The automotive manufacturing industry generates a wide array of waste materials, including plastic scraps, cardboard, rubber trimmings, textiles, wood, composite materials, and non-recyclable foam. These waste streams, coupled with wastewater from parts washing and surface treatments, create a complex waste management challenge.

Seeking to cut costs and advance towards zero-waste targets, an automobile manufacturing plant in Texas engaged VLS Environmental Solutions to devise a waste management strategy that not only addressed these issues but also converted waste into a resource through our waste-to-energy and Alternative Engineered Fuel (AEF) methods.

The VLS Approach: Innovating Waste Management

Our process began with a detailed evaluation of the client’s waste streams. Our team identified materials with heating values exceeding 5,000 BTUs, suitable for recycling into energy. We assisted the client in applying for exemptions using TCEQ Form 0525, which streamlined the waste handling process and reduced costs by eliminating certain regulatory fees on exempt waste shipments.

With regulatory measures in place, we optimized logistics by directing waste streams to our Houston facility. This local processing reduced transportation costs and supported the client’s sustainability goals by minimizing the carbon footprint associated with waste transport.

Our AEF technology transformed non-hazardous waste into energy at partnered cement kilns. The initial load processed was over 18 tons, converted into heat and gas, replacing nonrenewable resources like coal. This resulted in a CO2 emissions reduction equivalent to 38 metric tons—comparable to removing 8 cars from the road for a year or the energy use of 10 homes annually, according to EPA data. 

Rob Wheatley, Chief Strategy Officer also added, “Converting waste into energy is a powerful example of innovation in action, reducing our environmental impact and improving the efficiency of our processes.”

Monte Dilick, Director of National Accounts commented, “We provide not only a sustainable solution but also help cut costs and promote environmental benefits that work towards our clients’ sustainability goals.”

How We Made a Difference

Processed 18.6 tons of non-hazardous waste through our innovative AEF program.

Assisted with TCEQ Form 0525 for Class 1 waste management, creating cost savings for the client.

Minimized cost and carbon footprint through local in-state processing.

Maintained zero safety incidents.

In a time when industries are under increasing pressure to reduce their environmental impact, VLS provides powerful solutions for the automotive sector and beyond. By converting waste into energy, optimizing logistics, and navigating complex regulations, we empower our clients to achieve their sustainability goals while enhancing business operations.