The FUJIFILM Speciality Ink Systems multi award-winning factory in Broadstairs, UK, manufactures high performance inks for a range of markets, including Uvijet UV inkjet inks for wide format applications, alongside a range of screen and flexo inks. For more than a decade, we, the team on-site, have steadily implemented new systems, technologies and processes to monitor and measure our progress, as Fujifilm takes steps to reduce its environmental impact.
Our latest achievement at the Broadstairs site is Zero to Landfill certification from environmental compliance and recycling solutions provider, Valpak. The milestone confirms that the site is sending zero packaging, production or hazardous waste to landfill, while highlighting our commitment to continuously improving our waste management through reducing, recycling and reusing resources.
Zero Waste to Landfill: what is it?
Zero Waste to Landfill is a process in which all waste materials and products generated by an organisation are diverted away from landfill to treatment processes further up the waste hierarchy.
According to DEFRA, the UK’s department for the Environment, Food and Rural Affairs, this hierarchy begins with Prevention: using fewer materials to begin with. It then moves to Preparing for re-use: checking, cleaning, repairing, refurbishing, whole items or spare parts. Then comes Recycling: turning waste into a new substance or product. This can include composting, provided it meets quality protocols. Next comes Other Recovery: this can include: anaerobic digestion, incineration (with energy recovery), gasification, and pyrolysis, all of which can produce energy (fuel, heat and power), as well as other materials, from waste. Finally, at the bottom of the inverted pyramid, sits
Disposal to landfill (without energy recovery).
In July 2002 the Zero Waste Charter was launched at the House of Commons, and in the years since, it has received wide national and international backing. The initiative requires companies to aim for massive reductions in their landfill usage, with at least 99% of waste being diverted from landfill. The achievement is formally recognised with Zero Waste to Landfill certification, awarded by accredited organisations such as Valpak.
Certification requirements
Fujifilm achieved Zero Waste to Landfill certification from Valpak by following a highly structured protocol. First, we conducted our own waste audit to evaluate our waste management practices and assess the amount of waste our site produced to establish a baseline. We then developed a waste management plan, which included strategies for waste prevention, where possible, as well as reduction, reuse, recycling and redirection. Next, was the ‘implement and monitor’ stage, which involved continuously monitoring waste streams and diversion rates. Valpak provided guidance as we carried out these procedures, and also conducted an extensive audit.
Audit process
The audit applied to all Fujifilm Broadstairs’ site departments and product areas, including: packaging & engineering; R&D; raw material storage; production; quality control; screen making products; solvent blending; UV screen ink; narrow web production & packaging; digital manufacturing; digital packaging, as well as solvent-based, water-based and plastisol screen inks. The audit also included scrutiny of our International logistics centre for finished products and our customer demonstration area.
During the audit, we demonstrated how we measure and monitor our waste using a range of key performance indicators:
- Waste in each department is properly and responsibly disposed of in the correct bins
- Hazardous waste containers are sealed, once full, and removed by the onsite waste management team
- Balers are used for plastic polythene and cardboard
- The canteen has separate bins for metal cans, coffee cups, food and general waste
- Food waste is composted (the weight of food waste is also recorded and has been since October 2023)
- Raw materials and packaging are recycled or reused
- There are mixed recycling bins in place across the site
- Importantly, we record our waste data via an online system to measure and improve our practices.
We proved (from 1 April 2023 to 31 March 2024) that in addition to sending zero waste to landfill, we achieved a recycling rate of 53.64%. In addition to increasing the amount of waste being recycled, we also reduced the overall waste being produced.
Upon certification, we committed to lead by example through the continued monitoring and improvement of our waste management practices.
A team effort
Obtaining Zero Waste to Landfill certification was a team effort and each department played a crucial role in the process. From segregating waste at the source to implementing efficient recycling measures, demonstrating that such a significant environmental achievement was made possible through our unified and sustained effort. By fostering a culture of knowledge and innovation, our team felt empowered enough to contribute to Fujifilm’s waste reduction efforts and best practices.
In particular, Paul Dannahy, Goods Team Leader at the Broadstairs site played a key role in identifying waste processing companies which allowed us to move waste from incineration to recycling centres, and in other areas, generate value from the waste. For example, pallets were broken down into pellets for fuel. The pellets were then sent away from the site, sold and reused in other applications). Since we received Zero to Landfill certification, Dannahy continues to oversee the process, ensuring each Zero to Landfill process remains on-track.
We also have a staff suggestion scheme; waste contractor site inspections; daily and weekly managers’ meetings; and bi-annual sustainability meetings with our department heads, to facilitate proactivity and ideas to improve our management practices.
Looking forward
But it doesn’t end here! We’re continuously looking at new ways that we can lower our levels of waste at the Broadstairs site still further. For example, one project we’ve recently trialled involved us reducing the amount of waste phenoxide phylactery (PEA) solution that’s produced when flushing out our systems. We did this by reusing it for a second flush, rather than disposing of it after each use. The testing process was a success and the second flush procedure is expected to halve the amount of waste PEA solution that gets disposed.
Other future plans include: further expanding our renewable energy capabilities with more solar panels, adding to the 1400 MWh of annual solar power generation that already exists on site; working with OEMs to ensure that their packaging is recyclable; improving signs across the site to promote our environmentally conscious efforts; and reusing or replacing one litre and five litre single-use bottles on the site.
Click here to read more about Fujifilm sustainability initiatives and their key objectives as they focus on a greener future.
