Sustainable Composite Decking with Fiberon

For decades, plastic and paper waste has been sent overseas to be recycled. Domestic recycling is often more efficient, environmentally friendly, and cost-effective. Repurposing plastic waste where it’s created can provide a new income stream for businesses while eliminating the need to ship waste materials across the ocean. Fiberon has embraced this process, proving that being attentive to the environment does not always have to be a financial burden.

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Fiberon X WEIMA

Fiberon Key Facts

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1997
Founded in New London, North Carolina
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500+
Employees
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14+
Industry Awards
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A Concise History

Recycling in the United States goes beyond placing plastic beverage bottles in a curbside collection bin. Post-consumer recycling is crucial in providing sorted waste streams for reclaim, but that’s not where the process ends. Companies that seek to manufacture new products from recycled contents can source reusable materials from collection centers where these materials are sorted by type—if there is enough recycled material available.

aerial view of fiberon decking production plant in north america

Fiberon Decking location in North London, North Carolina, USA

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Post-industrial waste as a resource

Significant amounts of post-industrial waste end up in landfills for a variety of reasons. Companies often are unaware that recycling and reintegrating their waste materials is possible. For this reason, these valuable materials are frequently discarded instead of being repurposed or recycled.

Thinking circularly, rather than in a linear way, allows companies to reimagine what can be produced from these “single-use” scrap materials that would typically go to a landfill. Forward-thinking companies have an opportunity to take the scrap that would traditionally be hauled away and make it into something new, thus creating a new revenue stream.

Having the tools to create that second life for that scrap makes it easier to create a product that gives and gives, rather than taking from the environment. It’s about thinking creatively and putting the infrastructure in place to reclaim this scrap.

weima single shaft shredder with extrusion line at fiberon in north carolina

Fiberon decking recycling line with WEIMA shredder

forklift loads film waste made of plastic on conveyor belt with weima shredder in background

Feeding of WEIMA shredder with plastic film scrap

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“As a country, we’ve had to shift our focus and bring recycling initiatives and infrastructure into our daily practices, and that includes into our manufacturing processes.”

– Madison Burt, CEO of WEIMA America, Inc.

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Recycling initiatives at Fiberon

Fiberon, based out of New London, North Carolina, manufactures top-of-the-line composite decking. They do this by sourcing secondary polypropylene scrap—which is strong and easy to use and reuse—from various companies and combining it with a proprietary (recycled or post-industrial) wood fiber blend. The decking created is beautiful and will last for decades.

two full conveyor belts with shredded plastic waste and weima plastic shredders in background

High throughputs achievable with WEIMA shredders

close up with of heavy duty orange red weima shredder and conveying system

WEIMA S7 lift-up shredder with discharge conveyor belt

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“Fiberon uses recycled materials to make its products. We mix together recycled wood and recycled polymers and create a product that will last a lifetime. Our manufacturing processes require large amounts of water, but by utilizing a closed loop system we are able to recycle the vast majority of water used in our system on a daily basis. It’s not only about cost, but it’s also about being a good steward of the environment.”

– Mike Huskey, VP of Operations for Fiberon Decking

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Fiberon production plant insights

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Environmental and economic benefits

The composite decking that Fiberon produces from recycled materials provides a substantial environmental benefit to the company while creating a new income stream.

Fiberon is a tangible example of what it means to recycle production scrap on the spot. They chose WEIMA as a recycling partner to provide size reduction equipment within their New London plant. This machinery breaks down the reclaimed material streams they have sourced to be used in various ways. WEIMA shredders are at the beginning of Fiberon’s process—the shredder takes the material and prepares it for conversion into something useful.

hands with regranulate from recycling of plastic film

Fiberon regranulate after extrusion

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“Being environmentally responsible is something that most corporations really strive for, and I think there’s a misconception that recycling initiatives within a corporation have to be an up-front expense, and that’s just not the case. You can make incredible ROI from the scrap that would have otherwise been thrown away, and Fiberon is proof of that.”

– Audrey Brewer, North American Marketing Manager of WEIMA America, Inc.

WEIMA shredders are incredible tools that manufacturers can stage in-house to create a circular economy from production scrap or from sourced plastic waste materials. The goal is to reimagine and reuse plastic waste in new and versatile ways.

Contact

WEIMA Maschinenbau GmbH

Bustadt 6-10

74360 Ilsfeld

Contact

Additional Information

About WEIMA

More than 40,000 machines sold worldwide! WEIMA has been manufacturing robust shredders and briquetting presses for the disposal and processing of all types of waste for more than four decades. Our machines include single-shaft shredders, four-shaft shredders, cutting mills and briquette presses. The popular blood orange machines are used in the wood, plastics, paper, metal and waste-to-energy industries.

Made in Germany. Built for the world.

Shredders and briquette presses from WEIMA are exclusively made in Germany and come from production plants in Saxony-Anhalt and Baden-Wuerttemberg. Every year, more than 300 employees work on around 1,200 customer solutions from around the globe. We have long-standing sales and service locations in the USA, Poland, India and China. More than 80 representatives supplement this global presence.

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