Sustainable manufacturing : turning waste into profitable co-products

At 2009 rates of disposal, there are only 8 years of remaining landfill capacity at permitted sites in England and Wales. Industry – encouraged by financial penalties from the Government – faces the challenges of cleaner and more sustainable production whilst trying to remain competitive in the market place. This thesis presents development of several theoretical propositions: a ‘fit thinking’ design framework, the ‘All Seeing Eye of Business’ (All-SEB) and the ‘waste alchemist’ industrial role. The ALL-SEB is a model to understand the impact and potential uses of manufacturing waste. The insights provided by the All-SEB model, resulted in a general waste elimination framework developed to serve as a guiding strategy for waste elimination. The main objective of this study was to investigate a major hypothesis derived from the All-SEB: unavoidable waste could be transmuted into profitable co-products as a measure to divert waste from landfill. The ATM (analyse, transform and market) methodology was developed as a way to help companies transmute waste into ‘co-products’. A tool for idea generation (the wheel of waste) was developed to be used in the Analysis phase of the ATM methodology. Case study research was undertaken in order to test the ATM methodology and the way in which unavoidable waste could be transmuted into a profitable co-product in a real world manufacturing setting. The case study results revealed the generative mechanisms that enable waste transmutation into profitable co-products; based on these findings a refined ATM methodology for waste transmutation was proposed. The implementation of the theoretical propositions in industrial settings shed light into strategic aspects of resource efficiency: from waste prevention through ‘fit thinking’, to manufacturing process innovation all the way to a better company integration into the industrial ecosystem. Companies looking to achieve zero waste to landfill status would benefit from using the refined ATM methodology. It was found that the ATM methodology and the wheel of waste are useful to several other actors in the industrial ecosystem: waste management companies looking to transform themselves into ‘resource and energy providers’, to external consultants and to third party companies dubbed ‘waste alchemists’ that could offer waste transmutation services to manufacturers.