Gypsum Wallboard Recycling - The Successful Scandinavian Solution Henrik Lund-Nielsen, MBA, CEO...

Gypsum Wallboard Recycling -

The Successful Scandinavian Solution

Henrik Lund-Nielsen, MBA, CEO Gypsum Recycling International A/S Leopardvej 2, 7700 Thisted, Denmark Office: +45 70 22 17 30 Cell: +45 2447 7337, [email protected]

SWANA 2005 Gypsum Recycling International A/S

Gypsum Wallboard Recycling - The Successful Scandinavian Solution

No more landfilling!

Instead Gypsum waste should be recycled



Content of presentation About Gypsum Recycling International The unique recycling system, successfully

implemented in Scandinavia Video Lessons from Denmark, from the first full-scale

gypsum recycling system in Europe Intended operations in Massachusetts – The North

East of US



2001 – Denmark(1998/99 idea started)

2003 – Sweden

2003 – Norway

2004 – Holland

2005 (March) – Ireland

2005 (Aug) - UK

2005 (Nov) – USA

In total 7 countries - far more than anybody else



About GRI

Knauf - 2001

BPB - 2003

Lafarge - 2004

US Gypsum – 2004/5

National Gypsum – 2004/5

GRI serves all the top 5 wallboard groups in the world. In total 15 different plants are under contract with GRI for the supply of recycled gypsum wallboard waste



About GRI

The unique recycling system, successfully implemented in Scandinavia3 important characteristics to remember:

A) GRI makes recycling on commercial terms => We know how to establish competitive systems=> Nowhere in Europe is there a ban on landfilling

B) GRI has a background from the demolition industry => We can handle all types of gypsum wallboard waste

C) Low transport cost is “the name of the game” when establishing commercial recycling systems => Our system and concept is focussed on exactly that



The unique recycling system, successfully implemented in ScandinaviaThe 4 main components of the system:A) Dumpsters: Gypsum wallboard waste is deposited in specially developed dumpsters

B) Logistics: The materials are collected and brought to central warehouses

C) Recycling Unit: The recycling unit is at the warehouse transforming the materials into Gypsum powder

D) Reprocessed waste supplied to wallboard plants The Gypsum powder is brought to the Gypsum wallboard manufacturers who can use it directly in the production



Re. A) Dumpsters: Specially designed by GRI to allow for easy filling and easy removal of

the plasterboard waste; equipped with lids, the top lid being hydraulic assisted

Contract manufactured for GRI; sold or leased to the customers for 80 $ per month. Customers own container/dumpster can also be used

The 40 cubic yards dumpsters contain 7-8 tons wallboard waste Other dumpsters will be used as appropriate (30 cubic yard, 10 cubic

yard front end loaded etc). Always with top lid.



Re. B) Logistics system:

Dumpsters are at new building, reconstruction and demolition sites, at

waste transfer stations + public recycling centres etc.

Dumpsters are unloaded according to needs, and brought to the

nearest GRI warehouse.

The collected wallboard waste is weighed on the truck, and this

information is used to invoice the customer – typical price per ton is

80 $. Price includes collection.



Re. B) Logistics system, continued: The recycling unit is mobile and can easily be moved around from warehouse

to warehouse, allowing an optimal location of the warehouses to minimise transportation cost

Dismantling/setting up of the unit can be done in a few hours The warehouses should be located close to a gypsum wallboard plant



The unique recycling system, successfully implemented in Scandinavia

Re. C) Recycling unit: Specially designed and developed by GRI Based on proprietary technology/patents Produces recycable gypsum powder and paper

separately. The paper can be reused (animal bedding, building products etc.)

Capacity: Up to almost 100.000 tons p.a. Dimensions: L*W*H = 80*10*13 feet. Weight 52 tons




Re. C) The recycling unit - continued:

Capable of handling new construction waste and demolition waste: Acceptable: - Gypsum waste based on synthetic or rock gypsum raw materials - Virgin wallboard cut-offs - Wallboard underlayers/dunnage

- Complete boards or broken parts - Gypsum ceilings, floors, walls etc. - The gypsum waste may contain nails and screws- Wallpaper, glass tissue and other wall coverings on the gypsum boards

Non-acceptable: - Plastics and foils - Insulation materials (glass wool/stone wool/Rockwool) - Steel rails and bars - Wood - Other impurities



The unique recycling system, successfully implemented in ScandinaviaSummary:

How does the system from GRI differ from what other suppliers can offer?

It is a commercially driven system, that works because all parties are gaining advantages by participating in it

It is a complete system with all the necessary elements; especially for assuring low transport cost

It is based on the concept of multiple smaller warehouses and a mobile recycling unit to optimise locations and transportation costs




5 minutes Video



Lessons from Denmark, from the first full-scale gypsum recycling programme in Europe Gypsum Wallboard waste is NOT banned from landfills in Denmark ! 5 million inhabitants in Denmark and similar size to MA Started in the fall of 2001 with collection activities. 400 containers out in the market: 85% of all public waste transfer stations are now

covered with GRI containers and increasing fast Other main suppliers of gypsum waste include construction and demolition

companies Presently more than 65% of all gypsum wallboard waste in Denmark is being

recycled by GRI and increasing fast. Danogips (Knauf) and Gyproc (BPB) receive and use the recycled gypsum powder

for production of new virgin boards Warehouses close to the 2 wallboard plants in Denmark



Hobro (Knauf)

Kalundborg(BPB)

Copenhagen

Lessons from Denmark, from the first full-scale gypsum recycling programme in Europe

70 miles

Sweden

Norway



Intended operations in Massachusetts

Warehouse in Cambridge, Boston to start with Collection done by dumpsters. Price per ton collected: 80 $. Alternatively 399 $ for a full loaded

30 cuy dumpster collected. Price for customers for renting of dumpsters: 80 $ per month Customers own dumpsters can also be used Customers can also deliver materials directly to the warehouses with a discount of app. 15-20 $

per tons New construction waste ONLY for the first 18 month; up to 3% contamination in the form of

wood, metal, plastic etc. allowed. Demolition waste to be considered there after Absolutely no asbestos accepted Start of operations end of November Expansion to other locations in 2006



National Burlington

USG + National Baltimore

USG Stony Point

National Portsmouth

USG Boston

National Rensselaer

= 120 miles radius

Gypsum Wallboard Recycling - The Successful Scandinavian Solution Henrik Lund-Nielsen, MBA, CEO...

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