CertainTeed Siding Plant Upcycles its Manufacturing Waste into Protective Corners

(Valley Forge, Pa.) – The development team at CertainTeed Corporation’s McPherson, Kan., polymer shake siding manufacturing facility is thinking outside of the box with the development of the Cobra Corner Guard, a product that takes regrind waste from the manufacturing process and “upcycles” or repurposes it into corner guards that protect pallets of packaged product during shipment.

“The idea was born out of a desire to save the plant money and to recycle the regrind that results from production color changes during the manufacture of our Cedar Impressions(R) polymer shake siding,” says Austin Butcher, Project Engineer for the McPherson Plant. “Regrind can’t be used for manufacturing new siding and it was quickly accumulating. So, our team came up with this truly unique solution – the Cobra Corner Guard which protects the edges of corrugated siding cartons.”

“I feel the McPherson Plant has overall done a great job of keeping environmentally friendly activities top-of-mind,” says Tad Radzinski, Founder and President of Sustainable Solutions Corporation and an industry expert in sustainability.  Radzinski helps companies develop innovative and practical solutions that reduce environmental impact, improve efficiency and save money. “I have had the opportunity to visit many plants and facilities and the McPherson Plant has gone above and beyond to establish a comprehensive recycling program. The new Cobra Corner Guard product is a fine example of this.”

Cobra Corner Guard, which went into production this summer, features two injection-molded in-ribs that act as a strap guide to ensure the banding materials don’t slide off. Further distinguishing the design are the “fangs” that attach or “bite” into the carton and hold it in place.

Cobra Corner Guards also are now in use at CertainTeed Siding Plants in Hagerstown, Md., and Jackson, Mich.

“The purpose of this project was to offer our sister plants a better functioning corner guard, reduce costs and manufacturing waste from our facility through the use of sustainable tactics,” adds Butcher. “I am happy to report that we accomplished all three goals.”  

About CertainTeed

Through innovation and creative product design, CertainTeed has helped shape the building products industry for more than 100 years. Founded in 1904 as General Roofing Manufacturing Company, the firm made its slogan "Quality Made Certain, Satisfaction Guaranteed," which quickly inspired the name CertainTeed. Today, CertainTeed(R) is North America’s leading brand of exterior and interior building products, including roofing, siding, windows, fence, decking, railing, trim, foundations, pipe, insulation, gypsum, ceilings and access covers.

Headquartered in Valley Forge, Pa., CertainTeed and its affiliates have more than 7,000 employees and more than 70 manufacturing facilities throughout the United States and Canada. In 2007 the group had consolidated sales of more than $3 billion. www.certainteed.com