Efficient operations, new blending systems and a dedicated focus on the environment allowed DaVinci Roofscapes to recycle 820,000 pounds of composite roofing scrap in 2017. The excess shake and slate composite roofing tiles were crushed, then ground down and used to create starter tiles for the roofing company.
“The big story this past year is that our company molded 30 percent more pounds of composite roofing tiles than in 2016 while simultaneously reducing our scrap by 242,000 pounds over the past year,” says Bryan Ward, vice president of operations at DaVinci Roofscapes in Lenexa, Kan. “This is a terrific achievement when considering Earth Day and our companies’ dedicated commitment to the environment.
“We were able to advance production while reducing composite roofing scrap by enhancing our recycling efforts. Searching for ways to reduce waste is a full-time dedicated endeavor at our company.”
Zero Scrap Outsourced
Thanks in part to an investment in a new blending system, which makes manufacturing operations more efficient, the team at DaVinci Roofscapes sold zero scrap to outside firms in 2017.
“It’s very significant that we were able to recycle and reuse 100 percent of all scrap items at our facility last year,” says Ward. “In 2016 we transferred 567,000 pounds of scrap to an outside end-user who makes pallets, crates and totes.
“That’s a great use for the composite roofing product because it doesn’t end up in landfills. However, in 2017 our company was able to keep every pound of scrap in-house and reuse it for our own products. That’s a significant achievement.”
Where Does Scrap Come From?
DaVinci Roofscapes continues to meet their goal of zero scrap going into landfills. The industry’s leading composite shake and slate manufacturer produces polymer slate and shake roofing tiles in 49 standard colors, plus custom colors.
Each time the manufacturing operation changes color runs, there is a transitioning between colors. Those transition tiles are “off spec,” cannot be used and are recycled. The tiles — which are 100 percent recyclable — are segregated by color and then ground up and molded into starter shingles, which are generally unseen on the roof.
“Every year we take stock on Earth Day to evaluate the progress of our recycling operations and share the good news about our enhanced efforts,” says Ward. “Our manufacturing operation continues to become more efficient each year.
“The fact that we increased manufacturing production of roofing tiles in 2017 while substantially decreasing the amount of composite roofing scrap generated is a huge accomplishment. We’re on a path toward continually making our operations more efficient, which is great for the environment.”