Despite a decline over the past two decades, manufacturing still forms an important pillar in the UK economy, accounting for 9.1% of the value added and 7.2% of the employment in 2023[1]. Yet, with every product made, every process completed, there’s an unavoidable byproduct: waste. Data from Gov.uk[2] suggests that the commercial and industrial sectors generated over 40.4 million tonnes of waste in 2020. For manufacturers, this isn’t just an environmental concern; it’s a direct impact on operational efficiency, resource consumption, and ultimately, profitability.
Given the inherent nature of manufacturing – transforming raw materials into finished goods – there will always be a leftover component. As such, the vast amount of waste produced is unsurprising. The core challenge lies not just in the volume, but in the origins and lost potential of this waste. It often stems from inefficiencies in various production processes, including material miscuts, product defects, off-spec batches, and excessive packaging. What’s often overlooked are the hidden costs associated with this waste: not just disposal fees, but also the wasted value of raw materials, the energy consumed in processing them, and the storage space they occupy. Identifying and addressing these overlooked areas represents a significant opportunity.
The power of proactive waste reduction
Moving forward, the continued adoption of proactive waste reduction strategies will be key for manufacturers. By improving efficiency within their processes, manufacturers can reduce the amount of waste they produce. Common and effective methods include minimising overstocking and overproduction, reducing packaging waste, and incorporating recycled materials into products.
Specifically, manufacturers can embrace Lean Manufacturing principles[3]. This means constantly identifying and eliminating “waste” in all its forms, from excess inventory (minimising overstocking) to unnecessary motion or defects. Implementing Just-In-Time (JIT) production can dramatically cut down on material waste by ensuring materials arrive only when needed for production, reducing storage requirements and the risk of spoilage or obsolescence. Applying Value Stream Mapping helps visualise the entire production process, pinpointing bottlenecks and non-value-added steps that generate waste.
Managing the unavoidable waste
While waste reduction is essential, there will always be some unavoidable waste remaining. This is where a robust waste management strategy comes into play. But what are the most effective options for different elements of the remaining waste?
For unavoidable byproducts, reuse should be prioritised. Can internal packaging be repurposed? Can water be recycled within the plant? Following this, establishing comprehensive recycling programs is critical. This means rigorously segregating diverse waste streams like wood, cardboard, paper, metal, glass, plastic, plasterboard, and aggregates. Partnering with waste management experts who operate advanced Materials Recycling Facilities (MRF) ensures the maximum amount of recyclables is recovered.
When reuse and recycling aren’t feasible, energy recovery options, such as converting industrial waste into energy, can be considered as a more sustainable alternative to landfill. For any truly unavoidable and unrecoverable waste, responsible disposal is paramount, strictly adhering to environmental regulations and ensuring hazardous materials are handled safely.
For manufacturers, effective waste management isn’t just about regulatory compliance; it’s a strategic imperative. By proactively reducing waste and thoughtfully managing what’s left, they can significantly cut costs, improve operational efficiency, enhance their brand reputation, and contribute positively to a more sustainable, circular economy. It’s an ongoing journey, but one that offers substantial returns for both business and the planet. For more information on how Willshee’s can help, please visit https://www.willshees.co.uk.
[1] https://www.ciip.group.cam.ac.uk/innovation/structure-and-performance-of-the-uk-economy-25/
[2] https://www.gov.uk/government/statistics/uk-waste-data/uk-statistics-on-waste
[3] https://www.ascm.org/topics/principles-of-lean-manufacturing/
Social