Shredder
Eupen, Belgium
AstenJohnson Eupen installed and commissioned a brand-new shredder in April 2024.
The machine performs well by shredding Eupen waste clothing material into very small pieces. Cutting production waste in small pieces is an essential condition for recycling. AJ Eupen is actually in contact with several potential partners.
This represents a big step toward better recycling.
Roll Stretch Wrappers
Hampton, New Hampshire
Reducing waste going to landfills start by producing less waste in every step of the production, including packaging.
In late 2023, AstenJohnson Nonwovens Hampton installed two roll stretch wrappers.
The reduction in plastic used for the packaging is around 200 to 300% in density. This machine also allows for CO2 emissions reduction.
As a graphic designer, I try to show that design and sustainability can coexist in harmony. I prefer sustainable options for our merchandising, showcase our sustainable efforts through social media, and practice sustainable behavior in the office. I believe every action matters.
It's a challenge I take up with passion every day. I firmly believe that we can also contribute to a better future through our professional actions.
Gene Simon Corporate Visual Identity manager, Eupen
Shredder & Pelletizer
Hampton, New Hampshire
AJ Nonwovens Hampton is proud to announce the successful installation and implementation of its new recycling equipment in 2023. The pelletizer and shredder represent a huge step forward in the sustainable future of the company.
The new machines will allow AJ Nonwovens Hampton to recycle all its PET waste directly on site. After being thoroughly separated from other materials, PET waste is first cut into very small pieces through the shredder. The shredded material is then lead through conveyor belts to the pelletizer. Once created, those pellets are raw material for Hampton to use in their Fiber lines. The Fiber created is then used in the Fabric lines to create the final product for customers.
AJ Nonwovens Hampton is not the only site that will benefit from this equipment. Thanks to its capacity, PET waste from several North American AJ PMC sites will be collected and recycled too. About 4 million pounds will be saved inside the company.
Success Story
Eupen, Belgium
The Eupen sales team arranged a pickup of about 90 steel tubes with a local customer. This represents another step in developing our sustainable efforts and prioritize reuse when possible.
Bottle Flake — AJ Nonwovens
HAMPTON, NEW HAMPSHIRE
As a manufacturer of PET fiber, a larger portion of the PET resin used by AJ Nonwovens to make the fiber comes from recycled beverage bottles. Since 2016, AJ Nonwovens has consumed 190 million pounds of resin from bottles.
The 190 million pounds is broken down as follows:
- Clear Flake – 85MM lbs
- Green Flake – 65MM lbs
- PCR Pellet – 40MM lbs
A soda bottle weighs 23 grams and a lightweight water bottle weighs 8.8 grams. If we assume it is broken up 50/50, and we convert it to pounds, the average weight of a bottle is 0.035 lbs/bottle. This means that AJ Nonwovens has used 5.43 billion bottles since 2016 which otherwise might have gone into a landfill.
Learn More About the Process
Success Story
Eupen, Belgium
Late 2023, AstenJohnson Eupen enhanced their efforts in waste recycling, focusing on the proper collection of PMD waste (Plastic packaging, Metal packaging, Drinks cartons).
Since the implementation of the new rules, the proportion of waste correctly separated and recycled significantly increased in just a few months.
We are proud to see the associates’ response to better waste collection!
Pelletizing the Plastic
Suzhou, China
In an effort to build a circular economy, a key sustainability value, we collaborate with partners to create circular opportunities. An example is our waste scrap recycling in our Asian sites. We work with a local partner that takes our scrap waste and gives it new life by turning it into new items.
How does this work?
The Process:
Side trim from weaving and residual weaving monofilament is delivered to the chipping station at the recycling partner.
The recycling partner feeds the pelletizer and produces the chips. The chips are loaded into super sacks.
End use is for garbage cans, buckets, storage bins, and other non-food applications.
Success Story
Valleyfield, Quebec
While some customers are reusing fabric for gardening to prevent weeds, others are using press felt for carpet at their campground site. The "Wooden box garden" is another nice example. In Valleyfield, the packaging boxes are reused by a customer to create a garden. AstenJohnson associates also reuse the boxes for projects at home.
Green Belt Project
Suzhou, China
The LEAN Sigma program is an excellent complement to Sustainability Goals. Associates working toward Green Belt status develop projects focused on continual improvements that will remove waste and inefficiencies, and improve working conditions. In addition, these projects address issues that are important to AstenJohnson.
One of the projects we’ve developed is the garbage classification project. Garbage is identified as 4 main categories:
- Food waste
- Recyclable waste
- Harmful waste
- Others
I am actively engaged in the garbage classification project, because environment protection is obviously benefitting ourselves, our children and our next generations. Practicing 'NO WASTE' in work and life, and influencing my associates as much as possible are important matters. The more we save, the more we contribute to those who are potentially in need.
Helen Zhao HR Manager, Suzhou
Electronics Recycling
Charleston, SC
Associates at AstenJohnson Charleston participated in an electronics recycling drive late in 2022. Associates brought in old devices and small household appliances to recycle. This first event kept over 100 pounds of waste out of the landfill. Associates are already making plans for the next drive and intend to make it an annual occurrence.
Eupen, Belgium
In 2021, AstenJohnson Eupen recycled 14 smartphones in collaboration with a recycling partner. 6 devices were put back into circulation in Europe and 8 others were used for spare parts to recycle and repair other phones. In addition to the direct reuse of the smartphones, this collect generated some money that contributed to donate reconditioned appliances to BXL refugees.
Writing Tools Recycling
Strakonice, Czech Republic
Eupen, Belgium
AstenJohnson Strakonice and AstenJohnson Eupen implemented a system to recycle empty, written-out markers, highlighters, pens, rollerball pens and pencils. They are collected in recycling boxes located at several locations in our plant. The capacity of the box is 170 markers, but pens and narrower markers can hold up to 300.
The plastic parts obtained by dismantling the discarded pens are then shredded and the resulting material is used in the production of new markers.
Eupen, Belgium
AstenJohnson Strakonice and AstenJohnson Eupen implemented a system to recycle empty, written-out markers, highlighters, pens, rollerball pens and pencils. They are collected in recycling boxes located at several locations in our plant. The capacity of the box is 170 markers, but pens and narrower markers can hold up to 300.
The plastic parts obtained by dismantling the discarded pens are then shredded and the resulting material is used in the production of new markers.
