The Green Box

The Green Box is a manufacturing facility that has a 100% reclamation process for 500 tons of organic solid waste each day. This waste stream is remanufactured into commercially marketable products, without any waste-water discharge, and without any waste material going to landfill. The 500 tons of waste material being processed is currently directed to landfills by the companies that generate it.

The Green Box performs this activity in a 240,000 square foot facility on approximately 30 acres, with about 250 employees. The 500 tons of waste material is sorted with white, brown, and poly-coated papers and is converted into 200 tons per day of pulp. The pulp is converted into over 50,000 tons per year of tissue products such as bathroom and facial tissues, napkins, and paper towels. Pulp is also converted into 600 million paper cups per Green Box each year. The pulp is approved by the FDA to be used in a concentration of up to 40% for poly-coated paper cups.

Waste generated by the sorting system, pulping system, and tissue converting system is converted into high-tech fuel pellets. These fuel pellets generate between 10,500 and 16,000 BTU’s per pound and can be commercially sold or consumed by the in-house gasification process that also produces synthetic gas and biodiesel. The gas is used to power generators that make up to 12 megawatts of energy that completely power the entire Green Box operation. Any excess is sold back to the grid. Over 6.5 million gallons of biodiesel per year is sold to be blended and used in diesel vehicle engines. This process enables 100% reclamation and sustainability of organic waste stream.

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