Managing waste

Waste is a significant issue, in general, in the manufacturing sector, both because of its growing cost implications and environmental impact. Waste is considered as part of our ISO 14001 management system and we are continually looking for new ways to reduce the generation of waste and, where it is generated, to reuse and recycle wherever possible. We currently recycle steel, paper, cardboard, wood and plastic at all Kingspan manufacturing sites.

In respect of the main manufacturing sites in the UK and Ireland for Insulated Panels and Insulation Boards, 45% of the total waste produced was recycled in 2008, and the target for 2009 is for a landfill reduction of 20%.

Certain facilities in the Group now offer a full pallet return service and we have also launched trials on recycling all Kingspan Insulated Panels packaging from construction sites. In the case of Insulation Boards, off-cuts from waste are used in substitution for pallets. We also re-cycle approximately four tonnes of chemicals per month back into the manufacturing process, which would otherwise have been incinerated.

Kingspan is a major user of steel in the manufacture of insulated panels, structural sections and light weight framing across Europe, Asia, North America and Australia, and 23% of the steel Kingspan uses is from a recycled source. In addition, steel has an inherent environmental advantage over competing products in the construction industry, such as cement, in that it is extremely durable, adaptable, reusable and recyclable. The inherent environmental advantage of steel is enhanced by Kingspan in its manufacture of insulated panels in two ways: (i) the structural value of the steel is enhanced by the factory applied insulation core so less steel is used compared to so called built-up systems using site applied mineral fibre insulation, and (ii) because the insulation core used by Kingspan in an insulated panel is about 50% thinner and lighter than the equivalent insulation in mineral fibre, less steel or concrete is required in the building structure. Likewise, Kingspan’s thinner higher performing Insulation Boards also result in less concrete and steel being used in the built-up environment.

Apart from steel, the other main raw materials used in Kingspan are polyols, in the Insulated Panels and Insulation Boards divisions, and timber, in the Off-site division. All polyols used are made from recycled industrial waste stream. The timber used in the Off-site division is all sourced from sustainably managed forests.

The Kingspan Insulated Panels division has long been at the forefront of work to provide end-of-life solutions for composite panel systems, and now with the addition of a shredder plant at the Kingscourt manufacturing facility in Ireland, a 100% on the spot recycling for their site waste is provided. This is the start of a process which will potentially allow for a totally closed loop process for Kingspan’s high performing products once they have reached the end of their useful life. The shredder plant was built as an extension to the existing line at Kingscourt. The system operates very similarly to a conventional shredder plant, although on a smaller scale. The insulated panels are shredded with the steel being recycled as per usual and the insulation material is directed back to the production process and re-entered into the virgin product. This is a huge step for Kingspan Insulated Panels in achieving its goal of zero waste to landfill at all its manufacturing plants and its ultimate target of having a 100% recyclable product. The same process is to be introduced at Kingspan’s sites at Holywell in North Wales and Sherburn in Yorkshire, with the aim of being operational in 2009/10. This model of recycling will then be rolled out to other plants in Central Europe and North America.

In the manufacture of Insulation Boards, not all waste can be managed away completely, but Kingspan seeks as far as possible to re-use its own waste. In 2008, approximately 25% of production waste was recycled in this way, saving costs by replacing virgin materials and reducing what might otherwise end up in landfill. Where foam waste cannot be recycled in this way, it is turned into briquettes which are sold on to a specialist company who use the material in the manufacture of a building board.

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