Recycling Operations Management Strategies
The Aggregates Recycling Committee held its first meeting of the year, with Lauren Asfour and Neil Mullan as chair and co-chair. The committee aims to educate members on optimizing operations and developing end markets, with a focus on content related to operations and increasing recycling rates. Robert Tassey presented on managing downtime in recycling operations, emphasizing the importance of balancing production with maintenance to protect equipment investments. He discussed different types of downtime, including planned and unplanned shutdowns, and shared strategies for managing unexpected events and maintaining productivity.
Manufacturing Downtime Management Strategies
Robert discussed strategies for managing and analyzing downtime in manufacturing facilities. He emphasized the importance of focusing on solutions rather than blaming when errors occur and suggested using mistakes as learning opportunities for the team. Tassey also explained how tracking and analyzing downtime data can help optimize plant utilization and minimize costs. He recommended keeping data collection simple and consistent, using tools like Procore and Power BI for analysis, and taking a proactive approach to maintenance rather than a reactive one. Tassey invited the group to share their own experiences and strategies for managing downtime costs.
Material Quality and Operations Management
Robert explained that the quality of incoming materials significantly impacts plant downtime, with lower-quality materials often causing more issues. He emphasized making business decisions on a case-by-case basis, such as diverting problematic projects to landfills or C&D transfer stations. A question was asked about adjustments to plant operations, and Robert mentioned that decisions depend on the project, considering factors like tip fees and material quality. Discussion included the use of fleet management systems, noting that some companies use basic metrics due to limited manpower. It was suggested that AI analysis could be helpful in managing data, and it was agreed that technology would become more prevalent in their operations. A question was asked about balancing facility uptime with equipment needs, and it was explained that decisions are made based on the project’s risks and benefits.
Plant Utilization and Maintenance Strategies
The importance of tracking data and setting realistic goals for plant utilization, emphasizing the need to understand costs and the impact of maintenance practices was discussed. The benefits of having ownership with field experience and the value of a culture of continuous improvement was highlighted. Questions about human error in maintenance and downtime were asked to which the response focused on emphasizing the learning experience and the importance of addressing repeated errors. Common customer questions about operating wash plants in harsh climates and the challenges of handling waste were asked.
Year-Round Mobile Screening Operations
Robert explained that his company typically shuts down for 8-10 weeks after Christmas due to harsh winter conditions, but they recently acquired a mobile dry screening unit to keep operations running year-round. He described how the machine allows them to process material without relying on a wet process that could freeze and explained that while some of the screened material is washed, other fractions are sorted and crushed for recycling. A question was asked about the sustainability of this process through spring and summer, to which Robert confirmed it would continue due to the backlog generated. It was noted that data collection has helped determine when plant upgrades are worthwhile, with Robert agreeing that tracking downtime and maintenance issues can quantify return on investment for ownership.
CDRA Aggregates Committee Updates
The CDRA Aggregates Committee meeting covered upcoming events, including a Shingle Recycling Forum in Raleigh, North Carolina, and the CDRA next trade show in January in Bonita Springs, Florida. Andy announced a trip to Northern Ireland for CDRA members, organized by Invest Northern Ireland, running from May 17-22, 2026. The trip will be customized based on member interest in either C&D processing or aggregates, with a deadline to sign up by March 6th.
The next Aggregates Recycling Committee meeting will be held on April 21, 2026.