Smithfield’s Switch from Cardboard to Reusable Plastic Totes Pays Off

“Changing these two processes to utilize reusable, folding, plastic combos and baskets greatly reduced cardboard waste,” says Smithfield Environmental Coordinator Ross Weatherford. “With reusable baskets replacing boxes, the waste is further recycled beyond the Sioux City plant.

“The cardboard reduction project also helps the plant’s goal of becoming landfill free and reduces the cardboard recycling transportation costs,” states Weatherford. In addition, it saves more than 3,300 trees per year.

The project was completed in May 2020, and payback was achieved in three-and-a half months. Projected savings over five years are expected to be more than $1 million. 

This project was originally started at Smithfield’s facility in Sioux Falls, S.D. Reusable collapsible boxes were used to send product to other plants, and reusable totes were used in-house. After some research and logistical realignment, the project was implemented at the Sioux City plant for similar operations. Any Smithfield plant that ships products to another Smithfield facility can use the reusable combos and baskets rather than cardboard combos and boxes. The use of plastic totes will increase sanitation workload, because they must be cleaned before they are reused, Weatherford notes.