In traditional surfboard manufacturing, there is approximately double the finished surfboard's weight in waste (or trash) generated in the production process. This consists of materials from offcuts of fiberglass cloth or tech materials like basalt patches, tape, resin, gloves, stir sticks, foam dust, sand paper, and more. As much as we love surfing, this is far more waste than we'd like to think is acceptable.
So, we've been developing the world's first Zero Waste Manufacturing system to eliminate all of that waste we generate during production. Waste streams from all production rooms are categorized, then sorted. Eps blank offcuts are sent directly to Marko Foam where they are recycled. The rest of our manufacturing waste is upcycled and recycled into our Greenlines Zero Waste products. As you can see above, we purposefully keep our drip trays covered with trash. This allows the waste to saturate with resin that falls off boards during production, and once hard enough we run this waste through our high density shredder.
In partnership with Regenerative Education Centers (@recentersorg non-profit) based in Kahului, Hawai'i, Earth Technologies houses a population of special super meal worms that bio remediate organic materials as well as poly styrene. These worms (used in the larvae stage), have a special enzyme in their gut that can break down poly styrene (and EPS, the foam blank in our surfboards) into a semi-organic material. In the same ecosystem, to finish the process and bio remediate completely to an organic material, a funghi finishes off the job. We make sure to keep some cactus or fruit in the ecosystem as their water source, to keep them happy and doing their thing.
The waste that these epic creatures cannot handle, pretty much anything that resin touches, is processed through an industrial shredder into particles. These particles are then upcycled into various Greenlines products handmade in Los Angeles including coasters, handplanes, and more to come!