Early planning for recycling opportunities in the initial design of products and the production or construction process can quickly expand the amount of materials recycled and make the inter-related recycling processes work much more smoothly. "Design for Recycling" focuses on setting up processes to enhance production, reduce waste, reclaim resources, protect the environment, and benefit the public. Our goal is to increase the number of products and processes designed for recycling.

New Packages

In 1996, Motorola developed a new packaging system for the production of its pagers -- a new multi-use tray that would hold several different styles of pager housings and the associated parts. The new tray is manufactured from 100 percent postconsumer recycled HDPE, which, in turn, helps create a demand for recycled plastic in communities surrounding Motorola's manufacturing facilities. The new trays require less than 50 percent of the material that was needed to manufacture the old trays and the new trays have been combined with a central database for scheduling packaging and production needs. The system significantly reduces costs, increases efficiency, reduces packaging waste, and absorbs collected plastics from recycling programs in surrounding communities. Implementation of this system resulted in a savings of $4.1 million in 1997 and eliminated a minimum of 250,000 pounds of packaging waste.

As its commitment to the Challenge, Motorola will be expanding this unique packaging system to other product lines over the next two years.

"Designing" in Recycled

Telcordia Technologies, formerly Bell Core, is presently recycling 72 percent of all generated solid waste. Recycled commodities include: all grades of printing/writing paper, newspaper, aluminum cans, glass and plastic containers, steel cans, corrugated, laser toner printer cartridges, solvents, lead/acid batteries, small (alkaline, lithium, etc.) batteries, and fluorescent lamps. Since 1998, Telcordia has recycled over 25 million pounds of paper, recycled over 56,000 fluorescent lamps and over 24,000 laser toner printer cartridges. Savings, as of November 1999, exceeded $3.3 million.

For the Challenge, Telcordia incorporated a new Design Recycled element into a major new building construction project, to assure recycling is considered in the up-front design phase. This includes recycling of construction debris; the planned use of recycled fiber polyester carpet and other building materials, use of energy efficient products, and built-in recycling bins in common areas; initiating office supplies recycling centers at each major Bell Core facility to promote reuse of surplus supplies (binders, paper, clips, staples, equipment, etc.) instead of disposing of old and buying new; and promoting cafeteria source reduction by replacing disposable trays with recycled content plastic trays, which saved $4,000 per week, and promoting use of china and silverware over disposables through a coordinated publicity program.

Design and "Drive" Recycled

The most recycled product in the United States is the automobile. However, the White House has challenged the automobile industry and its suppliers to develop a 2,000 pound and up to 80 mpg vehicle for the 21st century. This project is called the "Partnership for New Generation Vehicle" (PNGV). With this challenge in mind, the U.S. steel industry launched an international consortium to search for steel-based solutions utilizing high strength steel while continuing to use recycled content and assuring future recyclability.

The consortium, Ultra Light Steel Auto Body (ULSAB) is investing $20 million over four years and commissioned Porsche Engineering Services to undertake a program of developing the necessary automotive engineering. The ULSAB project developed steel for body-in-white and is now addressing outside closures (e.g., trunks and hoods), suspension systems, engine cradle, and all structural and safety relevant components. ULSAB's Advanced Vehicle Concept (AVC) project is the steel industry's contribution to the PNGV challenge. In addition to meeting all anticipates safety requirements for 2004, current leading edge concepts for powertrain, electrical systems, passive restraints, and interior comfort will be incorporated into the design, always keeping in mind that recycling and recycled content or "Design for Recycling" is a linchpin of this effort.

Greener Packaging

Norm Thompson Outfitters, Inc. (NTO), a $175 million direct marketing company based in Portland, OR, is committed to conserving resources through energy-efficiency, source reduction, recycling, and purchasing recycled content products. The company prints 90 percent of non-catalog materials on 100 percent recycled paper and is working with a paper company to obtain 10 percent postconsumer content paper for catalogs. NTO also has redesigned products to increase their recycled content and recyclability, actively uses the mail preference services to reduce unwanted and undeliverable mailings, and promotes the mail preference service to customers. It is also working to create an industry task force to define and increase demand for environmentally preferable papers and printing practices. In the mid-90s, the company built a model green building for its headquarters which has saved 35 percent annually on energy costs and energy usage. The building includes many innovative recycled content products, such as flooring made from wood recycled from boxcars. NTO also plans to expand its recycling program to allow employees to recycle batteries and plastics and to create an on-site composting facility for food scraps.

For the Challenge, NTO commits to greening the more than 2 million packages it ships annually. The company has launched an intensive review of its packaging processes with the goal of developing aesthetically appealing, cost effective, biodegradable, reusable, recyclable and/or recycled content methods. NTO is partnering with students from the University of Portland to evaluate packaging alternatives using the following criteria: cost, quality, aesthetics and adherence to The Natural Step principles of sustainability. Based on the results of this analysis, the company plans to implement changes that become the model for its industry.

New Life for Old Carpet

In the last five years, Collins & Aikman has reduced waste by 78 percent, reduced energy usage by 43 percent (while manufacturing has grown), and reduced water usage by 43 percent (through a unique recycling system). Collins & Aikman was the first to develop a closed-loop recycling process for commercial carpet backing made of 100 percent reclaimed carpet and to receive a U.S. patent for this environmental technology. This carpet is recognized by the interior design industry as the first carpet meeting the full quality, design, and performance standards of virgin material.

Collins & Aikman will commit to license its breakthrough technology to other American companies to invigorate more innovative recycling programs across the United States. Collins & Aikman also is committed to increasing consumer knowledge about recycling. It will educate its sales staff about sustainability, recycling, and environmental preferability so that they, in turn, can educate Collins & Aikman's customers.

Green Beer

Miller Brewing Company's tradition of innovation and leadership in beer freshness and its strong record on the environment spearheaded the development of a cutting-edge plastic bottle for beer. Miller formed a partnership with Continental PET Technologies (CPT) and leading plastics and plastics recycling industry organizations to design the package with recycling in mind. As part of the testing of this product, CPT participated in the APR's "Champions for Change" program, a nationally recognized program that provides guidelines for companies wishing to design PET packages that are compatible with the current recycling stream. Miller changed the bottle cap and label in order to increase its recyclability. Miller and CPT also conducted extensive laboratory testing to ensure that the plastic bottle would meet all reasonable recycling needs. Recycling tests revealed that most of the bottle's proprietary barrier material is removed during the typical PET recycling process, and that the low levels that remain have no significant impact on the process and resulting recycled product.

Miller Brewing commits that the new plastic beer bottle will be the first nationally distributed plastic carbonated beverage container of any significance to use postconsumer recycled material. In other words, this product not only will include recycled material, but also can be recycled for use in additional bottles and other PET packaging. Because two of the Miller plastic bottles are amber, and in order to jump-start the market for amber PET, CPT has agreed to implement a buy-back program through which the company offers a premium for amber PET bottles and bales. This premium is above the price of mixed-colored PET bales already received from recycling programs. The buy-back program will be in place for at least a year.

A Model Package

Seventh Generation markets the leading brand of non-toxic and environmentally friendly household products. The Company's brand name items include 100 percent recycled content paper towels, bathroom and facial tissue, napkins and paper plates manufactured without the use of chlorine bleach; cleaning and laundry products that are renewable resource-based, phosphate free, and biodegradable; natural formula baby wipes; 80 -percent recycled content plastic trash bags; full spectrum light bulbs; and The Food Freshness System, a new product that extends the shelf life of produce and fresh foods in refrigerators. The Company markets and distributes to natural food stores, supermarkets, and mail-order catalogs in the United States and Canada. Seventh Generation differentiates itself from traditional companies based on how its products, including the ingredients, manufacturing and disposal processes, impact health and the environment. Seventh Generation has won numerous awards nationally and locally for its environmental and recycling efforts and continues to be recognized for its innovation.

Seventh Generation's commitment to the National Recycling Challenge is to "green" the more than one million packages sold annually. Factors to be addressed include increasing the postconsumer recycled content of paper products and packaging, while maintaining the commitment to chlorine free bleaching, and evaluating plastic containers to either increase the amount of recycled content and/or to improve their recyclability by switching to alternative materials where higher demand exists for the recycled materials. As part of the review process, Seventh Generation will seek opportunities to reduce the total amount of packaging used, increase the amount of "re-used" packaging materials, and improve the durability of the packaging itself. Seventh Generation strives to be a model, not just in the Natural Products Industry, but rather an example that traditional companies can learn from as well.