase Haworth
Materials and Resources
LCA, EPD, BIFMA, FSC, GREENGUARD
LCA, EPD, BIFMA, GREENGUARD
BIFMA and FSC
BIFMA and FSC
Google Portico, BIFMA and FSC
Repurpose Takes into consideration
Takes into consideration
Not Addressed
Takes into consideration
Not Addressed
Circular Economy
Not Addressed Takes into consideration
Takes into consideration
Not Addressed
Not Addressed
Packaging Traditional Wooden Pallets
CoorLoc Palltets
ExpandOS Melamine pallets
Expand OS
Innovation Not Addressed Not Addressed Hydrogen fuel cells in operating forklifts
Partnership with research institutes
CutRite and 3TEC technology
Third-party sustainability initiatives
Not Addressed Takes into consideration
Global Lighting Challenge
Not Addressed
Project clarity
Transportation Not Addressed Not Addressed Green Freight Asia
Not Addressed
Not Addressed
Working closely with the suppliers
Takes into consideration
Not Addressed Takes into consideration
Not Addressed
Not Addressed
Waste Reduction
Zero waste to landfill and Scrap fabric program
Takes into consideration
Bailing machines
Scrap fabric and wealth from waste
Zero waste to landfill
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CHAPTER 3 METHODOLOGY
3.1 Overview
The aim/objective of this research is to find the most sustainable strategies and
practices to reduce industrial waste by following the best waste management systems.
In the initial phase of the research, the existing literature was reviewed to understand
the need for waste management. The various benefits of diverting waste from landfilling
or recycling to the environment and human health are discussed. This research will
gather data from Knoll—Environmental, Health, and Safety annual reports, which are
disclosed to the general public. This helps in providing the necessary information to
understand the sustainability measures adopted by Knoll over the past years. A further
literature review was performed to understand the global problems of waste
management and drifts in industrial waste management practices.
An interview with Rachel Miley, Environmental Health and Safety Manager of
Knoll, Inc. located in East Greenville, PA, was conducted to understand the
sustainability principles followed by Knoll. The interview was conducted at Knoll’s East
Greenville, PA factory to gather the data about the different green certifications, third-
party certification, and Life Cycle Assessment (LCA) for different products considered
by Knoll. This data helped in understanding the factors that drive the waste
management system. The expected results are to understand the driving factors of
waste generation in the United States and sustainability practices followed by a green
product manufacturing system. The data collected from the interview were analyzed
using a qualitative analysis technique.
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3.2 Interview Questionnaire Design
The interview questionnaire can be found in its entirety in Appendix C. The
interview questionnaire consists of 3 sections: 1) Past 2) Present and, 3) Future. The
sections of the interview questionnaire are designed according to the timeline. The
questions in the first section cover the sustainability practices followed by Knoll in the
past, followed by the current practices in the second section and the upcoming
sustainability goals in the last section. The interview was anonymous, voluntary, and in
agreement with the University of Florida Institutional Review Board (UFIRB-02). An in-
depth report of the questionnaire and its significance to this research is covered below.
Past
The first segment of the interview questionnaire was intended to determine the
factors that inspired Knoll to start its sustainability program. Sustainability is a very
broad term. Hence, the questions in the first section are designed to understand the
Knoll sustainability principles, key strategies, and management philosophies. The
questions in this section were important to establish a better understanding of different
sustainability programs Knoll designed and factors responsible for this change.
Present
The second segment of the interview questionnaire was more focused on
understanding the current trends of waste management practices adopted by Knoll. The
main aim of this section is to understand the waste generation, waste handling, and
minimization factors. The questions in this section were important to establish a better
understanding of different green certifications, green products, and how life cycle
assessments are considered.
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Future
The last segment of the interview questionnaire is focused towards the future
short-term and long-term sustainability goals of Knoll. Various Knoll manufacturing
facilities recently achieved 98% landfill-free award and few facilities run at 98 percent
landfill-free division rate. Hence, the questionnaire aims at identifying the techniques
and sustainable waste management practices Knoll follows at its manufacturing facilities
which helped it achieving these goals.
The literature review also focuses on understanding the current waste generation
in the United States and to study the responsible material cycle strategies various
industries follow globally. The thesis with the help of annual sustainability reports of
different furniture manufacturers such as Haworth, Steelcase, IKEA, and Herman Miller
helps in analyzing the best responsible materials cycle strategies of green product
manufacturers in the United States. The thesis also aims at studying the behavior of
different automobile manufacturing industries in Europe in handling Industrial waste and
material cycle strategies. The methodology also aims at understanding how the
international standards, governance power and sustainable practices are followed in
different industries which are state-of-the-art technology and can be implemented in
construction industry.
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CHAPTER 4 DISCUSSION AND ANALYSIS
4.1 Overview
This thesis compiles some of the best sustainable waste management practices
by analyzing the interview held at Knoll, Inc. and various annual sustainable reports of
different manufacturing industries of furniture and automobile facilities in the United
States and the Europe. The figure 4-1 compiles different material cycle strategies which
the manufacturing industries can follow at different levels. The figure also shows
different performance checks as goals after each level. This chapter is divided majorly
into 5 sections in contrast with the figure 4-1. The section 4.2 Design and supply chain
elaborates best sustainable waste management practices manufacturing industry can
follow. Similarly, section 4.3 talks about various practices a company can follow at
manufacturing and showrooms level. The section 4.4 talks about the practices devoted
entirely to client support and performance. The section 4.5 talks about the practices a
company can follow when its products are nearby achieving or have achieved end-of-
life product. Lastly, the section 4.6 talks about various measures that can be taken at
recycling centers aiming circular economy.
A qualitative approach was picked as a data analysis method for this research for
several convincing reasons. Qualitative research is helpful in finding the experiences of
human interaction. The motivation behind this research was to find the significance of
waste management systems followed by a green product manufacturing company.
In particular, when the nature of research requires exploration, a qualitative
method for data analysis is justified. The questions of qualitative research address
“how” or “what,” which helps the researcher gain an inside-and-out comprehension of
49
what is happening with respect to the subject (Patton, 2002). For this research, I gained
an in-depth understanding of participant experience with current waste management
practices followed by Knoll by asking the following questions:
How many types of waste do you produce? At what quantity?
What are Knoll’s sustainability goals at present? What methods does Knoll
implement in achieving its sustainability goals, and how have they evolved
over the past years?
What are the current challenges Knoll is facing in achieving the
abovementioned sustainability goals?
How often does Knoll commission its East Greenville manufacturing plant
to keep its LEED Gold rating intact?
Qualitative research as a data analysis method underlines the researcher’s part
as an important member in the research. For this research, I, the researcher, was the
principal investigator for data collection and the transcriber for the data outcomes.
Multinational furniture manufacturing companies such as Knoll, Haworth,
Steelcase, and Amazon are leading brands among thousands of companies in the
United States. The role of these companies should be more than just selling their goods
or products: the power and impact of these companies would be huge on the market. A
small change or improvement in their business ethics could have a great impact. This
would not only benefit them but also the communities and organizations they serve.
Some of the best waste management practices are discussed below.
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4.2 Design and Supply Chain
The Design and Supply Chain is the first step for any manufacturing industry in
the world. Working closely with the suppliers at an initial stage for sourcing of raw
materials and following suppliers’ code of conduct can be called upon as first step of the
process. The involvement in various different sustainable initiatives and programs and
annual sustainability reports helps in driving sustainability in company. The product
declarations and suppliers code of conduct acts as a performance check at this stage.
Working Closely with Suppliers
Companies such as Steelcase and Haworth are responsible for generating
millions of tons of waste on an annual basis. IKEA sells their products in more than 49
countries and receives supplies from more than 100 countries. IKEA worked with their
cotton suppliers in Hillong and improved their production process by understanding the
country’s problem of water scarcity. Initiatives like this not only help in keeping their
orders on track and keep them in business but also create a healthy relationship with
suppliers and educate them about state-of-the-art technologies. Developing countries
can increase their production level if such companies provide them a helping hand by
creating awareness.
Updating Sustainability Standards
Green Globes and LEED are developing updated sustainability standards. It is
time to respond to the increasing market demand by updating standards and developing
more stringent rules. Knoll, Haworth, Steelcase and Herman Miller are some of the
leading furniture brands around the globe and have a good impact on their users.
Companies such as Google, Facebook, and Microsoft follow principles of sustainability
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so seriously that they have set their sustainability standards in terms of operations,
business ethics, and furniture. Hence, to be eligible to sell their products, it is time for
furniture companies to update their sustainability standards and maintain transparency
about their products. Some companies consider this standard a necessity to continue
doing business globally. Globally, if a stringent rule makes manufacturing companies
responsible for the products they produce, then manufacturers would force them to
adopt these updated standards by being transparent to keep their business. The
companies would also become more transparent about their products.
Suppliers’ Code of Conduct
The suppliers code of conduct helps in assessment of suppliers in context to
sustainable procurement techniques of raw materials. The code of conduct aims at
enforcing suppliers to follow sustainable practices of sourcing raw materials from
different parts of the world. The code of conduct also helps in keeping transparency with
the end-consumer and the manufacturer. It also helps manufacturers in mitigating risk
and acts as a performance check over the suppliers in terms of sourcing of the raw
materials.
Involvement in Different Programs
The Global Lighting Challenge, Better Cotton Initiative, Carbon- Offsetting
projects, and Zero Waste to Landfills awards are merely a few of the programs that aim
globally to create awareness amongst citizens in adopting sustainability. Such programs
have shown results in creating a better world. Thus, increasingly more involvement and
initiative in these programs are of utmost importance.
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Annual Sustainability Reports
Not all companies believe in publishing sustainability reports or expend efforts in
adopting sustainability principles. Companies should no longer consider sustainability
reports as a moral issue but should view them as ways to improve their brand by
connecting them to the users. With that said, a growing number of investors and users
today believe in important sustainable concerns of climate change and other
environmental and social factors. Hence, transparency in these reports would help
connect better with the users, especially when the users are aware of the quality and
details of the products they are purchasing.
4.3 Manufacturing and Showrooms
The second step after the product gets designed is the manufacturing of the
product and its transportation to various showrooms. The use of CorrLoc pallets for
storing and transportation and ExpandOS systems are some sustainable techniques of
handling waste at this step. The awards, certifications such as 100 percent landfill free
award are some of the performance check which motivates people in doing better.
Packaging
There is no all-in-one solution for packaging. Each product is different in terms of
weight, size, height, and volume. Hence, innovation and research are the key elements.
Elimination of EPS foam is a sustainable solution. CorrLoc Pallets and ExpandOS
systems are efficient and sustainable solutions. The new shelf-packaging used by
Hershey’s is both innovative and sustainable.
4.4 Client Supports and Performance
After the products reach the desired showroom they are ready for the end-
consumers for its use. Thus, client supports and performance acts as a check on these
53
products. The Innovating packaging technology, transparency with the Sourcemap,
annual sustainability reports helps the consumer connect better with the company.
Innovation
The abovementioned practices can be called sustainable practices, but they lack
innovation. With the help of advanced software, procedures or techniques, one can use
resources more efficiently. For example, Haworth Company uses CutRite, Schelling,
and 3TEC software, which uses nesting technology to cut materials efficiently. In
addition, Steelcase Company uses wood with grain defects to make different patented
products. The display-ready box packaging is another innovative packaging technique
which was developed by Hershey’s. The Sourcemap technology used by Hershey’s in
keeping transparency about their products with the consumers not only helps in building
trust but also educates them. This technology helps in educating with the help of videos
and process about sourcing of raw materials and extraction process. The use of fuel cell
technology by IKEA in forklifts is another innovative sustainable operational measure.
Steelcase furniture is partnering with the Biomimicry Institute and is looking for
innovative solutions that later can be adopted by small or mid-sized companies.
New Updated Sustainability Standards
The new updated sustainability standards will help in bridging the gap between
the project team and the manufacturing industries. The Green Globes has addressed
supply chain waste minimization as a category in its upcoming version which have not
been introduced by LEED Version four. Alternatively, Building product declaration and
optimization – sourcing of raw materials have been addressed in LEED Version four
and yet not in Green Globes. The introduction of new updated stringent sustainability
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standards focusing on manufacturing industries would make them responsible and drive
sustainability goals. See Table 4-1.
4.5 End of Life Cycle
Once the products nears its end-of-life the company should aim at circular
economy and repurposing programs. The repurpose of products by the manufacturers
would make the industry viable and responsible for the products they manufacture. The
circular economy not only helps in being sustainable but also aims at resource-
efficiency. The product take back programs acts as a performance check at this stage.
Circular Economy
Not all companies are participating in the circular economy. Closing the loop,
commonly called the circular economy, has highlighted alternatives over the past few
years. The circular economy emphasizes recycling, repurposing, remanufacturing and
refurbishment of products. For over 50 years, Davies Office, a remanufacturer based in
New York, has disassembled all its used office furniture to recover the “core,” and with
some small changes such as a change in fabric or a new paint job, they sell this nearly
new furniture. The aim of the circular economy is to divert the waste being dumped into
landfills and to take responsibility for the products by the manufacturers. Another
measure companies such as Knoll, Steelcase, and Haworth could take is to repurpose
the used products dropped off at local or regional stores by customers and transport
them back to the factories. Generally, companies opt for road transportation, and
products are delivered at regional centers or stores. However, on their way back, they
can be filled with used or damaged products, and at least some of the core materials or
parts of the products can be used again.
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Embodied Energy
The Embodied energy of some recycled materials is lower than the
embodied energy in its virgin form. See Table 4-2. Aluminum in its virgin form has an
embodied energy of 227 Mj/kg and its recycled form has 8.1 Mj/kg which states that
recycling of aluminum is far more sustainable technique in comparison to extract. See
Table 4-2.
4.6 Recycle Centers
The introduction of recycle centers help in taking responsibilities of the products
by the manufacturing industries. The dismantling of the products occurs at recycling
centers. The dismantling of the products helps in segregating the helathy materials from
unhealthy materials. The healthy materials can reused back at first stage of Design and
supply chain. The repurpose programs helps in circular economy thereby mitigating the
dependence on rare-earth materials and making it more sustainable.
Figure 4-1. The figure compiles different materials cycle strategies manufacturing
industries can follow at 5 steps and their respective performance check adapted from Spirkova et al. (2016).
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Table 4-1. Table below displays different issues which are being addressed by the
LEED and the Green Globes in recent versions.
Issue Green Globes (upcoming version)
LEED V4
Supply Chain Waste Minimization
Addressed Not Addressed
Building Product Disclosure and Optimization – sourcing of raw materials
Not Addressed Addressed
Table 4-2. Table below displays the embodied energy of aluminum and steel in its virgin and recycled form.
Material Embodied Energy (MJ/kg)
Aluminium (virgin) 227 Aluminium (recycled) 8.1 Steel (virgin) 32.0 Steel (recycled) 8.9
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CHAPTER 5 CONCLUSION AND RECOMMENDATION
State-of-the-art technology, environmental regulations, efficient use of resources
are some of the methods which have significantly reduced the environmental impacts.
However, Inclination towards waste recycling, clean production, and the circular
economy is still unnoticeable in the manufacturing industry. The significant rate at which
the waste is generated needs to be reduced in order to regulate the adverse effects on
the environment. This research verifies different waste management strategies which
can be taken into consideration to divert waste from landfill.
5.1 Waste Management Practices
The findings of the research compliments the (Alwan, Jones, & Holgate, 2017;
Shahbazi, Wiktorsson, Kurdve, Jonsson, & Bjelkemyr, 2016) which focuses on the
significance of effective leadership at various levels such as government, society,
industries, and suppliers. In sum, updating sustainability standards or introduction of
industrial sustainability standards, working closely with suppliers as a two-way
relationship, involvement in different sustainable programs are some of the economical
ways of managing the resources efficiently. Involving everyone and measuring the goals
of zero waste are some of the proven waste reduction strategies as the results are
visible to everyone. These results are the motivating factor for people to do better. The
factors such as ‘design for environment’ should also be introduced in manufacturing
industries thereby keeping transparency between the supplier, manufacturer, and
consumer. The transparency from where the raw materials are sourced to the
packaging style develops consumer trust and increases brand value. Achieving 100
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percent landfill-free reward could be an unrealistic dream but participating in these
waste management practices would definitely increase the recycling rate. These waste
management practices are some of the steps taken by global companies in real life.
Hence, the challenges, benefits and success factors are transparent enough through
sustainable reports by which small manufacturing companies can motivate and
implement.
5.2 Future Scope of Study
Amongst various third-party green certification, the waste management system is
still not considered as compared to other segments like energy and water. Hence, the
subsequent gap is being observed in the manufacturing industry. Introduction of
‘Industrial Ecology’ and ‘closed-loop recycling’ as prerequisites are identifying factors
that could be included in future. Lastly, the study did not find a one-stop solution for a
best waste management practice which every manufacturing industry can follow and is
universally accepted. These results may provide grounds for the future researchers to
innovate technology which can be incorporated in product development process with
the aim of the circular economy. The implementation of sustainability goals for a
company is ethical. Thus, more research can be done in the field of motivating behavior
of investors for paying extra to choose environmental sustainable practice.
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APPENDIX A UNIVERSITY OF FLORIDA INSTITUTIONAL REVIEW BOARD EXEMPT APPROVAL
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APPENDIX B INTERVIEW CONSENT FORM
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APPENDIX C QUESTIONNAIRE FORM
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BIOGRAPHICAL SKETCH
Sahil Motwani was born in Indore, a small town located in central part of India in
the year 1990. He pursued a Bachelor of Architecture from School of Architecture,
Indore from 2010 to 2015 which falls under Rajiv Gandhi Technological University,
Bhopal. After pursuing architecture for a year he started pursuing his Master of Science
in Construction Management degree from spring 2016. He has lead student
organizations at the University of Florida through his involvement with various cross-
cultural, student government and philanthropy events. He also received graduate
research assistantship in the year 2016 and worked at Walt Disney world for 8 months
as a project management intern.