REM ANUFACTURING
THE BEST SOLUTION
FOR THE ENVIRONMENT
CLOVER TECHNOLOGIES GROUP
WHITE PAPER
Who is Clover Technologies Group?
What is Our Vision?
How Are We Committed to the Environment?
Core Values
Environmental Stewardship
At Clover, we believe that we can have a significant positive impact
on the environm...
ISO 9001:2000-Certified
ISO 9001:2000 is a family of standards and guidelines for quality in
the manufacturing and service...
What is a remanufactured cartridge?
Remanufactured cartridges are essentially reused cartridges. They
are empty cartridges...
Where does Clover remanufacture
and recycle cartridges?
All of Clover’s remanufacturing and recycling processes are con-
d...
How do remanufactured cartridges
reduce landfill waste?
Each discarded laser cartridge adds approximately 2.5 pounds of
me...
Judge goes on to explain in her article that while a well-known
OEM’s recycling efforts should be applauded, their results...
10-STEP LASER TONER
REMANUFACTURING PROCESS
1. INCOMING RAW MATERIALS INSPECTION
All materials, drums, toner, blades, PCR’...
END-OF-LIFE 6-STEP
CARTRIDGE GRINDING PROCESS
1. CARTRIDGE EVALUATION
All inbound units are designated for Remanufacturing...
Remanufactured Imaging
Supplies - the Environmentally Responsible Solution
In summary, Clover Technologies Group firmly st...
Upcoming SlideShare
Loading in …5
×

Remanufacturing the_best_solution_for_the_environment

415 views

Published on

0 Comments
0 Likes
Statistics
Notes
  • Be the first to comment

  • Be the first to like this

No Downloads
Views
Total views
415
On SlideShare
0
From Embeds
0
Number of Embeds
1
Actions
Shares
0
Downloads
6
Comments
0
Likes
0
Embeds 0
No embeds

No notes for slide

Remanufacturing the_best_solution_for_the_environment

  1. 1. REM ANUFACTURING THE BEST SOLUTION FOR THE ENVIRONMENT CLOVER TECHNOLOGIES GROUP WHITE PAPER
  2. 2. Who is Clover Technologies Group? What is Our Vision? How Are We Committed to the Environment?
  3. 3. Core Values Environmental Stewardship At Clover, we believe that we can have a significant positive impact on the environment. As an organization, we are committed to in- vesting our time, money and resources into creating innovative environmental solutions that will make the communities where we work and live a cleaner and better place. Superior Product Quality and Value Quality and value are at the center of everything we do at Clover. Each cartridge that rolls off our assembly lines represents countless hours our team has invested in designing, engineering and manu- facturing a product that we are proud to put our name on. Clover work diligently to improve product quality and value through tech- nological innovation, automation and streamlining of manufactur- ing and distribution processes. In turn, we pass these efficiencies onto our customers, through lower prices and superior quality. Relentless Customer Commitment Clover understands that our customers have many choices. Our dedicated employees uphold a “customer always comes first” phi- losophy. From the CEO on down, every movement within the or- ganization is focused on ensuring our customers an outstanding experience. We are committed to remaining flexible and responsive to our customer needs. We pledge to treat every customer the way we would like to be treated and will constantly challenge ourselves to find new and innovative ways to bring value to our partnership. Environmental Commitment Clover is committed to exceeding the expectations of our custom- ers while preventing pollution and minimizing the environmental impact of our activities. Clover’s best practices include: • Avoid landfilling with a goal of zero-landfill waste • Prioritize remanufacturing, reclaim as much reusable material as possible through recycling • End-of-life processing for all assets collected that cannot be re- manufactured • Industry’s only grinding operation focused on the reclamation of raw materials from end-of-life laser toner cartridges • Disassemble all products in North America • Exceed global industry practices for responsible materials recy- cling and final disposition of electronics products. Clover is dedicated to continual improvement in all of its environ- mental activities. This is achieved through rigorous process man- agement and employee empowerment and accountability for achieving all company goals and objectives. Internal Organizational Goals Driving Continuous Improvement: Goals are measured daily and reported on monthly. Recycling of Metals Recycling of Plastic Recycling of Wood Materials Recycling of Corrugate Electricity Consumption Landfill Waste Reduction Associate Awareness Training Water Consumption About Clover Clover Technologies Group was founded in 1996. Clover is the global leader in providing resell- ers, mass merchants and value-added specialty suppliers with total environmental solutions in- cluding the remanufacturing and recycling of consumable imaging supplies. Clover is the world’s largest collector and recycler of cell phones, inkjet and laser cartridges. Our innovative recycling programs offer our partners an additional revenue stream while ensuring clients the industry’s most advanced and environmentally responsible recycling solutions. Mission Statement To provide our customers with industry-leading environmental solutions, world-class service and the highest quality imaging products at the most competitive prices.
  4. 4. ISO 9001:2000-Certified ISO 9001:2000 is a family of standards and guidelines for quality in the manufacturing and service industries from the International Or- ganization for Standardization (ISO). ISO certification ensures that the processes that develop the product are documented and per- formed in a quality manner. ISO 14001-Certified ISO 14001 is the international specification for an environmental management system (EMS). It specifies requirements for establish- ing an environmental policy, determining environmental aspects and impacts of products/activities/services, planning environmen- tal objectives and measurable targets, implementation and opera- tion of programs to meet objectives and targets, checking and cor- rective action and management review. Cradle to Cradle Approved Cradle to Cradle Approval provides a company with a means to tan- gibly and credibly measure achievement in environmentally-intelli- gent design. It also helps customers purchase and specify products that are pursuing a broader definition of quality. This means using environmentally safe and healthy materials; designing for material reutilization, such as recycling or composting; utilizing renewable energy and promoting energy efficiency; efficiently using water and maximum water quality associated with production; and insti- tuting strategies for social responsibility. 3 Degrees Partner 3 Degrees enables businesses and individuals to fund clean energy and carbon reduction projects. They do this by originating and providing Green-e Energy Certified Renewable Energy Certificates and third-party certified Verified Emission Reductions (aka, carbon offsets) from around the world to help their partners reduce their environmental footprint. EPA Green Power Partner In buying green power, Clover receives valuable recognition from the EPA for helping protect the environment. Green power can be one of the easiest and most effective ways to reduce the environ- mental impacts associated with your organization’s conventional electricity use. By partnering with EPA, Clover also receives tech- nical support in identifying green power products that meet the internal goals of Clover and the needs and environmental goals of your organization. Sustainable Forestry Initiative (SFI) - Certified The Sustainable Forestry Initiative® (SFI) program is based on the premise that responsible environmental behavior and sound busi- ness decisions can co-exist. SFI program participants practice sus- tainable forestry on all the lands they manage. They also influence millions of additional acres through the training of loggers and for- esters in best management practices and landowner outreach pro- grams. This unique commitment to sustainable forestry recognizes that all forest landowners, not just SFI program participants, play a critical role in ensuring the long-term health and sustainability of our forests Compliance and Certifications Clover has key certifications and partnerships that demonstrate our ongoing commitment to quality and environmental responsibility. We work with these organizations on an ongoing basis to continually improve and evaluate our environmental and quality goals. By adhering to these best practices, Clover has become the industry leader in the collections and recycling of car- tridges, cell phones and small electronics.
  5. 5. What is a remanufactured cartridge? Remanufactured cartridges are essentially reused cartridges. They are empty cartridges that have been collected, inspected, cleaned and rebuilt. The process differs by manufacturer and materials used with varying results in quality and page yields. Clover’s re- manufactured cartridges are produced to stringent quality control standards, using lab-tested components to ensure consistent OEM- equivalent performance. What happens when Clover receives an empty cartridge? When Clover receives an empty cartridge, it is evaluated first for refurbishment and secondarily for material recovery through recy- cling. A remanufacturable cartridge is disassembled and as many components as possible are reused. Each and every component of an empty cartridge that is reused, instead of recycled, conserves non-renewable natural resources that are required in the process of recycling. Cartridges that are non-remanufacturable are disas- sembled, sorted into material types and recycled. Clover’s propri- etary Closed-Loop Environmental Process ensures that every com- ponent of the empty cartridges collected is either remanufactured or recycled. Where do the empty cartridges come from? Clover is the world’s largest collector of empty cartridges. Over 90% of the cores used for remanufacturing are from our internal collections programs. All of the cartridges that are collected are dis- assembled and stringently assessed. As many components as pos- sible are reused. The remaining components are sorted into mate- rial types and sent to recycling facilities. Is Remanufacturing Really The Best Solution for the Environment? As many businesses and consumers are becoming more environmentally conscious, Original Equipment Manufacturers (OEMs) of imaging supplies have begun to heavily promote their re- cycling programs while attacking remanufacturers for falsely portraying their environmental stewardship. Clover Technologies Group would like to set the record straight. Before purchasing toner and ink cartridges, consumers should have the true facts about remanufactured imaging supplies and their impact on the environment.
  6. 6. Where does Clover remanufacture and recycle cartridges? All of Clover’s remanufacturing and recycling processes are con- ducted in North America. Empty cartridges are collected at Clover’s collection facilities in Calexico, California. Cartridges are then sent to Mexicali, Mexico, where they are dismantled, refurbished and recycled. Some OEMs have claimed that the fossil fuels consumed in the transporting of empty cartridges negate the positive environmen- tal impact of remanufacturing but this simply is not the case. As Imaging Spectrum reported in their June 2008 edition, The recent award of a contract to Clover Technologies by the U.S. Postal Service (USPS) also shed a harsh light on HP’s claims. The contract al- lows Clover to recover the empties dropped at USPS offices and Clover pays for the costs of recovery. This refutes HP’s claims that OEM recov- ery efforts are superior and demonstrates that US remanufacturers are searching for ways to recover empties locally and efficiently.2 Despite many manufacturers moving production overseas, Clover remains committed to manufacturing and recycling in North Amer- ica. This stance enables us to conserve fossil fuels with a shorter supply chain, closely monitor product quality and continually fine tune our remanufacturing and recycling processes. How many cartridges does Clover collect? Clover collects approximately 2.5 million units per month. Of those 2.5 million units, 600,000 are laser cartridges and 1.9 million are inkjet cartridges. It is estimated that each empty laser cartridge contributes about 2.5 pounds in landfill waste1 and Clover estimates that each inkjet cartridge contributes about 1 ounce. That means that each month, Clover prevents about 1.6 million pounds of plastic and metal from being dumped in landfills. 100% of the cartridges Clover collects are evaluated for refurbishment. If a cartridge cannot be reused because of damage or a defect, it is recycled internally or sold to other remanufacturers. How does Clover work towards environmentally sustainability? Clover is committed to providing our customers with environmen- tally sustainable solutions. Our remanufactured imaging supplies achieve this objective through reuse, “green” packaging and re- sponsible, efficient manufacturing. Reuse of empty cartridges – By reusing empty cartridges and com- ponents, Clover reduces landfilling and conserves non-renewable natural resources. Environmentally-friendly packaging – All the components in our re- manufactured products are environmentally friendly, from the cor- rugated box and cardboard box inserts to the installation sheets, which are printed on recycled paper. All our packaging is SFI-certi- fied by the Sustainable Forestry Initiative. Efficient production – Clover’s manufacturing facilities are both ISO 9001:2000 and ISO 14001-certified. Clover follows rigid quality and environmental standards to ensure efficiency, conservation of natural resources and environmental responsibility. Additionally, Clover has established goals within the organization to drive continuous improvement upon our environmental sustain- ability objectives. Cartridges are dropped off at recycling location Carriers deliver cartridges to collection center Cartridges evaluated for remanufacturing or end-of-life process Cartridges sorted and placed in inventory Cartridges sent for remanufacturing Cartridges 100% post tested for quality control Cartridges sorted and placed in inventory ISO 9001:2000 certified remanufacturing process Cartridges ready for re-use Cartridges sent to end of life processing Cartridges sorted by material type Cartridges disassembled to component level Components recycled Raw material ready for re-use End-of-Life Workflow Remanufacturing Workflow
  7. 7. How do remanufactured cartridges reduce landfill waste? Each discarded laser cartridge adds approximately 2.5 pounds of metal and plastic waste to our landfills - waste that will take as long as 1,000 years to decompose3 . It is estimated that 100 million laser printer cartridges and 400 million inkjet printer cartridges are pro- duced each year. Remanufacturing these 500 million cartridges will save an estimated four million cubic feet of landfill space. Environmentally stewardship is one of Clover’s core values. Clover is committed to reducing landfill waste and invests significant time and resources into finding innovative ways to protect the environ- ment. Our “Zero Landfill” policy has been independently verified by McDonough Braungart Design Chemistry, LLC (MBDC)4 and serves as a guarantee to our customers that empty cartridges that are non-remanufacturable are responsibly recycled. Why is remanufacturing a superior choice to OEM recycling programs? (See Diagram 1) When a cartridge is remanufactured, it is reused. Reuse is the high- est form of environmental responsibility. It is superior to recycling in that it doesn’t use non-renewable resources to breakdown plas- tic and metal. A cartridge and all its components should always first be evaluated for refurbishment. If refurbishment is not possible then responsible recycling should be pursued. Unfortunately, many times when an empty cartridge is collected for recycling instead of remanufacturing, it does not end up where the consumer intended. In her recent article, “A Response to HP’s Argu- ment for Recycling versus Reuse” that appeared in Imaging Spec- trum Magazine, Tricia Judge, Executive Director of the International Imaging Technology Council, paints a vivid picture of where many of the world’s empty cartridges that are not remanufactured find their final resting place - Guiyu, China. Guiyu has become the world’s dumping ground for what is defined as “e-waste.” Sadly, the cartridges that end up here were originally bound for recycling. Heaps of empty cartridges line the streets and riversides after being scavenged only for their toner. Once the toner is swept out by fingers or paintbrushes, the cartridges and other printer parts are burned – fouling the air – or are discarded along the Lianjiang River. This practice of low-level recycling and then dumping has rendered lo- cal drinking water dangerous; the river contains 200 times the accept- able levels of acid and 2,400 times the acceptable levels of lead. Many residents have developed respiratory problems. A local school survey found that 100 of the 1,000 students had severe asthma or other re- spiratory problems. The residents here have to choose between utter poverty and pollution levels akin to poisoning. And the net gain for the average laborer? Roughly $1.50 per day. As Imaging Spectrum has cov- ered before, it is clear that these empties come from U.S. brokers that have been collecting large quantities of “virgin,” or once-used OEM products. Such cartridges are the lifeblood of the cartridge remanu- facturer, but have been diverted to this Chinese cartridge graveyard for the simple reason that they needed to be removed from the US market- place for competitive reasons5 . Diagram 1
  8. 8. Judge goes on to explain in her article that while a well-known OEM’s recycling efforts should be applauded, their results don’t come close to matching the impact remanufacturers are having on reducing landfilling, “The recycling of 140 million cartridges over 15 years pales in comparison to the reuse of 105 million cartridges in 2006 alone. That equates to 84,000 tons of industrial-grade plastic being reused annually, not just recycled, thanks to remanufactur- ing.” Just as important as the reduction in landfill waste is the reduction in the consumption of ecologically-damaging fossil fuels. The plas- tic in each new laser toner cartridge takes three and a half quarts of oil to produce while each new inkjet cartridge requires two and a half ounces of oil6 . Best Foot Forward was recently commissioned by the Centre for Remanufacturing and Reuse7 to study the carbon footprint of a re- manufactured mono toner printer versus a new cartridge. Table 1 illustrates their findings. The results of this study make it clear that the large number of reused components in the remanufacturing process significantly reduces the carbon impact. In several reports, the U.S. Dept. of Energy Office of Industrial Tech- nologies has stated that although the recycling of toner cartridges does have a number of benefits, remanufacturing is a superior choice, both environmentally and economically and that govern- ment agencies should purchase remanufactured product when available8 . In addition, the Environmental Protection Agency’s Re- covered Materials Advisory Notice (RMAN) recommends that pro- curing agencies establish procedures and policies that give priority to remanufacturing the agencies’ expended toner cartridges. The EPA recommends that under such policies and procedures, agen- cies procure remanufacturing services for expended cartridges and when such services are unavailable or not practicable, obtain re- manufactured toner cartridges or new toner cartridges made with recovered materials from product vendors9 . Do remanufactured cartridges perform as well as OEM products? All of Clover’s products are designed to meet or exceed OEM per- formance and are backed with a 100% satisfaction guarantee. Clo- ver has invested significant resources into developing state-of-the art manufacturing and collection facilities to ensure optimal refur- bishment of each empty cartridge collected. Every empty cartridge that is received goes through a rigorous, proprietary process that is overseen by quality control specialists so that by the time it reaches the customer’s hands it performs like new. Table 1: Carbon Footprint Analysis - Remanufactured vs. OEM Life Cycle Stage Emissions per new cartridge (gCO2) Emissions during remanufacturing (gCO2) Components (inc. End of Life) 2136 223 Components Packaging 286 65 Cartridge Packaging 980 380 Components Shipping 203 19 Distribution 33 451 Energy Use 761 663 Total 4,399 1,802
  9. 9. 10-STEP LASER TONER REMANUFACTURING PROCESS 1. INCOMING RAW MATERIALS INSPECTION All materials, drums, toner, blades, PCR’s, magnetic rollers, etc... are verified against our stringent stan- dards before they reach the production floor. 2. SORT & GRADE All empty cartridges are sorted and graded. Only premium empty cartridges are used in our products. This assures optimum quality of the finished product. 3. RECYCLE All used packaging materials, used hopper, and non-conforming components are disassembled and recycled to help protect our environment. 4. SPLIT & CLEAN Premium empty cartridges are carefully disassembled and cleaned with our unique state-of-the-art process. Through automation we can precisely split the toner hopper with custom splitting equipment and prepare them for the sealing phase. 5. DIGITAL AUTO FILLING State-of-the-art automated filling equipment is used to ensure precise fill weights for each cartridge. Toner hoppers are filled with premium toners, which are technically matched to the OPC’s (drum) for optimum yields and printer performance. 6. SEALING Each toner hopper is sealed with an OEM style seal. Our quality sealing process ensures a leak-proof cartridge and ease of installation for the consumer. 7. ASSEMBLY Our factory-trained technicians assemble all cartridges with OEM grade compatible components (up to 75% new components are used in each cartridge.) The assembly process includes installation of pre- qualified drum, wiper blade, doctor blade, PCR and magnetic roller. 8. 100% POST TESTING Each and every cartridge is post tested utilizing industry standard print tests to ensure outstanding performance and quality. 9. PACKAGING All cartridges receive a final inspection to assure they conform with our quality standards. Cartridges are cleaned, polished, heat-sealed in a static resistant bag then boxed. A full set of instructions and warranty information is included. 10. QUALITY CONTROL Each step in our manufacturing process is monitored by dedicated Quality Control experts. Each step in our production process undergoes regular and spot inspections to ensure our products will meet the expectations of the consumer. 1 3 6 9 2 5 8 4 7 10
  10. 10. END-OF-LIFE 6-STEP CARTRIDGE GRINDING PROCESS 1. CARTRIDGE EVALUATION All inbound units are designated for Remanufacturing or End-of-Life grinding process. 2. CARTRIDGES SORTED Units assigned to End-of-Life grinders are disassembled. 3. CARTRIDGES DISASSEMBLED Components are sorted for recycling, plastic, blades, gears & PCR drums. 4. GRINDING Cartridge plastic is inducted into the grinder to produce plastic regrind. 5. PLASTIC READY FOR REUSE Plastic regrind is reused in various injection molding processes. 6. NEW PRODUCT DEVELOPMENT New product is created utilizing post consumer waste which completes closed loop solution. 1 3 6 2 5 4 2.5 million cartridges processed a month
  11. 11. Remanufactured Imaging Supplies - the Environmentally Responsible Solution In summary, Clover Technologies Group firmly stands behind its position that remanufactured imaging supplies are the most environmentally sustainable and responsible choice. The research clearly indicates that remanufacturing significantly reduces landfill waste and lessens non-re- newable energy consumption that is inherent to the recycling process. Experts in the field agree that refurbishment first, material recovery through recycling second is the optimal solution for environmental sustainability10 . Recycling is the best alternative only after refurbishment or re- use - making remanufactured imaging supplies the conclusive choice for ecologically-minded businesses and consumers. 1 The Recycler, April, 24, 2007. http://www.therecycler.com/viewarticle.asp?article=1255 2 Judge, Tricia, “A Response to HP’s Argument for Recycling versus Reuse,” Image Spectrum Magazine, June 2008. 3 International Imaging Technology Council, http://www.consumerchoice.info/faq.htm, October 2008. 4 From a 2008 independent study performed by McDonough Braungart Design Chemistry, LLC and commissioned by the United States Postal Service, auditing the USPS Mail Back Program. 5 Judge, Tricia, “A Response to HP’s Argument for Recycling versus Reuse,” Image Spectrum Magazine, June 2008. 6 Recharger Magazine. 7 From a 2008 independent study performed by Best Foot Forward and commissioned by Centre for Remanufacturing and Reuse. 8 “Greening the Government,” U.S. Dept. of Energy Office of Industrial Technologies http://www1.eere.energy.gov/femp/pdfs/greengov.pdf 9 Environmental Protection Agency, http://www.epa.gov/epawaste/conserve/tools/cpg/index.htm, October 2008. 10 From a 2008 independent study performed by McDonough Braungart Design Chemistry, LLC and commissioned by the United States Postal Service, auditing the USPS Mail Back Program. © Clover Technologies Group 09009A

×