GREEN INGENUITY
Setting the standard for
environmentally-friendly solutions
With a global focus on the environment, sustainability, and renewable energy, Plastic Ingenuity is once again setting the standard in the thermoforming industry. Our green initiatives include unique ideas and technological advancements that result in environmentally-friendly packaging, all while operating our manufacturing facilities in efficient and responsible manners.
Our guiding vision today is no different than when Joe Kuehn founded PI in 1972: "We will be ever mindful of our natural environment."
This isn't an empty promise; it's our focus. These nine words are embedded in our mission statement, and the pursuit of environmentally-friendly practices has been our priority for 36 years.
GREEN TIER
As a participant in the Wisconsin Department of Natural Resources' Green Tier program, we've made a binding commitment to superior environmental performance, as well as to meld our business and environmental goals. Our corporate headquarters are located next to Black Earth Creek—a Class I trout stream—so we are ever mindful of its waters. Runoff filters and grassed swales remove pollutants from the site's storm water, and rain gardens and a rock weeper dam reduce the temperature of the storm water before it enters the stream. We've also instituted a stringent pellet loss program to prevent spills of our raw materials, while at the same time reusing or selling 99% of our scrap plastic. This is only the beginning. We continue daily to build on our environmental achievements through our Environmental Management System.
PHOTOVOLTAIC
Continually pushing our ability to find sources of renewable energy, we currently produce some of our energy from the 50, 200-watt photovoltaic solar panels on our headquarter's rooftop. Producing this same amount of energy from non-renewable sources would dump nearly 30,000 pounds of carbon dioxide into the atmosphere. In addition, we've replaced all of our HD and T12 lighting fixtures with T8 fixtures, reducing our lighting system's power consumption by 66%. Again, these are only first steps—we've set a goal to produce 10% of our energy from renewable sources within the next five years.
PLA MATERIAL: INNOVATION IN PRACTICE
Our proprietary processes significantly increase heat deflection temperature in corn-based PLA (Polylactic Acid) material. This advancement includes a material enhancement along with unique processing techniques. With these techniques we've formed PLA parts that have heat deflection temperatures higher than PET, and comparable to HIPS. And with the enhanced PLA, the material remains biodegradable and compostable per EN13432 (ASTM D6400) industry standards. We've also sampled over 200 new and different bio-materials/bio-material combinations. It's our commitment to find multiple bio-based materials that meet the requirements of a multitude of packages—this whether their vital characteristics are clarity, impact strength, or heat deflection resistance.
PULP THERMOFORMING
We currently use wood pulp in a multitude of our thermoforming applications. The process of converting paper or corrugated feedstock into a sustainable packaging material results in strong, well-defined, and smooth-surfaced parts. This is important because pulp is a viable alternative to petroleum-based packaging. Pulp thermoforming maintains part integrity, all while incorporating 100% recycled materials into the process. The feedstock derives from a variety of sources including newspaper, cardboard, and office paper scrap. We've also utilized our expertise in process ingenuity to design and build a specialized pulp thermoformer. This technology produces a premium pulp fiber part with a double sided smooth finish, while giving our customers a viable green alternative.
SMART THERMOFORMING
In thermoforming, air compressors and vacuum pumps are utilized for process air. These units produce a great deal of heat, which is a valuable commodity. We've implemented a system that captures this heat and re-circulates it throughout our warehouse, in turn reducing natural gas usage. Another waste-reduction measure comes in the form of material regrind. This process is a popular, cost-saving method for incorporating environmentally sound practices into rigid package manufacturing. All of our plastic scraps are recycled and saved from the landfill, and then make their way into new materials.
