“Zero waste” shows up a lot in sustainability conversations, corporate reports, and marketing materials. It sounds like a clear, achievable target: send nothing to the landfill. But for manufacturers and industrial facilities generating waste streams every day, the honest answer is more complicated. True zero waste is extremely difficult to reach, and for most businesses, it isn’t really the right goal to chase in the first place.

This blog breaks down what zero waste actually means, why it’s so hard to achieve in an industrial setting, and what a realistic, effective sustainability strategy looks like instead.

What “Zero Waste” Actually Means

Zero waste doesn’t mean literally zero. Most recognized zero waste standards, including the definition used by the Zero Waste International Alliance, set the bar at diverting roughly 90% of waste away from landfills and incineration through reuse, recycling, and composting. That remaining 10% acknowledges a simple reality: some materials, in some quantities, are genuinely difficult or impossible to recycle with current markets and technology.

That distinction matters. A facility that reaches 90% diversion has accomplished something significant. A facility chasing a literal 100% figure is often chasing a number that doesn’t exist for most manufacturing waste streams.

Why True Zero Waste Is Hard to Achieve in Manufacturing

A few structural realities make full elimination of waste unrealistic for most industrial operations:

• Mixed and contaminated materials. Not every waste stream separates cleanly. Multi-material packaging, contaminated plastics, and mixed-resin scrap often have no viable recycling market, regardless of how well-intentioned the sorting process is.
• Inconsistent end markets. Recycling depends on someone downstream wanting the material. Commodity prices shift, buyers change their specifications, and a material that was recyclable last year may not have a market today.
• Cost and logistics constraints. Even when a recycling path technically exists, it isn’t always economically practical. Hauling small volumes of a niche material long distances can cost more than is being saved by keeping it out of the landfill. 

None of this means the effort isn’t worthwhile. It just means the finish line looks different than “zero” for most facilities.

A More Realistic Goal: Waste Reduction, Not Elimination

Rather than aiming for a perfect zero, most manufacturers get better, more sustainable results by focusing on continuous waste reduction and diversion. That shift in framing changes the conversation from “have we hit zero?” to “how much have we improved, and where’s the next opportunity?”

This is a more useful goal for a few reasons. It’s measurable in a way that produces value year over year, it doesn’t depend on markets you can’t control, and it lets you prioritize the changes that make the biggest financial and environmental impact first, rather than chasing every last pound of material regardless of cost.

Steps That Get You Closer to Zero Waste

Even if literal zero waste isn’t a possible target, most facilities have significant room to improve their diversion rate. Some of the highest-impact steps include:

• Start with a waste stream audit. You can’t improve what you haven’t measured. A waste audit identifies what materials your facility is generating, in what volumes, and where they’re currently ending up.
• Separate materials at the source. Mixed loads are one of the biggest reasons recyclable material ends up in a landfill. Setting up separate collection points for different resin types, paper grades, or metal streams preserves value that gets lost when everything goes into one container. Quincy Recycle pays more for separated recyclables than mixed. 
• Find markets for byproducts. Materials that look like pure waste can still have buyers. Sawdust and wood shavings get baled for animal bedding or fuel pellets. Aluminum litho plates can become sheet stock again. Off-spec baking products end up in animal feed. Identifying those markets turns a disposal cost into a revenue opportunity.
• Invest in the right equipment. Balers, compactors, and shredders can make separated materials easier to store, transport, and sell, which improves both the economics and the practicality of recycling more of those materials.
• Work with a recycling partner who tracks the details. Scrap prices swing, new regulations show up, and recycling technology keeps evolving. A partner who’s paying attention to those shifts can tell you when it’s time to switch materials, renegotiate a contract, or try a market that didn’t exist a year ago.

Measuring Progress the Right Way

Instead of measuring success against an all-or-nothing zero waste standard, it’s more useful to track diversion rate over time, the percentage of total waste that’s recycled, reused, or repurposed rather than landfilled. Watching that number move in the right direction, quarter over quarter or year over year, gives a much clearer picture of real progress than a single pass/fail grade ever could.

Not Sure Where to Start?

Quincy Recycle works with manufacturers and industrial facilities across the country to assess their current waste streams and build practical, cost-effective strategies to reduce what ends up in the landfill. Whether you’re just getting started or looking to push your diversion rate further, our team can help you identify the byproduct markets and process changes that turn waste into revenue.

Reach out today to talk through your facility’s waste stream with our team.

A baler is one of those machines that earns its keep quietly. It runs shift after shift, turning cardboard, plastic, or metal into manageable bales, and as long as it’s cycling, most facilities don’t give it much thought. But like any piece of heavy equipment, a baler gives off warning signs well before it actually breaks down. Catching these warning signs early – and integrating preventative maintenance into your routine – can keep minor issues from becoming a costly breakdown and unexpected production downtime.

Here are five signs it may be time to schedule a service call for your baler.

1. Your Bales Are Coming Out Loose or Inconsistent

A well-tuned baler produces bales that are dense, uniform, and hold together on their own. When that starts to slip, mechanical issues are usually already well underway.

Loose, uneven, or oddly shaped bales typically point to a drop in compression force, which can come from worn hydraulic seals, a failing pump, or pressure that isn’t building the way it should. It can also be a sign that the platen, wear strips, or guide shoes have worn down enough to affect how force is distributed across the chamber, or that cutter bars need adjusting. Bale wire plays a role too – using the wrong wire gauge or type, or tying inconsistently, can leave bales loose even when the baler itself is performing fine. Inconsistent bales aren’t just a cosmetic problem – they’re harder to stack, transport, and store, and buyers on the other end often price down material that isn’t holding its shape.

2. Cycle Times Are Getting Longer

If a cycle that used to take a set amount of time now consistently runs long, that’s worth paying attention to. Slower cycles, longer dwell times, or cycles that seem to hesitate partway through are classic signs of hydraulic wear.

A pump that’s lost efficiency, cylinders that are no longer sealing properly, valves that aren’t shifting cleanly, or dirty hydraulic oil and plugged oil filters can all cause this kind of slowdown. On their own, these parts are usually replaceable. Left alone, they tend to compound – slower cycles mean lower throughput, which means more operator time spent waiting on the machine instead of the machine keeping up with production.

3. You’re Hearing Noises That Weren’t There Before

Grinding, knocking, squealing, or a hydraulic whine that wasn’t part of the baler’s normal operating sound is rarely something to ignore. Balers are loud machines by nature, but operators who run the same equipment day in and day out usually notice when something sounds different.

New noises can point to a number of issues: worn bearings, a failing pump, or components rubbing where they shouldn’t be. Vibration that wasn’t there before often travels with the noise and can be a sign of misalignment or a structural issue developing in the frame. Either way, unusual sound and vibration are early warnings, and they’re almost always cheaper to address before the underlying part fails completely.

4. Jams and Downtime Are Becoming More Frequent

Horizontal balers jam occasionally – that’s normal. What’s not normal is a baler that jams often enough to become part of the daily routine. If your team is clearing jams multiple times a shift, or if the machine is going down for short stretches on a regular basis, that pattern is worth investigating rather than working around.

Frequent jams can stem from worn cutter bars, worn-out wear plates, or sensor issues, resulting in a chamber that’s no longer clearing material the way it was designed to. Regardless of the cause, repeated downtime adds up in ways that are easy to underestimate – lost production time, backed-up material waiting to be processed, and staff time spent troubleshooting instead of running the line.

5. Safety Features Aren’t Working the Way They Should

Balers are built with safety systems for a reason – interlocks, guarding, emergency stops, and gate sensors all exist to protect operators around a machine that generates enormous force. Over time, these components can wear out just like anything else, and a safety feature that’s slow to respond, intermittent, or bypassed to keep production moving is a serious red flag.

This is one area where “it still mostly works” isn’t good enough. If an interlock doesn’t engage reliably, an e-stop doesn’t cut power immediately, or a door sensor is inconsistent, that’s not a maintenance backlog item – it’s a service call that should happen right away.

Not Sure If It’s Time for Service – or a New Baler?

Most baler issues don’t show up out of nowhere – they build gradually, and the machines that stay reliable longest are usually the ones with a consistent service schedule rather than a reactive one. Routine maintenance like checking hydraulic fluid, inspecting wear components, greasing chains, and testing safety systems will catch small issues before they turn into full repairs or unplanned downtime.

If you’re noticing any of the signs above, it’s worth having a technician take a look sooner rather than later. A service call is almost always less disruptive than the breakdown it prevents.

Quincy Recycle works with manufacturers and industrial facilities to keep balers running efficiently, and we know that routine preventative maintenance is what keeps most of these warning signs from turning into unplanned downtime in the first place. When something does need attention, we can help determine whether it’s a quick fix, a maintenance gap, or a sign that it’s time to consider a new or upgraded unit. Whether you’re running a vertical or horizontal baler, our team can take a look at what you’re experiencing and help you figure out the right next step.

Reach out today to set up a conversation with our team.

Plastic waste is one of the more complicated parts of running a manufacturing facility. Unlike cardboard or clean metal scrap, plastic comes in dozens of resin types, each with different recycling requirements, different market values, and different handling considerations. What gets recycled, what gets landfilled, and what can actually generate revenue depends heavily on knowing what you have and how to manage it.

This guide is intended to give plant managers a clearer picture of how industrial plastic waste streams work, what factors affect recyclability and value, and how to build a more efficient process around the plastic scrap your facility generates.

Start by Knowing What You Have

The first step in managing a plastic waste stream effectively is identifying the resin types your facility produces. Most plastics are labeled with a resin identification code — the number inside the recycling symbol — that indicates what the material is made of. These codes run from #1 through #7, and the code matters significantly when it comes to recyclability and downstream value.

Common industrial plastics include:

• #1 PET (Polyethylene Terephthalate) — Widely recycled, strong market demand, commonly found in packaging and film applications.
• #2 HDPE (High-Density Polyethylene) — One of the most valuable and easily recycled industrial plastics. Natural (unpigmented) HDPE commands a higher price than colored material.
• #4 LDPE (Low-Density Polyethylene) — Includes shrink wrap and film. Can be recycled but requires separate handling from rigid plastics.
• #5 PP (Polypropylene) — Common in industrial containers, parts, and packaging. Recyclable with a growing secondary market.
• #6 PS (Polystyrene) — More limited recycling options depending on form and contamination level.
• Engineering-Grade Plastics and ABS — Higher-performance materials that often retain significant scrap value when kept clean and separated.

Facilities that mix resin types together often find that the resulting stream has little to no recycling value. Separation at the source is one of the highest-leverage changes a plant can make to improve both recyclability and the revenue potential of its plastic scrap.

Rigid Plastics vs. Film: Why They Need Different Processes

One of the most common waste stream problems in manufacturing facilities is rigid plastics and film ending up in the same container. These two categories look similar enough that they get combined by default, but they require completely different handling and go to different end markets.

Rigid plastics — think containers, totes, parts, and trim — can typically be baled or granulated and moved as a relatively straightforward scrap stream, provided resin types are kept consistent. Film — shrink wrap, poly bags, stretch film, and similar materials — is lighter, more prone to contamination, and needs to be kept dry and free of debris to have recycling value.

Setting up separate collection points for film and rigid material is a simple operational change that can meaningfully improve what you’re able to recover from your plastic waste stream. Film that’s mixed with rigid scrap typically ends up landfilled. Film that’s kept clean and separate often has a buyer.

Contamination is the Biggest Value Killer

In plastic recycling, contamination is the issue that derails more waste streams than anything else. A load of otherwise recyclable plastic scrap can lose most or all of its value if it contains the wrong materials, residue, or mixed resins.

Common contamination problems in industrial settings include:

• Metal fasteners, labels, or inserts left on plastic parts
• Food residue or chemical exposure in containers
• Mixed resin types in a single collection bin
• Moisture in film streams
• Painted or coated plastics mixed with uncoated material

The standard for what counts as “clean” varies by resin type and end market, but the general principle holds: the cleaner and more consistent the material, the more options you have and the better the value. Contaminated loads often get downgraded, rejected, or reclassified as waste.

Some Plastic Scrap Has Real Revenue Potential

Plant managers who treat all plastic scrap as a disposal cost are often leaving money on the table. Certain resin types — particularly clean HDPE, natural PET, and engineering-grade materials — carry meaningful market value, especially when volumes are consistent and material quality is maintained.

The factors that most affect whether scrap plastic pays you rather than costs you include:

• Volume. Higher volumes give you more leverage with buyers and make logistics more efficient.
• Resin consistency. Single-resin streams are almost always more valuable than mixed loads.
• Cleanliness. Material that requires minimal processing on the buyer’s end commands better pricing.
• Form. Baled or granulated material is typically easier to move and price than loose scrap.

Even streams that don’t generate revenue directly can reduce landfill costs significantly when handled correctly. Either way, the economics of a well-managed plastic waste stream tend to look considerably better than a poorly managed one.

Equipment That Helps

For facilities generating meaningful volumes of plastic scrap, the right equipment can make a significant difference in how efficiently the waste stream runs and what it costs to manage.

Balers

Vertical and horizontal balers compress plastic scrap into dense, uniform bales that are easier to store and transport. Baled material is also generally more attractive to buyers than loose scrap because it’s easier to weigh, handle, and process. For facilities with consistent plastic volume, a baler often pays for itself relatively quickly through reduced hauling frequency and improved material value.

Shredders and Granulators

For bulky or irregularly shaped plastic parts, shredders and granulators reduce material to a more manageable size and can make it more compatible with downstream processing. Granulated plastic is often closer to a finished feedstock form, which can increase its value to buyers who would otherwise need to do that processing themselves.

Sweed Choppers

Sweed choppers are primarily used to process plastic – the PET or PP straps used to secure pallets and shipments. Chopping this material into smaller, uniform pieces makes it far easier to collect and handle than loose or tangled strapping. Sweed choppers can also process slitter line scrap, though facilities generating significant volumes of that material more often rely on other equipment better suited to the task.

When to Bring in a Recycling Partner

Most plant managers don’t have the time or resources to stay current on plastic commodity markets, resin-specific recycling requirements, and the logistics of moving material to the right end markets. That’s where an experienced industrial recycling partner becomes genuinely useful.

A good recycling partner does more than just pick up your scrap. They help you identify which streams have value, recommend separation and handling practices that improve what you recover, connect you with appropriate end markets for difficult materials, and handle logistics so your team can stay focused on production.

It’s also worth noting that the plastics recycling market fluctuates. Commodity prices shift, end markets open and close, and what a given resin type is worth today may be different in six months. Having a partner who tracks those changes and adjusts accordingly is more sustainable than trying to manage it in-house.

Not Sure Where to Start?

Quincy Recycle works with manufacturers and industrial facilities across the country to develop custom plastic recycling solutions. Whether you’re generating a single clean resin stream or a mix of materials you’re not sure how to handle, our team can assess what you have and help you build a process that reduces costs and recovers value where possible.

We process thousands of tons of plastic recycling material every month for our manufacturing and industrial partners. Reach out today to set up a conversation with our team.