Case Studies

Across industries, manufacturers that rely on fiber-based materials with specialized coatings and adhesives face significant recycling challenges. These materials often contain multiple components that make them incompatible with standard recycling methods, leaving companies searching for innovative ways to reduce waste and minimize landfill dependency.

Zebra Technologies is committed to advancing sustainability through waste reduction, energy efficiency, and circular economy initiatives. Their approach includes improving material recovery, reducing landfill waste, and integrating responsible manufacturing practices across their operations.

One facility where these efforts are taking shape is Flowery Branch, a key production hub for Zebra’s labeling solutions. While labels play a critical role in enabling asset visibility across industries, the manufacturing process generates label trimmings—a byproduct that, like many complex materials, has historically been difficult to recycle. To align with their commitment to waste reduction and circular economy principles, Zebra sought a scalable waste management strategy that would minimize landfill impact while supporting their sustainability initiatives.

To achieve this, Zebra turned to us at iSustain to develop a program that would repurpose label trimmings into a valuable resource instead of sending them to landfills.

Many manufacturing processes generate byproducts that cannot be processed through conventional recycling methods due to their unique material composition. Label trimmings, in particular, often consist of fiber, plastics, adhesives, and coatings, which complicate recycling and contribute to landfill waste.

Recognizing an opportunity to take a more sustainable approach, Zebra sought a long-term, scalable solution that would:

• Reduce landfill dependency by finding an effective and responsible use for label trimmings waste.

• Support circular economy efforts by repurposing manufacturing byproducts into reusable resources.

• Advance sustainability commitments by aligning with best practices for waste reduction and renewable energy initiatives.

After evaluating the waste stream at Flowery Branch, we developed a waste-to-fuel strategy that successfully diverted label waste from landfills. The process involved converting the material into Alternative Engineered Fuel (AEF), a clean-burning energy source that is used to power turbines and industrial heating applications, directly replacing coal and natural gas.

What is AEF?

AEF is an engineered fuel pellet created by compressing non-recyclable materials into a high-energy alternative fuel. These pellets provide energy output comparable to fossil fuels and are widely used in industrial energy systems. Unlike incineration, AEF production displaces virgin resource consumption while helping manufacturers advance their waste reduction goals.

With this approach, materials that were previously landfill-bound are now contributing to renewable energy generation.

How We Made It Happen

Through close collaboration with Zebra, we developed a landfill diversion program that integrated seamlessly into Flowery Branch’s existing operations.

1. Optimizing Infrastructure for Waste Collection

   • We upgraded the facility’s pneumatic collection system with advanced screening and filtration technology, allowing label waste to be efficiently collected and prepared for fuel conversion.

2. Enhancing Operational Efficiency with Compaction Technology

   • A horizontal baler was installed to compress waste into dense, transport-ready bales, reducing handling costs and maximizing efficiency for fuel conversion.

3. Repurposing Waste as a Renewable Energy Source

   • The baled material is then delivered to iSustain’s renewable energy partners, where it is processed into AEF fuel pellets used for industrial heating and power generation, reducing the demand for fossil fuel consumption.

Through this waste-to-energy model, Zebra successfully repurposes manufacturing byproducts while actively supporting clean energy initiatives.

While the program’s full impact will be realized in 2025, early results highlight measurable progress in waste reduction and energy recovery.

• Landfill Diversion Success

  • The Flowery Branch facility is now diverting 95% of label waste that would have previously been landfilled.

• Supporting Renewable Energy

  • The AEF produced from diverted materials is helping generate clean energy, reducing reliance on virgin fossil fuels.

• Advancing Corporate Sustainability Initiatives

  • This program supports Zebra’s long-term commitment to waste reduction and circular economy initiatives.

The success of the Flowery Branch project demonstrates how manufacturers can transform complex waste streams into valuable resources. With this initiative, Zebra has:

• Significantly reduced landfill dependency with an innovative material recovery strategy.

• Contributed to renewable energy production by offsetting the use of virgin fossil fuels.

• Developed a scalable model that can be expanded across other facilities.

By working with iSustain, Zebra has successfully implemented a landfill diversion strategy that enhances sustainability while maintaining operational efficiency.