They Send Nothing to Landfills—Here’s How These U.S. Companies Pulled It Off

Many U.S. companies are embracing zero waste to landfill initiatives to eliminate landfill trash from their operations. This means aggressively diverting waste through recycling, reuse, composting, or energy recovery so that little or nothing ends up in a dump. Typically, achieving “landfill-free” status requires diverting over 90% of waste from landfills. The benefits are twofold: significant environmental impact (reducing pollution and greenhouse gases from landfills) and operational savings or new revenue from repurposed materials.

The examples below highlight how three companies from different industries – automotive manufacturing, consumer goods, and brewing – have implemented landfill-free operations, detailing their approaches, technologies, and results. These case studies show that with commitment and innovation, zero-waste goals are both attainable and profitable, offering inspiration for others to follow.

Subaru: Pioneering Zero-Landfill Automotive Manufacturing

Subaru of Indiana Automotive (SIA) became the first automotive assembly plant in the U.S. to achieve zero-landfill status back in 2004. Since then, Subaru’s main factory in Lafayette, Indiana (which produces nearly 1 million vehicles per year) has sent no waste to landfill, with 100% of manufacturing waste either recycled or used for energy. For over 15 years, Subaru has maintained this landfill-free operation, an accomplishment often cited as a model in the auto industry. How did Subaru achieve this feat? The company took a comprehensive approach to waste reduction:

• Rigorous Waste Tracking: Every piece of waste is tracked (even using barcodes) and analyzed to find recycling or reuse options. This data-driven oversight ensures nothing is discarded without considering recovery opportunities.
• In-Plant Recycling & Reuse: Subaru recycles all types of production waste – from waste oil to paint sludge – and reuses materials wherever possible (for example, shipping packaging is reused multiple times). Any materials that one department can’t use are sent to other departments or plants where they can be recycled or repurposed.
• Minimal Incineration: Only the most difficult-to-recycle residue is incinerated for energy, and this accounts for less than 5% of Subaru’s total waste. By leveraging waste-to-energy for that small fraction, the facility avoids landfilling without resorting to excessive incineration.
• Design for Recyclability: Subaru even considers end-of-life in its product design – 96% of the components in each Subaru vehicle are reusable or recyclable, reducing future waste.

Thanks to these measures, Subaru’s Indiana plant recycles or reuses 99.6% of all its waste, and the zero-landfill program has saved the company over $13 million in the past 15 years. They have also installed on-site composters to handle organic wastes (like cafeteria scraps), ensuring those are diverted as well. Subaru’s waste reduction ethos extends beyond its factory walls – the company has even partnered with the National Park Service to bring zero-landfill practices to U.S. national parks, sharing their expertise to help reduce park waste. By proving that a large-scale manufacturing plant can operate without landfilling waste, Subaru set a new standard in the auto industry and demonstrated that environmental stewardship can go hand-in-hand with efficient operations.

Procter & Gamble: Innovating Waste Reuse in Consumer Products

Consumer goods giant Procter & Gamble (P&G) launched a corporate-wide Zero Manufacturing Waste to Landfill program in 2008 and has made steady progress toward eliminating waste at its factories worldwide. By 2013, P&G had already certified 45 of its manufacturing facilities as zero-waste, and by 2018 it was diverting about 80% of operational waste from landfills, with a goal of reaching 100% diversion by 2020. (As of 2023, P&G reports that over 100 of its sites across 35+ countries have achieved zero manufacturing waste to landfill.) Achieving these milestones required P&G to get creative with how it handles by-products and scrap from the making of shampoos, diapers, detergents, and other household staples.

A dedicated team at P&G – the Global Asset Recovery Purchases (GARP) group – was formed to find innovative reuse opportunities for every manufacturing by-product. In practice, this has led to some remarkable waste-to-product transformations. For example, P&G found ways to:

• Repurpose Diaper Factory Scrap: Plastic scraps from diaper and wipes production are converted into plastic pellets, which P&G uses to manufacture cleaning tools like brooms and buckets.
• Turn Paper Waste into Roofing: Scrap fibers left over from making Charmin toilet paper and other paper products are processed into a material for low-cost roofing tiles, rather than being thrown out.
• Convert Other Waste to New Products: Even difficult residues have been tackled – waste from shampoo production has been turned into industrial fertilizer, and rejected feminine care materials have been formed into pellets for plastic shoe soles. In other words, P&G treats “waste” as a resource that can feed into other value streams.

Thanks to such efforts, P&G today utilizes more than 99% of all materials that enter its plants, with only a tiny fraction (on the order of 0.4%) ending up as disposal waste. This aggressive waste elimination has delivered significant business benefits as well. By finding revenue-generating or cost-saving outlets for material that used to be waste, P&G’s zero-waste program has saved the company roughly $1.9 billion since 2007. The company is now looking beyond its factory walls to tackle consumer waste: P&G has pledged to make 100% of its product packaging recyclable or reusable by 2030, aiming to reduce the waste its products generate after consumer use. Through internal innovation and a culture that views waste as worth, P&G has turned its landfills into relics and proven that cutting waste can bolster the bottom line while benefiting the environment.

Sierra Nevada Brewing: Crafting a Zero-Waste Brewery Culture

Family-owned Sierra Nevada Brewing Co. – known for its craft beers – has demonstrated that even mid-sized manufacturers can achieve virtually zero waste. Since 2013, Sierra Nevada has diverted 99.8% of its solid waste from landfill across its operations. In practical terms, only 0.2% of the brewery’s waste ends up as trash – an almost negligible amount. Sierra Nevada’s approach combines innovative reuse of brewing by-products with a company-wide culture of sustainability:

• Byproduct Reuse (Spent Grain): Brewing beer generates large quantities of “spent” barley and hops. Instead of discarding these, Sierra Nevada supplies these brewing by-products to local livestock farms as animal feed, keeping them out of landfills while supporting sustainable agriculture. The majority of the brewery’s waste by volume is this organic grain and hop residue, so finding a reuse stream for it was critical.
• Composting Systems: The brewery invested in advanced on-site composting technology (the HotRot system) to process organic waste like food scraps, paper, and other compostables from its breweries and taprooms. This turns what would be trash into rich compost used in the company’s own fields and gardens, closing the loop for organic waste.
• Employee Engagement and Reuse Culture: Sierra Nevada has woven zero-waste practices into its company culture. Every new employee is given reusable items (such as reusable water bottles, coffee mugs, and shopping bags) on day one and encouraged to avoid disposable products. Workers are empowered to find waste reduction ideas, and waste sorting and recycling are standard practice at all facilities. This high level of employee buy-in has helped eliminate the typical office and operational wastes that many businesses send to landfill.

All these efforts have paid off: Sierra Nevada’s original Chico, CA brewery was certified at the Platinum level for Zero Waste (the highest possible level) by the U.S. Zero Waste Business Council. This platinum certification signifies not only a >99% diversion rate, but also excellence in waste monitoring and continuous improvement. In addition, Sierra Nevada has received awards for sustainability leadership in the brewing industry, showing that a focus on waste reduction can enhance a company’s brand. By proving that even challenging waste streams (like tons of wet spent grain) can be beneficially reused, Sierra Nevada offers a blueprint for other food and beverage manufacturers to follow. The company continues to push boundaries – even capturing CO₂ from fermentation to reuse in carbonation – reinforcing that no waste is truly waste in a well-run circular system.

Key Takeaways and Path Forward

The experiences of Subaru, Procter & Gamble, Sierra Nevada, and many others make one thing clear: zero waste to landfill is an achievable goal when a company commits to rethinking its waste as resources. A few common strategies emerge from these case studies:

• Executive Commitment and Culture Change: Each of these organizations set bold zero-waste goals and invested in training and engaging employees at all levels. Building a culture that values recycling and innovation (as Sierra Nevada did) ensures everyone works toward the same waste-free vision.
• Innovative Waste Repurposing: Instead of simply disposing of by-products, these leaders find creative reuse or recycling solutions for them. Subaru reuses packaging and even tracks every scrap; P&G turned manufacturing scraps into new products; Sierra Nevada found local partners to use its spent ingredients. This innovation often requires dedicated teams (like P&G’s GARP) to brainstorm new uses for waste streams.
• Investing in Technology: Technologies such as on-site composters and efficient sorting systems, as well as waste-to-energy for non-recyclables, help push diversion rates into the high 90% range. For example, Sierra Nevada’s composting system and Subaru’s waste-to-energy usage for the last few percent of waste both helped close the loop. Many companies also pursue third-party certifications (like UL’s Zero Waste to Landfill standard or the TRUE Zero Waste certification) to validate their progress.
• Measuring and Monitoring: “You can’t manage what you don’t measure” holds true for waste reduction. All of these companies closely track waste metrics – whether it’s Subaru’s barcode system for waste streams or Google’s data-driven approach to achieve 91% waste diversion at its data centers. Detailed waste audits and reporting help identify new opportunities and maintain accountability.

The results speak for themselves. Environmental impacts have been dramatically reduced – for instance, Mars, Inc.(maker of M&M’s and other foods) achieved zero waste to landfill at all 126 of its factories worldwide, cutting tons of waste and even capturing methane for energy in the process. Many companies also realize significant cost savings or even new revenue. P&G’s program returned nearly $2 billion in value by turning waste into worth, and Subaru saved millions by avoiding disposal fees and selling recyclables. These financial gains help make the business case for sustainability. Moreover, companies often gain community and brand benefits – being known as a zero-waste leader can strengthen customer loyalty and industry reputation.

For organizations looking to adopt similar waste reduction initiatives, the journey may seem daunting but is entirely feasible with a systematic approach. Start with a thorough waste audit and set clear diversion targets. Engage employees and suppliers in the effort, because collaboration can uncover novel solutions for difficult wastes. It’s also wise to leverage external expertise and tools. Sustainability consultants and digital waste tracking platforms (for example, Wastebits or similar solutions) can act as strategic partners – providing data management, compliance tracking, and insights to optimize waste streams. By using such tools to monitor progress in real time, companies can identify quick wins (like improving recycling in one department) and long-term projects (like product redesign for waste reduction).

In conclusion, the move toward landfill-free operations is transforming how businesses think about waste. The case studies above illustrate that zero waste to landfill is not just an environmental slogan, but a practical, rewarding business strategy. Whether it’s an auto manufacturer reusing every scrap of material, a consumer products company inventing new uses for factory waste, or a brewery turning leftovers into farm feed, the pioneers of zero waste are forging a path that others can confidently follow. With careful planning, the right technology and partners, and a commitment to continual improvement, any organization can significantly reduce its waste footprint. The result is a win-win: cleaner communities and ecosystems, and a more efficient, sustainable operation that can proudly claim “nothing we make goes to waste.”

Whether you’re taking your first steps toward zero waste or optimizing an existing program, Wastebits helps you move from reactive to proactive waste management. We’ve supported organizations across manufacturing, distribution, and industrial sectors with landfill diversion, waste-to-energy strategies, and customized sustainability consulting.

Let’s talk about how we can help your organization eliminate landfill waste and unlock value in your materials.

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