Each year, over 11 million metric tons of plastic end up in the ocean, which is like dumping a garbage truck full of plastic every minute. For years, we’ve known that marine animals eat this debris, but no one had measured exactly how much plastic it takes to kill them. Dr. Erin Murphy, who leads ocean plastics research at the Ocean Conservancy, is the principal author of a major study published in the Proceedings of the National Academy of Sciences. Her team analyzed more than 10,000 necropsies from 95 species of seabirds, sea turtles, and marine mammals worldwide. Earth911’s summary describes this critical study, which found lethal plastic thresholds that could change how we view the plastic crisis.
The study measured how deadly different types of plastic are to sea life, which makes the results especially useful for policymakers. Each finding suggests a clear policy action, such as banning balloon releases like Florida has done, banning plastic bags as in California’s SB 54, or improving how fishing gear is marked and recovered. Still, Erin points out that focusing only on certain plastics is not enough. Her team found that even small amounts of any plastic can be dangerous. As she says, “At the end of the day, there is too much plastic in the ocean,” and we need big changes at every stage of the plastics life cycle, from production to disposal.
There’s encouraging evidence that interventions work. Communities in Hawaii conducted large-scale beach cleanups and saw the Hawaiian monk seal population rebound. A study published in Science confirmed that bag bans reduce plastic on beaches by 25 to 47%. And Ocean Conservancy’s International Coastal Cleanup, now in its 40th year, removed more than a million plastic bags from beaches last year. These actions address a parallel crisis in human health that is building from the same pollution source. Most of the microplastics now found in humans and around the world began as the same macroplastics that are killing puffins and turtles. As Erin puts it, “I do view this all as part of the same crisis.”
You can read the full study at pnas.org and learn more about Ocean Conservancy’s work at oceanconservancy.org.
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Interview Transcript
Mitch Ratcliffe 0:00
Hello, good morning, good afternoon or good evening, wherever you are on this beautiful planet of ours. Welcome to Sustainability In Your Ear. This is the podcast conversation about accelerating the transition to a sustainable, carbon-neutral society, and I’m your host, Mitch Ratcliffe. Thanks for joining the conversation today.
We’re going to talk about ocean plastics. Every year, more than 11 million metric tons of plastic enters the ocean. That’s the equivalent of dumping a garbage truck worth of plastic every minute. And we’ve known for decades that marine animals eat this debris. But until recently, no one had systematically quantified how much plastic it actually takes to kill them.
And the answer is, it turns out, disturbing. Less than three sugar cubes worth of plastic increases an Atlantic puffin’s risk of dying by 90%. A loggerhead turtle reaches the same threshold at about two baseballs worth, and for a harbor porpoise, a mass of plastic roughly the size of a soccer ball can kill. More concerning, at the 50% mortality level — that is, where half the animals who consume the plastic die — the volumes that kill them shrink to less than one sugar cube for a puffin and half a baseball for a loggerhead turtle.
Our guest today, Dr. Erin Murphy, is the manager of ocean plastics research at the Ocean Conservancy, and lead author of the study that produced these findings, published last month in the Proceedings of the National Academy of Sciences. Her team’s research analyzed more than 10,000 necroscopies across 95 species of seabirds, sea turtles, and marine mammals worldwide. It’s the most comprehensive assessment yet of how different plastic types — soft film like bags, hard fragments, synthetic rubber from balloons, and abandoned fishing gear — translate into mortality across marine life.
The findings matter beyond ocean conservation. A 2024 study in the New England Journal of Medicine found microplastics embedded in human arterial plaque of cardiovascular surgery patients, and those with detectable plastics were 4.5 times more likely to suffer a heart attack, stroke, or death in the following three years. The same polymers killing seabirds and sea turtles — polyethylene, PVC, and their chemical additives — are found in human blood, lungs, liver, and placenta.
Dr. Murphy’s research offers policymakers what they’ve been asking for: science-based data to inform decisions about which plastics to regulate and how aggressively to act. Nearly half the animals in her study that had ingested plastics were threatened or endangered species, and with global negotiations on a binding plastic treaty continuing and extended producer responsibility programs expanding across the United States, the timing of this research could not be more relevant.
So we’ll talk with Erin about what her team found, why balloon fragments are amongst the deadliest items for seabirds, how fishing gear became the leading killer of marine animals, and what her research means for the humans who share a planet and a body burden with these species. You can read the full study at pnas.org and find Ocean Conservancy’s work at oceanconservancy.org. Ocean Conservancy is all one word, no space, no dash. Oceanconservancy.org.
So how much plastic is too much for wildlife and for humans? Let’s find out right after this brief commercial break.
[COMMERCIAL BREAK]
Welcome to the show, Erin. How you doing today?
Erin Murphy 3:44
I’m doing well. Thank you so much for having me.
Mitch Ratcliffe 3:46
Well, thank you for joining me, and for this really important research. It was a fascinating read. We wrote it up, and I’m really pleased that you would join us to talk about it today. So can you explain what made this study different from previous attempts to quantify plastics’ lethality to marine life?
Erin Murphy 4:01
Yeah. So first, I’ll specify that we focus specifically on macroplastics, which are just plastics that are bigger than five millimeters in length. There’s more research on how microplastics, which are these smaller plastics, can harm animals, because scientists can study these in laboratory settings. Of course, it’s not feasible or ethical to feed animals like whales, sea turtles, or seabirds large plastic items and study what happens to them in the lab. And so as scientists, we really have to depend on opportunistically collecting dead animals in the environment and looking at what’s inside them to understand what’s happening with these bigger plastics.
And so previous research has looked at these sorts of threats as well, but they focused on fewer species, on smaller geographic areas, and they didn’t differentiate by plastic type, like hard plastics versus soft plastics. So they were really important for laying the groundwork for our larger study. But we were actually able to look globally and look at a broader set of species, and also differentiate by these different plastic types and by species size as well, which allowed us to get at some of these species-level understandings.
Mitch Ratcliffe 5:13
So the unfortunate truth is, we are feeding these animals this material by throwing it all away. That is a stark way of starting this conversation. And you use a lot of illustrative examples, like three sugar cubes worth of macroplastic can kill a puffin. How did you arrive at those kind of volume-based comparisons, and why is translating your data into those relatable measures important?
Erin Murphy 5:37
Yeah, so when we did this in the study, we actually looked at the influence of volume based on the animal’s body length. So we reported all of this as a deadly volume per centimeter of body length. But telling people 0.098 centimeters cubed per centimeter doesn’t really mean anything to them. And honestly, when I first got those centimeter-based thresholds, it didn’t mean that much to me.
And so we thought that choosing some iconic species that people could picture would help, but still saying, you know, three centimeters cubed of plastic kills a puffin, or 220 centimeters cubed of plastic kills a loggerhead, doesn’t really paint a picture in people’s heads, and three sugar cubes or a baseball are much easier to picture.
So we chose to do this because I think when people can picture these items, they can really understand that volume, and people do use plastic every single day, and so having volumes like that to compare to allows them to think about how little plastic can kill animals, especially when we compare it to how much we produce or use globally.
Mitch Ratcliffe 6:42
Can you put in context how long it takes for a puffin, for instance, to eat that much plastic? What do they eat in a day or a week generally?
Erin Murphy 6:52
Yeah, that’s a great question, and it’s actually the next step in our research. So to estimate the risk that something poses to wildlife, we have to understand two things. One is your question: how likely are they to be exposed to this threat? The second is, if they are exposed to it, how likely is it to harm them? And so this research really focused entirely on that second piece.
But to fully understand risk, we have to dig deeper into the first part, and that’s what we call likelihood of exposure. And so for puffins specifically, there’s not a lot of research, but we do know a lot about what species are eating, and we know that different species are more or less likely to eat plastic based on where they live, what they eat, and how they feed. So we’re really excited to be working with some really amazing researchers over the next few years to think about how we can connect exposure for these animals to the lethality and understand risk in a more comprehensive way.
Mitch Ratcliffe 7:48
I want to get a sense of what you found. You mentioned in the study that one whale can have a three-gallon bucket in its stomach. What’s the range of objects that you encountered as you were doing the research?
Erin Murphy 8:00
Yeah, this was pretty unbelievable to me, actually, some of the things that we saw in animals, and I’ll just give a few items that stood out to me. But there’s many more. Part of an oar handle from a plastic — or a plastic belt, webbing from the back of a lawn chair, a koozie, rubber pencil topper, fake Easter grass, ice cream tubs, single-use coffee pods, bungee cords, tons of different types of gear, ropes, nets, fishing line.
But I’ll just illustrate kind of how dramatic this can look with one example that really stood out to me, on a sperm whale that researchers in Spain reported on. Sperm whales feed very deep in the ocean, and they use echolocation to find their food. So it may be particularly hard for them to tell plastic from prey. And in this case, it seems like an entire greenhouse washed into the ocean, and this sperm whale happened upon it. It had plastic film cover material for a greenhouse in its stomach, along with a flower pot, a piece of a hose, a plastic burlap sack, plastic craft, and plastic spray bottle, and even fake plastic mulch in its stomach. And unfortunately, this was one of the individuals that did lose its life to plastic ingestion.
Mitch Ratcliffe 9:23
That’s — I mean, that’s shocking in so many ways. You found that one in five animals had plastic in their digestive tract when they died. Was this percentage higher or lower, and in the context of your previous answer, more or less shocking than you expected?
Erin Murphy 9:45
Yeah, I think, you know, it was higher than I expected. And it’s funny, because all of our research was based on previous research. It was a meta-analysis. So we collected data from existing literature. And I’d seen some, you know, similar numbers then reported at more local scales. But I think it still really shocked me to look at so many studies and see, you know, for sea turtles, that was one in two. Sea turtles had plastic in their gut. And for seabirds, one in three.
And when thinking about that at a global scale, that felt higher to me than it should be, and I suppose it’s because it is higher than it should be. These really are high ingestion rates. And for some of these individuals, the bulk amount of plastic in their gut, like that sperm whale, is particularly shocking.
Mitch Ratcliffe 10:35
I want to step back just for a second and talk about how long this kind of research has been going on. Because when I was a child, oceanography was very much in its infancy. How aggressively are we trying to understand what we’re doing to the ocean environment at this point, and where do you think we are in terms of the long arc of beginning to reach that understanding?
Erin Murphy 10:58
Yeah, I don’t know if we’ll ever fully understand it, which is one of the things that makes studying the ocean so interesting. It’s so complex and vast. But, you know, we’ve come a long way, and for plastic pollution in particular, the ’70s was really when we started seeing those first reports of animals eating plastics. You know, and it’s been 50 years since then. Now we have evidence of plastic ingestion in more than 1,300 species, and we’re starting to be able to get at these really more complicated analyses that help us understand like the potential quantity that kills an animal, like this one, or what does that mean possibly for populations.
I think the thing that’s been really impressive in the last decade, though, is how much research has been done on plastics. In particular, 10 years ago, roughly, the first study came out by Jambeck et al. that gave us an idea of the amount of plastic that was getting into the environment. And since then, we have learned so much as a scientific community, and people are working really hard to try to understand what these vast amounts of ocean plastic mean for ecosystems, for human health, for fishing industries and other marine industries that really depend on a healthy ocean, and we’ve been doing a lot of research on how to address it. So I don’t think we’ll ever fully understand everything that we’re doing to the ocean, but I think we’re working hard as a scientific community to get there.
Mitch Ratcliffe 12:38
It’s really disturbing to think about, because plastic in the 1970s was really only — was 10 years into widespread use, and widespread compared to today is nothing, since half the plastic we’ve manufactured in history has been made since 2002. So it sounds like what we’re really delving into now is a real-time accounting of the damage that we’re doing. How do you as a scientist think about what your goal is in terms of bringing the consequences of our decisions back to the public so we can think about it?
Erin Murphy 13:11
Yeah, that’s why I feel very lucky to work with an organization like Ocean Conservancy. We conduct research that we know governments and decision makers need to help address these problems, and we have a policy team and a communications team that are really well trained on helping us bring this research to the decision makers.
And the type of research we’re doing here, in particular on risk assessments, is something that governments are really craving. They want to set science-based targets as they try to address plastic pollution, and part of that is understanding environmental thresholds that we should be aiming for to better protect marine wildlife, to better protect marine ecosystems.
And so when we do research like this, a big part is getting it into the literature, in this sense to the scientific community, but it’s also working with our policy team and our communications team to make sure the public hears about it, and to make sure that decision makers nationally and abroad hear about the work that we’re doing, and can use this to help inform science-based targets that they’re setting right now.
Mitch Ratcliffe 14:22
So one of the materials that you found was most dangerous is rubber, particularly from balloons. It emerged as especially deadly for seabirds, where you estimated that just six pea-sized pieces could create a 90% mortality rate. What’s happening physiologically with balloon fragments that make them so lethal?
Erin Murphy 14:45
Yeah, so if you think about the design of a balloon, they’re super stretchy, and they’re long and they’re thin, and even the fragments seem to have this shape. And so they get stuck at those junctures in the gastrointestinal tract, like between the stomach and the intestine. And the gut moves things along through these wave-like contractions. And it seems like these stretchy materials just kind of stretch with it, and so the gut just isn’t able to move them through as easily. And we see similar things for those plastic bags as well.
Mitch Ratcliffe 15:20
Well, you also point out that sea turtles appear to mistake plastic bags for jellyfish. Is there anything we could do in terms of the chemistry of soft plastics or the appearance of soft plastics to make them less attractive to sea life?
Erin Murphy 15:35
Yeah, I don’t know if there’s a way that we can make them less attractive that I know of. And it’s unfortunate, because we know there are a lot of plastic bags in the environment compared to other plastics. Every year, Ocean Conservancy organizes the International Coastal Cleanup, and plastic bags are consistently in the top 10 items we see most frequently.
That being said, we do know ways of keeping plastic bags out of the ocean and protecting turtles in that way. And so every year — or in this last year, during our Coastal Cleanup — we collected, or our partner organizations collected, more than 1 million bags off our beaches. So this is really important for helping protect ocean animals, because those bags are already very close to their environment, and by removing them from beaches, we prevent them from getting into the ocean.
We also know that plastic bag bans, like the policy that California just implemented, are very effective in reducing the threat that plastic bags pose to marine wildlife, and help by preventing them from getting into the environment in the first place. So there was a recent study published in Science that actually showed that communities that implement bag bans, whether that’s a city, a state, or a country, do meaningfully reduce the amount of plastic bags that end up on beaches by 25 to 47%. So that’s a really significant reduction, and just provides further evidence that we know how to address some of these threats. We have ways of measuring if policies are effective, and it’s really about preventing these bags from getting into the environment in the first place.
Mitch Ratcliffe 17:18
Another example of really short-term human thinking is the impact of fishing gear pollution. Can you talk a little about what you found in terms of what’s being tossed overboard by the boats that are hoping to treat the ocean as an ongoing resource and source of living?
Erin Murphy 17:36
Yeah. I mean, I think a lot of the fishing gear that’s lost is lost on accident. Fishing gear can be really expensive for fishermen. Like crab pots can cost thousands of dollars. And so these are very valuable resources for fishers, and they’re expensive to replace.
But unfortunately, one of the challenges with fishing in turbid and wavy environments around storms, especially with things that are set, is that some gear does get lost. And we did see interactions and ingestion of fishing gear by many of these animals. And partially that’s because gear attracts prey species. So we know that for some animals, they’re more likely to interact with fishing gear, and this isn’t just ingestion, but also being entangled in fishing gear, because, you know, that gear is still fishing. And for a lot of these bigger species, fish are their prey, and so they’re also being drawn to these devices, or this lost gear that might have their food in it.
Mitch Ratcliffe 18:44
And your study didn’t look at the external plastic lethality, it was only that which was consumed. So we don’t really fully understand what the consequences of, say, for instance, a net lost at sea is for the ocean yet? Or do we?
Erin Murphy 19:01
Yeah, we have — there’s some studies that have looked at this, but this is actually another study we’re working on. So one of the next papers we’re working on right now is looking at entanglement lethality, and that really will be important for understanding the impacts of plastic pollution together, because ingestion and entanglement, when we talk about these bigger plastics, are the two main threats that we see.
Mitch Ratcliffe 19:24
I feel like we’ve got our bearings and can have a really productive conversation. But folks, we’re going to take a quick commercial break. We’ll be right back.
[COMMERCIAL BREAK]
Welcome back to Sustainability In Your Ear. Now, let’s get back to my discussion with the Ocean Conservancy’s Dr. Erin Murphy, who led a groundbreaking study about the lethal effects of macroplastics in sea life. Erin, nearly half the animals that you studied that had ingested plastics were already listed as threatened. Is plastic pollution accelerating extinction risk, and what species do you feel are most endangered?
Erin Murphy 20:03
Yeah, that’s a great question. Right now, there’s not a lot of research yet on population-level effects of plastic pollution, and our study is really helping build that information out. But it’s just very difficult to understand what’s happening to populations that often we have trouble studying in the first place.
Still, for many marine species, the IUCN Red List notes plastic pollution as a significant threat. Six out of seven sea turtle species are threatened. We saw really high ingestion rates for sea turtles. We know that 5% of the turtles in our data set died from plastic ingestion.
So I think there is a lot of evidence suggesting that this could be contributing to extinction risk. And there are some studies that look at very specific populations that we know are vulnerable, like the Hawaiian monk seal, that have found that plastic pollution is contributing to extinction risk.
And the hopeful piece in the Hawaiian monk seal case was actually that as communities started doing large-scale cleanup efforts in the Hawaiian Islands, they actually saw a rebound of that population. So again, just a reminder that even though we know that this is something that is posing a threat to marine species we really care about, it’s also evidence that targeted and effective intervention strategies can be really important in helping some of these species rebound.
Mitch Ratcliffe 21:34
That’s encouraging. So it isn’t as though we’re doomed, or that nature is doomed. We can intervene in our behavior today and make a change for the better in the future. How does the Ocean Conservancy encourage people to do that?
Erin Murphy 21:49
Yeah, so there was a study that we — some of us co-authored, and the Ocean Conservancy supported — that came out in 2020 that looked at what we would really need to do on a global scale to reduce plastic pollution in the ocean meaningfully enough to hit some of our potential targets. And in this case, we were thinking about just returning to 2010 annual leakage rates into the environment.
And what we found is that we really need sweeping change to our relationship with plastic and our waste management systems. And so we found that to achieve this goal, we would need a 40% reduction in plastic production globally. We would need waste management to reach levels of 98 to 99%, depending on the income of the country. And we would need, annually, 40% of waste that gets into the environment to then be cleaned up.
And at Ocean Conservancy, we really work on policy efforts in all three of those big buckets. And so we have the International Coastal Cleanup, but we also work on upstream policies with our policy teams at the sub-national, national, and international levels to try to work towards some of those goals of reducing plastic production and better managing the plastic waste that we do use.
Mitch Ratcliffe 23:10
You used the phrase “our relationship with plastic,” which is an interesting concept. In 2024, the New England Journal of Medicine reported that microplastics were found in human arterial plaque, and that resulted in much higher risk for cardiovascular events. Do you see what you’re studying as a parallel crisis, or the same crisis, just in a different species?
Erin Murphy 23:35
Yeah, I view that — you know, so they were looking specifically at microplastics, and we focused on macroplastics in this study. That being said, most microplastics that are in the environment are breaking off of these larger macroplastics. So in that sense, I do view this all as part of the same crisis, and I think we need to think about all of the harms that plastic materials are causing to human health, to animal health, and to sociocultural outcomes like our marine and terrestrial industries that are affected by plastic pollution, and we need to think about comprehensive policies that are addressing all of those harms.
Mitch Ratcliffe 24:17
Are there studies that are showing the same types of impacts from plastic in human and non-human species that we can use to start to tell the story in that same illustrative way that you did with the sugar cube analogy, so that people really take this seriously? I mean, the problem with our society is that we’re accustomed to throwing everything away.
Erin Murphy 24:40
Yeah, so there’s a lot of really great research that’s being done on microplastic exposure in other marine and aquatic organisms, and those are more similar to what’s happening in humans. But that human research, and the research on sort of sub-lethal microplastic risks — like the risks to cardiovascular systems, nervous system, gastrointestinal tracts — those are all pretty new, and so this body of research is really building, and I think we’re going to learn a lot in the next decade.
Mitch Ratcliffe 25:14
Do you see an acceleration of your ability to make those kinds of conclusions — well-grounded conclusions — emerging as a result of the advent of something like artificial intelligence? Are we at the dawn of a scientific revolution?
Erin Murphy 25:33
You know, that’s a good question. I don’t know in what ways AI will change the way that we’re doing research. Definitely, the rate at which we are producing research has increased. There’s more people working on these issues, and the scientific process is really just about iterating as a community and building on what we know. And so I think what we’re seeing here is a large-scale interest in this plastics issue and a big concern by the scientific community and by the public.
And as we learn more, we can answer more complicated questions. And so I was only able to do my work because over the last five decades, people have been studying what plastic is in the animals and reporting on that, and we have thousands of published papers now that tell us about what animals are consuming. And each one of those papers is really important in producing this bigger picture. And as we have, you know, similarly more studies on these sort of individual systems and humans, using model organisms like mice, we will be able to do the same sort of thing of painting this bigger picture for humans as well.
Mitch Ratcliffe 26:48
So as we get this higher-resolution view of what we’re doing, both to the planet and to ourselves, how does Ocean Conservancy potentially use those storytelling opportunities to get us to think about things like plastic bans, or the impact of extended producer responsibility on not just what ends up in the environment, but what we design so that it doesn’t end up in the environment in the future? It’s a big, complicated, multifaceted story. Where are we going?
Erin Murphy 27:17
Yeah, that is true, and I am not the policy expert at Ocean Conservancy, but the work that they do is amazing. And they, you know, they go and they talk to the public about these issues and educate the public through blogs and other resources to make sure that people understand the scale of the problem. And they work really closely with local decision makers who are interested in addressing these problems and help them develop bills, help them build support for bills. And, you know, we’ll meet with legislators and other leaders to help them kind of understand the reason that these policies are useful.
So Ocean Conservancy in the last 10 years has done a lot of work on state bills, like helping to push forward California’s SB 54, or specific bills that are targeting problematic plastics. Like recently, Florida passed a balloon release ban. Ocean Conservancy was also really involved in pushing that.
And I think we have seen with plastic pollution — what, for me, one of the things that’s most comforting in studying plastic pollution is actually that people do really seem to care about this issue and do seem willing to make change. So when people find out what I research — strangers — they always tell me about what they’re doing to reduce their plastic footprint, and I think that’s just a sign that there is appetite for change, and people want to understand how to do it. And as an organization, we’re just trying to leverage that passion and that stewardship that does kind of inherently exist in people, especially when they see the plastics that they’re using, and use that and sound science to help develop policies that can actually make a change on this issue.
Mitch Ratcliffe 29:06
Building on what you mentioned a moment ago, based on your findings about which plastics are the most lethal, it sounds like it’s a blend. But should policymakers prioritize specific materials, or just look at broad categories? No more of this type.
Erin Murphy 29:23
I think we need to do both. So we did find that different plastics pose different levels of risk, and I think there’s policies that are smaller and easier to implement, like balloon release bans and bag bans, that are effective in targeting some of these problematic plastics specifically. You know, using that Hawaiian monk seal example as well, having very targeted and strategic cleanups can be really important for protecting animals at sea turtle nesting beaches or seabird nesting areas. There’s these areas that we know are of particular importance for animals.
But still, the total plastic thresholds that we found were also low, and we see all types of plastics in these animals. So at the end of the day, there is too much plastic in the ocean, and we do need sweeping reforms along the entire plastics life cycle, from production to management to disposal, to meaningfully address this issue and protect our oceans.
And it takes longer to implement these policies because it does require some pretty extensive system-wide changes. But I think policies like California’s SB 54, which aims to reduce 25% of single-use plastics used, that’s really a step in the right direction. And so our policy team is on the front lines of making sure that that bill is fully implemented and that we understand the benefits of that policy by monitoring outcomes and effectiveness of it.
Mitch Ratcliffe 30:56
You mentioned earlier that on the International Coastal Cleanup Day, which is a distributed event all over the world but a day, they collected more than a million plastic bags last year. Is the goal in the long term to no longer need to do those cleanups? Or do you anticipate that we’re always going to be needing to do those cleanups?
Erin Murphy 31:18
Yeah, I think unfortunately, at this point, it’s hard to imagine a world where cleanups aren’t necessary. I think when we did that study in 2020, that was led by Lau et al., it was pretty alarming to see how much we would have to reduce plastic production and how well we would have to manage waste to no longer need cleanups at all, and we really did find that cleanups needed to be an important part of this solution.
And there’s already a lot of legacy plastics in the ocean. So I think as far as we can look forward, cleanups will always be an important part of the suite of solutions that we use.
They’re also really effective for monitoring what’s happening in our ocean. So I mentioned earlier that study that was published in Science that showed that plastic bag bans are effective. We were really excited to see that they actually used Ocean Conservancy International Coastal Cleanup data to do that analysis, and it really just emphasizes the value of citizen science. When you go out and collect data during a cleanup on your beach, we can see what changes occur through time in terms of what debris you’re seeing, and that helps us better understand whether it’s targeted policies or these broader policies, if they’re being effective or not.
Mitch Ratcliffe 32:42
What does the Ocean Conservancy do to help people do citizen science beyond the International Coastal Cleanup?
Erin Murphy 32:49
So that program has been going on for 40 years, and that’s really, in terms of citizen science, our main body of work. But we are interested in having citizens engage in other ways. So we often have — you can sign up for our newsletter and get information about opportunities to call your senators or write your senators or legislators about important ocean issues that are coming up.
And we also just have a lot of educational material so that people can start their own cleanup events, or find cleanup events to participate in, so that individuals can be engaged in being part of the solution.
Mitch Ratcliffe 33:31
You’ve mentioned a couple of items of research that you are beginning to pursue now. But if you had unlimited resources for the remainder of your career, what would you like to investigate and build on those findings with?
Erin Murphy 33:44
Yeah, it’s pretty hard to imagine unlimited resources, especially now, I know. But yeah, you know, we already started working on answering some of these next questions that are remaining for us, and I’m really excited about the work that we’re going to be doing over the next three to five years. And I will not be surprised if, you know, this body of work, trying to understand what’s happening to ocean animals, becomes a career-long question for me.
But in the short term, the things we’re really trying to get at is, first, that entanglement piece, which you mentioned — what is the lethality of plastic entanglement. And we also just launched a working group with scientists from all over the world to take what we have learned about the lethality of plastic ingestion and to build out, include what we are learning right now in our research about entanglement, and then bring in that exposure piece.
So that question you asked earlier about how much plastic is a puffin eating, how often does it have a lethal dose — that’s really what we want to get at. We want to know if we have an idea of what’s in the environment, how likely is that to have population-level effects for species? How likely are they to eat a lethal dose? How likely are they to die? And are we worried about populations because of this?
And right now, governments around the world are really trying to determine how to effectively address plastic pollution, and these sorts of comprehensive risk assessments are really helpful in setting targets. And so that’s really what I want to keep getting at: How can we take everything we know and help decision makers better understand, you know, a reasonable goal? Because a perfect goal is an ocean with no plastic, and I think we have to keep working towards that collectively. But it’s also really important to understand what species are being adversely affected and what we can do to immediately protect them now.
Mitch Ratcliffe 35:46
Well, it’s a multi-generational challenge, and I really applaud the work that you’re doing. How can folks keep up with the work that you’re undertaking?
Erin Murphy 35:55
Yeah, we have a brand new website at oceanconservancy.org, and we have a lot of information there, you know, specifically on what our plastics team is doing, but on what our entire organization is doing in terms of bills that we’re working on. They can also sign up for our newsletter to get information about what the organization is working on, and that will give them ample opportunities to participate in being part of the solution to the plastics crisis.
Mitch Ratcliffe 36:20
Erin, thanks so much for your time today. It’s been a fascinating conversation and an encouraging one.
Erin Murphy 36:26
Thank you. It was great to be here.
[COMMERCIAL BREAK]
Mitch Ratcliffe 36:34
Welcome back to Sustainability In Your Ear. You’ve been listening to my conversation with Dr. Erin Murphy, manager of ocean plastics research at the Ocean Conservancy, and she’s the lead author of the recent study published in the Proceedings of the National Academy of Sciences that quantifies, for the first time at this scale, how much plastic it takes to kill seabirds, sea turtles, and marine mammals.
You can explore the Ocean Conservancy’s wide-ranging work and sign up for a beach cleanup event at oceanconservancy.org. Ocean Conservancy is all one word, no space, no dash. Oceanconservancy.org.
The numbers Erin and her colleagues reported should stop us in our tracks. The volumes we heard about are disturbing, but imagine — one in five animals had plastic in their gut when they died. For sea turtles, it was one in two. What makes that study especially useful for policymakers is its differentiation by plastic type. Rubber fragments can be targeted because balloons are the deadliest material for seabirds. Soft plastics like bags are the top killer for sea turtles. Ghost fishing gear poses the greatest risk to marine mammals like whales. And each of these findings points to a specific, actionable policy lever: balloon release bans like Florida’s recent legislation, bag bans like California’s, and better gear-marking and recovery programs for the fishing industry.
But the targeted approach is only part of the answer. As Erin emphasized, the total plastic thresholds her team found were low across the board, meaning that every type of plastic poses a threat. “At the end of the day,” she said, “there is too much plastic in the ocean, and we need to do sweeping reforms along the entire plastics life cycle, from production to management to disposal.” That’s a very important quote. Keep it in mind.
A 2020 Ocean Conservancy-backed study quantified what “sweeping” means: a 40% reduction in global plastic production, waste management reaching 98 to 99% effectiveness in its collection and processing of plastic so it doesn’t reach nature, and annual cleanups of the 40% of plastic that still escapes into the environment — and that’s just to return to the 2010 leakage rates.
So that brings us to the elephant in the room — or maybe more to the point, the sperm whale with an entire greenhouse in its stomach — the global plastics treaty negotiations. Which were supposed to deliver a binding international agreement, collapsed in August 2025 in Geneva after oil-producing nations blocked provisions that called for production caps and toxic chemical phase-outs. More than 100 countries in the group known as the High Ambition Coalition were pushing for full life-cycle regulation for plastics, but the requirement that the negotiations reach a consensus gave a handful of petrochemical states an effective veto power. And effective it was.
So between the Busan round in late 2024 and the end of the Geneva talks in 2025, an estimated 7.4 million more metric tons of plastic entered the ocean. The world currently produces more than 460 million metric tons of plastic annually, and only 9% of that is being recycled. Every day, the equivalent of 2,000 garbage trucks of plastic is dumped into our oceans, rivers, and lakes.
However, the collapse of the treaty talks does not mean the end of progress. Erin pointed to evidence that targeted interventions can work. For example, communities in Hawaii conducted large beach cleanups and saw the Hawaiian monk seal population rebound. A study published in Science confirms that bag bans reduce plastic on beaches by between 25 and 47%. California’s SB 54 law aims to cut single-use plastics by 25%. And Ocean Conservancy’s International Coastal Cleanup, which is now in its 40th year, removed more than a million plastic bags from beaches last year. That cleanup data, collected by citizen scientists worldwide, is a research tool providing the time-series evidence that tells us whether policies are working.
So here’s what I want you to leave with from this conversation. Erin’s research focuses exclusively on acute mortality from ingested macroplastics — that’s obstruction, perforation, and torsion of the digestive tract. It does not capture the chronic effects of plastic and chemical exposure or entanglement, which her team will study next. That means the lethal thresholds that she reported likely underestimate the total harm plastic inflicts on marine life.
And the parallel crisis in human health is building from the same source of pollution, which has scattered microscopic shards of plastic across the planet, from the seas to the highest peaks. Most of these microplastics began as macroplastics, like those that are killing puffins and turtles. They break down in the environment into fragments small enough to enter our bloodstream, lungs, liver, and even women’s placentas. As Erin put it, it is all a part of the same crisis.
So one of the most encouraging things that Erin said was also the simplest. When strangers learn about what she studies, they stop and they tell her what they are doing to reduce their plastic footprint. That instinct to environmental stewardship is a real and powerful phenomenon, even if it’s currently being actively suppressed by governments. And the public’s will to protect nature is the foundation that policy, science, and investment will ultimately build on.
The ocean doesn’t need our sympathy. It needs a 40% cut in plastic production, waste systems that actually work, and the political will to treat a binding plastics agreement as a matter of human survival rather than an inconvenience for a few petrochemical companies. Until international negotiations deliver that agreement, the work continues at every other level: state legislatures, coastal cleanups, citizen science, and research programs like Erin’s that give decision makers the evidence-based targets that they’ve been asking for.
So stay tuned, folks, for more conversations about the solutions that can still turn this crisis around. And I hope you’ll take a moment to take a look at any of the more than 540 episodes of Sustainability In Your Ear in our archives. Take the time to share just one of them with your friends or your family. Writing a review on your favorite podcast platform will help your neighbors find us. Folks, you’re the amplifiers that can spread more ideas to create less waste. So please tell your friends, family, and co-workers they can find Sustainability In Your Ear on Apple Podcasts, Spotify, iHeartRadio, Audible, or whatever purveyor of podcast goodness they prefer.
Thank you all for your support. I’m Mitch Ratcliffe. This is Sustainability In Your Ear, and we will be back with another innovator interview soon. In the meantime, take care of yourself, take care of one another, and let’s all take care of this beautiful planet and its oceans. Have a green day.
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It always strikes us as amusing how many DIY projects you see online that seem to require more time and more money than it would take to simply buy the thing they’re trying to DIY in the first place. Are we missing the point?
We think that doing things ourselves and taking back the power to create instead of simply consuming is absolutely vital to the green movement. But if you don’t already have the materials and spend a lot of money purchasing craft supplies, does it really make sense to DIY?
These eight projects are true do-it-yourself masterpieces. One-of-a-kind outdoor projects you can make for almost nothing, with supplies you most likely already have or can easily pick up second hand for a song. Roll up your sleeves and let’s get started!
1. Teapot/Teacup Bird Feeder
Do you have one of Grandma’s old tea sets lying around that doesn’t quite fit into the sleek modern aesthetic you’ve been cultivating? Put it to great use by feeding the birds in your area — in style.
Thrift stores are always awash in old china, so if you don’t already have the old tea set, consider going wild and spending a few bucks for this DIY delight. You’ll find blogger Dinah Wulf’s instructions for the teacup bird feeder at DIY Inspired.
Safety note: Use sturdy twine or cord — not chain — to hang the feeder. Birds can catch their toes in chain links, which causes serious injury. The National Audubon Society also recommends cleaning seed feeders every two weeks (more often in hot, humid weather) by scrubbing with soap and water and soaking in a 50-50 vinegar-water solution to prevent the spread of avian disease.
2. Gardening Tool Storage
What on earth do you do with those rusty-as-heck, old-school garden rakes hanging around your garage? Well, if you’re any sort of DIY genius, you press them into service as a gardening tool holder.
The original inspiration for this project came from Beth Logan at Artstuff Ltd., whose blog has since gone offline. For a current walkthrough, see the Repurposed Rake Tool Rack tutorial at DIY n Crafts (project #14 in their roundup of 25 ways to reuse old garden tools). The concept is embarrassingly simple — remove the rake handle, mount the head tines-out on a fence or garage wall, and use the tines themselves as hooks for trowels, gloves, and pruners — but eye-catching enough to make you look like a DIY pro.
3. Bottle Tree
Do you like wine? No, I mean do you really like wine? Do you want a reason to drink more of it? And does your garden need a cute border? This sustainable, upcycled garden border may be just the project for you. You might have to expand your drinking list to include bottles of various shapes, sizes, and colors — but variety is the spice of life.
When friends ask how you managed to collect so many bottles, just laugh gaily and then distract them with your dainty teacup bird feeder. The bottle tree tradition itself runs deep — Mississippi garden writer Felder Rushing traces the practice back through African American Southern folk art and, by his own research, as far as ancient Egypt and Mesopotamia. See his bottle tree gallery and history for inspiration, or jump straight to his how-to guide for building one out of a cedar snag, rebar, or just about anything else.
4. Colorful Outdoor “Tiles”
If your backyard isn’t perfectly landscaped and manicured, with an impeccably tiled “outdoor living space,” don’t despair. You can use up all those half-empty paint cans and create a Pinterest-worthy colorful backdrop for evenings spent clustered around a fire or barbecue.
Pop a few coats of paint on cement tiles and you have a one-of-a-kind flooring solution. If you rent, the same effect could be achieved on a more temporary basis by letting the kids go wild with sidewalk chalk and create a mosaic masterpiece. Check out Elsie’s Painted Patio Tiles at A Beautiful Mess for the back story on this DIY idea. (Heads up: the original author noted she had to touch up the paint each spring in Missouri winters — a porch and patio floor enamel will hold up better than wall paint.)
5. Home Sweet Gnome
Okay, this one might be the least practical idea of the bunch, but that may be why I love it oh so much. If you have a stump in your backyard and you’re not willing or able to pay the truly insane amount it costs to have it ground down and removed, how about making it into a little gnome home? This is the perfect outdoor project if you have small children in your life.
Construct the trappings of a little house — door, windows, winding garden path — from found objects or natural materials, and affix them to the stump. Bonus points if you don’t tell the kids about this particular DIY project and allow them to simply stumble upon it one day in the garden. My mind would have been blown if I had come across one of these as a seven-year-old. For a step-by-step build, see this Gnome Tree Stump Home tutorial on Instructables.
Safety note: Don’t use an angle grinder to gouge windows or doors into a stump. Use a chisel and mallet for shallow detail work, or attach decorative pieces (driftwood, bark, polymer clay) to the outside instead.
6. Mosaic Stepping Stones from Broken China
Every household eventually accumulates a small graveyard of chipped mugs, a single survivor from a four-piece dinner set, or a beloved teapot with a hairline crack. Rather than tossing them — broken ceramics generally aren’t accepted in curbside recycling — embed them in concrete stepping stones for a garden path that’s genuinely one of a kind.
This pairs beautifully with the teacup project above: any teacups that don’t make it past Project #1 (you will break a few) can come back as paving. The DIY mosaic stepping stones tutorial at Gardening.org walks through the full process — breaking ceramics safely inside a drop cloth, sizing pieces to half-inch to one-inch fragments, pressing them into wet concrete, and sealing the surface so sharp edges don’t cause injury underfoot. Basic mold options include an old cake pan, a plastic plant saucer, or a purpose-built stepping stone form from a craft store.
Safety note: Wear safety glasses and heavy gloves when breaking ceramics. Once cured, run a finger over the surface to check for protruding edges and file or sand any down before placing the stone where bare feet might land.
7. Vertical Pallet Herb Garden
Shipping pallets are one of the world’s most abundant near-free materials. Small businesses, garden centers, and feed stores often have stacks of them out back, and asking politely beats the alternative of seeing them landfilled. Mounted vertically against a sunny wall or fence, a pallet becomes a stacked planter that holds enough herbs to keep a kitchen in basil, thyme, parsley, and chives all season.
Grit Magazine published a clear how-to for a vertical pallet planter — line the back and sides with landscape fabric or heavy plastic to hold soil, fill through the slats, and plant each gap as its own row. The gaps act as natural divisions, so different herbs don’t fight for the same root space.
Safety note: Use only heat-treated pallets for anything edible. Look for the IPPC stamp with the letters HT (heat treated) and avoid any stamped MB (methyl bromide — a fumigant restricted under the Montreal Protocol). Unstamped pallets are unknowns; skip them for food crops. The same heat-treated pallets are fine for ornamental flowers either way.
8. Punched Tin Can Lanterns
Steel food cans — soup, tomato, coffee — are one of the most recyclable materials on Earth, but the recycling-then-buying-something-decorative loop has plenty of slack in it. With nothing more than a hammer, a few nails of varying sizes, and the freezer, an empty can becomes an outdoor lantern that throws constellation patterns across a patio at dusk.
HGTV’s tin can lantern tutorial covers the trick that makes this project work: fill the can with water and freeze it solid before punching, so the ice supports the can wall and prevents denting. Sketch your pattern on paper, tape it to the frozen can, punch through with a nail at each marked dot, and let the ice thaw. Drop in a battery tealight (much safer outdoors than a real flame) and group them along a walkway or down the center of an outdoor table.
The Point of All This
None of these projects requires you to buy more than a tube of waterproof adhesive, a bag of concrete, or maybe a stepping stone mold. The materials — chipped china, leftover wine bottles, empty cans, a forgotten pallet, an old rake — are already in your house or someone else’s. That’s the point. The greenest project is the one that uses what already exists, and the best part is that yours will look like nobody else’s.
Editor’s Note: This article, originally authored by Madeleine Somerville on June 17, 2015, was updated with corrected links and new ideas in May 2026.
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More than half the world’s population—4.4 billion people—live in cities today. That number is expected to rise to 80% by 2050. Our guest, Nadina Galle, is a trailblazing ecological engineer and author of The Nature of Our Cities. She is an ecological engineer who studies the intersection of nature and technology in urban environments. Nadina developed the concept of an Internet of Nature (IoN) that uses tools like artificial intelligence, automation, and sensors to support and enhance ecosystems within cities. Nadina’s book offers a transformative perspective on how urban spaces can be reimagined in the face of climate change and sprawling development. She shares the inspiring story of the Groene Loper project in Maastricht, Netherlands, where soil sensors were deployed to monitor tree health. The results were remarkable, with trees supported by this technology growing up to three times larger than those without it. This is a powerful example of how technology can not only protect trees but also transform urban spaces into healthier, greener environments.
From fire and the wheel to the reinforced concrete frames that define modern buildings, we are surrounded by technology. We tend to forget that technology emerged in response to nature — too often, we treated nature as the enemy, the chaos to be contained instead of recognizing that nature’s cycles and changes are the harmony we need to join to sustain society. The loss of any semblance of natural patterns, which ultimately leads to the depletion of the resources necessary for life, has inevitably led to the collapse of previous major civilizations. Modern society has more runway than previous societies because we have created a global economy, but that risks an even greater fall for our species when the ecological underpinnings of our prosperity collapse. The Nature of Our Cities, is a powerful, straightforward, and emotionally resonant book to help you think through your role and choices in the restoration of nature. You can find it on Amazon or Powell’s Books.
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Editor’s Note: This episode originally aired in December 2024.
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Interview Transcript
Mitch Ratcliffe 0:09
Hello, good morning, good afternoon, or good evening, wherever you are on this beautiful planet of ours. Welcome to Sustainability In Your Ear. This is the podcast conversation about accelerating the transition to a sustainable, carbon-neutral society. And I’m your host, Mitch Ratcliffe. Thanks for joining the conversation today.
Americans throw away roughly 100 billion plastic bags a year, and most curbside programs won’t take a single one of them. Plastic film, those bags, the pallet wrap in the back of the stores, the bubble mailers, the dry cleaner sleeves, the overwrap on a case of bottled water — all of this has been the recycling industry’s white whale for decades. It jams machinery at materials recovery facilities, contaminates other waste streams, and ends up in landfills and oceans, and increasingly that plastic, especially microplastic, ends up in human tissue.
Meanwhile, the lumber industry sends sawdust to landfills by the truckload, and old orchards full of dying trees become a disposal problem for farmers. Two waste streams nobody wants, generated at industrial scale with very few takers. But more than 30 years ago, a small company in the Shenandoah Valley of Virginia looked at both of those streams and saw raw material. Today, that company has upcycled more than 5.5 billion pounds of waste plastic film and sourced over a billion pounds of waste wood in 2024 alone, and as a consequence, they’ve built one of the largest plastic film recycling operations in North America, all in service of making something as ordinary as backyard decking.
The deck happens to last about 25 to 50 years, requiring no staining, no sealing, and competes head to head with pressure-treated lumber on a price and performance basis. The sustainability story isn’t a marketing layer on top of the product, it is the product. And we’re talking about Trex, Trex decking.
Our guests today run two of the most consequential functions inside Trex. Amy Fernandez is Senior Vice President, Chief Legal Officer and Secretary, and Chief Sustainability Officer at Trex Company Incorporated, the world’s largest manufacturer of wood-alternative composite decking and railing. She holds the unusual combination of legal and sustainability oversight at a moment when these two domains are converging fast, with the IFRS Sustainability Disclosure Standards, California’s climate disclosure laws, and the SEC’s evolving stance all reshaping what public companies must say about their environmental performance. In 2024, Trex indexed its sustainability report to the IFRS standards before being required to, which tells you something about how Amy thinks about the relationship between disclosure, governance, and competitive position.
She’ll be joined today by Zachary Lauer, who is Senior Vice President and Chief Operations Officer at Trex, where he oversees manufacturing, supply chain, engineering, and research and development. His teams run plants in Virginia and Nevada, and they’re bringing a major new facility online in Little Rock, Arkansas, having built the operational machinery that turns approximately 95% recycled and reclaimed content into a product that has to perform outdoors for half a century. The R&D side of his portfolio is where Trex has cracked feedstock streams that other recyclers can’t process, including industrial film trimmings, end-of-life packaging from food and chemical manufacturers, and dunnage returns from distribution partners. All this work happens at the intersection of material science, logistics, and the unglamorous reality that recycled inputs don’t behave like virgin ones. It’s more expensive sometimes to recycle this stuff.
We’ll talk with Amy and Zach about how Trex actually makes its products, where the materials come from, and what it has taken to build a national feedstock network through the NexTrex program, a collection program spanning more than 10,000 retail drop-off locations and nearly 1,000 schools and community organizations. We’ll dig into a harder question, too: why Trex’s absolute emissions rose alongside production growth in 2024, and what the company is doing about end-of-life recycling of Trex boards now that the first generation is reaching replacement age, and what other manufacturers can learn from a company that is building a recycling infrastructure before there’s a market to feed it.
To learn more about Trex and its sustainability work, visit trex.com. So, circularity is a word that gets thrown around a lot these days. Trex was practicing it before the word existed. Let’s find out what three decades of doing that work has taught Amy Fernandez and Zach Lauer, right after this.
Welcome to the show, Amy Fernandez and Zachary Lauer. How are you doing today?
Zachary Lauer 4:54
Doing great.
Amy Fernandez 4:55
Great, great. Thank you, Mitch.
Mitch Ratcliffe 4:57
Well, thank you for joining me. And Trex does such interesting work. I mean, you were demonstrating what circularity means before the word had any cultural traction. I know you weren’t there at the beginning, but was this framed internally as an environmental project or as a sourcing strategy? Just the recognition that there was this massive volume of feedstock there that could be used.
Zachary Lauer 5:16
It was initially an environmental initiative by our founder, Roger Wittenberg. You know, he was bothered by the fact that there was no way to recycle or reuse his bread bags, and he wanted to formulate a product of value from that. He went through a couple of iterations and partnered with some other people, and they decided to turn it into composite decking and market it that way. Ever since that, it’s been part of our DNA, and we were always looking to extract value out of waste streams, you know, that aren’t currently used, and we continue to develop the next generation of materials out there that we can extract value from and create a great product from.
Mitch Ratcliffe 6:09
These days — just last week, a couple of weeks ago, we talked with the CEO of Emerald Packaging, who’s also looking for recycled PE to use in their products. There’s competition for this feedstock now. How has that changed the way that Trex organizes its efforts to collect and bring this to the three different locations you manufacture the decking?
Zachary Lauer 6:30
So, you know, with opportunities and growth in this space, one of the things that has developed over time, over the last 10 to 15 years, is the growth in the availability of recycled polyethylene films from distributors. Right, as Amazon grows and direct shipments to homes grow, the materials that are used continue to expand. So that’s opened up markets for increased stretch film and those types of materials. But as those markets grow, we often go deeper and deeper into the stream, more contaminated into the stream, to go after material streams that most people can’t deal with or process.
Mitch Ratcliffe 7:17
Well, one of the benefits of this kind of recycling is that you don’t have a lot of health-quality, you know, food-contact kinds of restrictions, and so forth with the plastic. You mentioned contamination. Just how contaminated can the loads be for Trex in order to make a viable product?
Zachary Lauer 7:36
We grade our materials on a scale of 5 to 15% contamination. We can go deeper than that. The contamination that we typically find in our streams are metals, non-ferrous metals, other forms of plastic, polypropylene, polystyrene, and those types of material, paper, cardboard. And so we’re able to design processes that can accommodate those and process those materials. Out-sorting is still critical to the long-term viability.
Amy Fernandez 8:10
Oh, yes. And we can go more contaminated depending on what that contamination is. So if it’s paper, we can handle more of that. If it’s metal, it’s a bit harder to handle. So the type of contamination also matters in terms of, you know, at what level we can accept that contaminated poly.
Mitch Ratcliffe 8:31
Amy, the 2024 sustainability report describes the program as a win-win for both business and society at large. As we all know, we live in a time where that’s a contested idea — that sustainability is a good thing for the economy. What’s the most concrete way that you explain or demonstrate that the business case and the environmental case are genuinely the same for Trex, that this is an inseparable configuration?
Amy Fernandez 8:58
Yeah, you know, a really good example was our last earnings call. And during that call, you might have heard our CFO started talking about the price of PVC and virgin materials and the volatility associated because of their connection to oil. So that’s one very recent concrete example of the fact that, because our material is this poly that we recycle, we’re not as exposed to that volatility that you might get from those virgin streams. And so that is truly one of those competitive advantages that we have — that we recycle this material, and we can make a beautiful, well-performing product out of it. That is the business case. So you see it through these little examples.
Mitch Ratcliffe 9:51
So in an era of reshoring, you’re actually in a position to be even more competitively advantaged.
Amy Fernandez 9:56
Yes.
Mitch Ratcliffe 9:58
Amy, you stepped into the CSO role while also serving as Chief Legal Officer, and that’s a combination that’s becoming more common as sustainability disclosure is shifting from voluntary to regulated. How has all of the upheaval in the regulatory environment that we live in changed Trex’s approach over the past year or two in terms of what you report and what you tell customers?
Amy Fernandez 10:19
Trex has always been a highly ethical company, and so we do what’s right. And if you’re founded in doing the right thing, you’re not as subject to these whims of, you know, what’s happening either politically or, you know, with changes with government regulations, things like that. And so because we’re grounded in this reality of, we’re not going to go out there and start talking about targets that we don’t think are achievable — so when it was, you know, common to start saying “by 2030” or “by 2050” or whatever dates companies were out there saying “we’re going to get to this target” without actually having a plan to get there, Trex would never do that.
And so one of the things that you would see is that we get asked questions: “Why don’t you have targets?” And it’s because our target is to continuously keep improving from a very solid base that we have, but we’re not going to put an unrealistic number out there just to try to get points. So the regulatory changes don’t affect us as much when we start from that just basic ethical “do the right thing, disclose important information that we think our investors, our communities, others want to see, want to know that is true and not misleading in any way.”
Mitch Ratcliffe 11:39
From a marketing perspective, saying that you live by a higher standard is pretty effective. Do you think it’s necessary to be a lawyer to be a chief sustainability officer these days?
Amy Fernandez 11:49
No, not at all. And actually, I think the only reason that we did decide to put it this way — yes, of course, I do have the regulatory mindset, but I also have a passion for this, right? I mean, I joined this company because it is something that is important for me personally. And so the chief sustainability officer could have lived in other places and just been informed by legal the way that I inform other functions in this company. But I basically raised my hand for it and said, I think it lives well here, and I have a passion for it.
Zachary Lauer 12:22
It resided in other areas in our business as well, right, under other people that have that same passion.
Mitch Ratcliffe 12:29
So, Zach, what happens between the time when a plastic bag is dropped at one of the 10,000 grocery stores that collect bags and a finished Trex board leaving the factory? Can you walk us through that process?
Zachary Lauer 12:40
Yeah, you’ve kind of highlighted the ends of that value chain, right? From the pickup to the actual product that goes to the customer. We actually have over 15,000 collection points across this country that come back to centralized collection points, and then actually make their way to our recycling facilities, where the cleaner films are put directly into our production lines, and the more contaminated films go into a reprocessing operation that turns it back into a pellet.
But the most challenging engineering point for us in this entire value chain is actually at the extrusion production line, and managing variation in the streams. We call it recipes, and we have a rolodex of thousands of recipes that can be used in the production process. I liken it to a cooking analogy. Today we’re baking with wheat flour, and tomorrow we might be baking with almond flour.
And so we’ve used a lot of technology to help us — machine intelligence, artificial intelligence — to help us manage those recipes. And not only does it help us manage the streams coming into the production lines, those raw materials, but then it modifies the process parameters, the cooking temperatures, and the speeds in order to process those streams. So that’s where the complexity is for us.
Amy Fernandez 14:14
We design our own equipment. And I mean, we don’t — you can’t just buy this equipment from equipment manufacturers. So being able to design and set up this equipment to be able to process this changing raw material stream continues to be one of our areas of excellence.
Mitch Ratcliffe 14:35
That’s fascinating. The idea that if you had a different kind of fiber, for instance, coming in — you brought in a chipped orchard as a source — that you’d have a different recipe, but you’re producing a product that is consistent in its standards and specifications. That’s, I mean, Zach, that’s got to be very complicated. You mentioned AI. Was this possible before AI, or slower before AI?
Zachary Lauer 14:57
No, we still did it, but we had to program a lot more, right, and program the intelligence on the line a lot more. It’s just becoming more rapid as we can read those streams and read the variation in line. It just makes that reaction quicker and faster for us on those production lines to do that. But no matter what our recipe is for the day, to your point, Mitch, it comes out a consistent product at the end.
And it just shows that we design our product around variability. Whereas most people focus on reducing variation in their raw material streams, we’ve designed our whole manufacturing process around being flexible and adapting to material streams — not only the ones we use today, but the ones we’ll use in the future.
Mitch Ratcliffe 15:51
The other area where you’ve got that kind of volatility is in the volume of recycled polyethylene that you’re bringing in. You had a big year in 2022; it went down by almost 100 million — excuse me, 100 million pounds — the next year, and then recovered, not quite back to the 2022 range, in ’24. What’s behind that volatility? Is it competition for feedstock? The fact that retailer collection participation changes? The contamination rates?
Zachary Lauer 16:20
A lot of things go into it. But what I tell people is, don’t equate our collection volume to our consumption volume. You know, one of the unique challenges about being a recycler is the fact that it’s a winner-take-all market. When you pick up an account, maybe a large grocery store, it’s like picking up the trash — you have to be there and you have to collect it regularly. Service is key. So there could be times when there is more availability or more collection in a period, and you have to accept it.
So how we manage that volatility, or, you know, the changes that can occur from year to year or season to season, is we do a very good job of long-term demand and supply planning in this space, and combining that with our space planning, and then we kind of layer in anticipated regulatory, market, and consumer preference changes into that. And so there could be a period where we see maybe a deficit or a surplus, and we will go in and consume that and store it for a future period, or there just could be a surge in a particular market where there’s the availability and you just have to be willing to take it. And that’s difficult to absorb — those huge swings like you mentioned — into your supply chain without having a plan.
Mitch Ratcliffe 17:55
You just said “as a recycler,” but should we be thinking about this in general as simply part of the manufacturing process — going back to onshoring and keeping more materials in country and reusing them across a wider variety of production streams? How does Trex think about organizing the wider material flow rather than recycling programs in the United States? What have you learned that we should be applying as a nation?
Zachary Lauer 18:23
You know, I think you have to be intentional if you’re going to enter into a stream where you’re going to recycle or pull materials out there. We’ve focused our effort on North America, right? And we do take collection from other areas, but it’s rare. And we adapt our collection based on changing preferences. So, Mitch, what I mean by that is, you know, one year we could be doing a lot of store collection or distribution collection, but then all of a sudden in a region of the country, regulation changes, or things change, and we go more to the recyclers for our material.
We continuously monitor and adapt to the changes that we see there, because our desire is to keep our supply chains as close to our factories as possible. We bear the cost of the freight, right? And we bear the entire cost of the supply chain. We develop the supply chain, and so we’re continuously looking at ways to optimize that and keep our costs manageable.
Mitch Ratcliffe 19:34
As you say, you’ve built this vast alternative collection system — 10,000 retail drop-off locations, you’ve got 84 grassroots community partners, there’s 936 schools that were involved as of 2024. What strategies did you have to develop in terms of communicating to the public what they should put in those bins at stores so that you get a clean load? And does that actually impact the quality of the materials you receive?
Zachary Lauer 20:02
It does. From our foundation, education has been key, right? So this has been a marketing and supply chain integrated strategy from the very beginning. And so we utilize things like our NexTrex program to educate students, to educate communities, and motivate them to recycle and incentivize them to recycle. But we’ve also at the same time incentivized our value chain or our supply chain to collect and be a part of it.
And some of that education is based on teaching people what can be used and how it can be used, and to let them know it’s actually being turned into a product that they can later consume and use. But we also come alongside other businesses to support their environmental sustainability goals as well. Most of our partners want to do the right thing too, and sometimes it only takes a little bit of incentive to get them to participate in this program that we have.
Amy Fernandez 21:09
And Zach, why don’t you add also a little bit about the logistics piece of this, because — so you talked about marketing and supply chain, but part of the supply chain was the logistics with the trailers and how we track them, and time them, and send them out at appropriate, you know, to basically maximize our efficiency in getting the materials.
Zachary Lauer 21:30
Yeah. So we also help our supply chain collect this material. We provide those that are willing to collect with balers to bale this, so that we’re efficient in hauling materials back. We also are very good at calculating what collection will be like in certain areas, and where to leave trailers, and where to incentivize them to backhaul to certain locations.
Right, the grocery stores, for example, they’re backhauling anyway to their warehouses — corrugate, all these other materials — so we take advantage of that backhaul to get to their distribution centers, and then collect from those points where they can fill a trailer within a couple of days. And we manage that entire network of trailers and supply chain, and we ensure that they’re weighed out before they hit the road, so that we’re optimizing the cost of bringing those materials in as well.
Mitch Ratcliffe 22:36
Does that mean that you generally collect this material at a lower rate than most of the industry could possibly achieve at this point?
Zachary Lauer 22:43
That’s correct. Because we’re getting it directly from the source versus maybe through a waste collector or a municipal recycling facility where it’s already been handled a couple of times, and the cost could be higher.
Mitch Ratcliffe 22:59
Amy, it doesn’t sound like it, but I want to ask about this — do the partners also come to you asking about getting credit for this, ESG credit, carbon credits, and so forth? Are you starting to hear that kind of conversation about how we can create further incentives within the collection economy?
Amy Fernandez 23:17
So we’re not starting to hear that yet, unless it’s come through Zach’s team. But as far as I know, we’re not hearing that. We are, though, starting to explore, for example, those companies that do want to say that their plastic is recyclable, because, as you know, all these regulations are coming out around that. If they want to put, for example, the NexTrex logo on there, and can assure that we’re picking it up. If we pick it up, it gets to our manufacturing site. So people that have put those trackers and things like, “Is my bag actually going to get where it’s supposed to go?” — we find them, they get to us. And so that’s part of it, is to support their recycling claims. We’re starting to get some questions and conversations about that.
Zachary Lauer 24:04
The other incentive too, Mitch, is for a lot of these individuals: they have their own goals, and one of those is to minimize what goes to the landfill. And so they’re also incentivized to not throw it away, and so we can help in that process too — we can help meet that need.
Mitch Ratcliffe 24:25
I know neither of you is in the marketing organization, but when people encounter a Trex deck, do you want them to think about the fact that it’s recycled? Do you want them to identify with the circular process?
Zachary Lauer 24:36
We do, and it is meaningful to the consumer. You know, if you were to have asked that question when I just joined Trex — and I’ve only been here 10 years — that, you know, that may have been, you know, it was still in the top 10 of the consumer preference, but it was around eight or nine. That continued to climb up the ladder, and it is in the top five of what the consumer is looking for when they’re looking for a product.
It’s a luxury product that lasts an extremely long time, and they can feel good about the product that they’re purchasing when they do it. And Trex obviously leads in this space with our recycled content on our decking products.
Amy Fernandez 25:27
We still start with performance and aesthetics, but sustainability is right there, right along with it.
Mitch Ratcliffe 25:35
I have to admit, I do stand on my deck and think about the fact it’s recycled. This is a great place to take a quick commercial break, folks. We’re going to be right back to continue this conversation. Stay tuned.
Welcome back to Sustainability In Your Ear. We’re talking with two of Trex Company’s leadership team: Amy Fernandez, she’s Chief Sustainability Officer, Chief Legal Officer, and I’m forgetting one other at Trex, and Zachary Lauer, who’s Senior Vice President and Chief Operations Officer. We’re talking about how Trex has built one of the largest recycling systems in the United States to source materials for its composite decking products.
Amy, Trex in 2024 decided to embrace the IFRS Sustainability Disclosure Standards, which were not mandated by the federal government as a requirement. What drove that choice? Why are you getting ahead of the game?
Amy Fernandez 26:30
There’s a big difference between complying when you’re required to comply and adopting best practices proactively. And in looking at the IFRS disclosure standards, it is a best practice. It’s benchmarking using globally consistent frameworks. It’s, you know, well recognized. It is a good-faith process that shows rigor. And so we’re not going to wait for a US regulation to force us to do something when, again, like I mentioned before, it’s just the right thing to do, and it’s a good framework, because it’s recognized globally. So although we are a US company, we do still have, you know, investors, customers, and others globally that are connected with Trex, so we want to be able to reach them.
Mitch Ratcliffe 27:23
Did taking that higher road require more work? Were there things about your business that the IFRS framework forced you to confront and address that you wouldn’t have otherwise? And this obviously would be of interest to other companies that are thinking about whether or not to pursue them.
Amy Fernandez 27:42
Well, we are looking at some of the gaps in there, right? So our scope three, for example, we’re working on that now, and we’re going to get limited assurance from some auditors just to start. That’s something that isn’t required yet in the US, but under IFRS it is a best practice. So we’re starting to work on that now, because that is one of our gaps with alignment to that framework.
And then the other piece of this too is the rigor around any financial planning related to sustainability risk. So by doing that benchmarking, we were able to identify where we have maybe some best-practices gaps — not regulatory gaps, of course, because we’ve already talked about, this isn’t required — but best practices. And what do we want to start doing, and what might be helpful for everybody that’s looking at Trex, right? Our employees, our prospective applicants, our investors and our communities. So that is part of what we’re finding from this exercise.
Mitch Ratcliffe 28:43
I also noted that Trex’s scope one and two emissions — you mentioned scope three a moment ago — have risen about 17%, partly due to greater volume and partly due to greater energy use. As you grow as a business — and this is one of those challenges that I think the sustainably-minded confront, which is, these companies are going to produce more carbon but less carbon relative to other alternatives — how do you talk to investors and within the organization itself about that rising net impact, and how do you rationalize that given your desire to reduce environmental impact?
Amy Fernandez 29:25
Yeah. You hit the nail on the head, right? When we bring on more production lines — so we did bring more on in ’24 than what we had in ’23, which accounted for a big portion of that increase that you saw in ’24. And then we also, by adding Little Rock, the Little Rock plant into the network — although we don’t have production there, we’re still using energy while we’re, you know, bringing it up. And so you’re absolutely right that because we are running more, that is going to require more energy.
But we’re trying to improve our efficiency of what we’re using. We’re also looking at our network and the grids and the energy available across Nevada, Arkansas, and Virginia, because they’re not all the same. So we’re going to start looking at where we can optimize that as an entire network. And, you know, just be working on that equipment that we talked about earlier that we design ourselves — what else can we put in there in order to reduce the energy use there?
Mitch Ratcliffe 30:28
Zach, what are the carbon intensity goals? I know you don’t necessarily state public goals, but how do you work toward reducing carbon intensity as a continuous improvement operation?
Zachary Lauer 30:39
So we’re always looking at how we’re manufacturing, and throughout the entire supply chain how we’re — I mentioned before, are we getting the maximum weight per load that we’re hauling? And on a per-pound basis of raw materials, we will actually, Mitch, fine or reduce the cost of what we’ll pay if the loads aren’t maximized and optimized.
But when we look at our manufacturing, we want it to be the lowest possible consumption of energy, because energy is expensive, right? And we want to be as efficient with that equipment as possible. Technology is going to continue to help us get there with that. But also, we drive our facilities off of manufacturing efficiencies, and our goal every year is to keep on getting faster, better, and higher, so that content per pound, that content per linear foot — because it is better and better every year. And that’s a focus for us.
Mitch Ratcliffe 31:41
When you enter a new location like the Little Rock plant that you’ve launched, which is purportedly — I haven’t seen the results yet, but supposed to drive 7.4 million kilowatt-hours in annual energy savings and reduce the use of water through a closed-loop recycling system — how do you decide what efficiency investments are going to pay back fast enough to justify the initial investment?
Zachary Lauer 32:05
Well, you know, not everything we do has a great — you know, our goal is for everything we do to have a great return on invested capital, but there are some things that you do just because it’s the right thing to do. One of those areas that’s difficult to get tremendous payback on is water, right? Water is generally still relatively inexpensive in this country. Now, we all know that water is becoming more and more of a challenge.
But a lot of what we do is not just motivated by the return on invested capital, it’s that we’re motivated by doing the right thing. Our employees live in the communities that we operate in. They take a lot of pride. A lot of people come to work for Trex for what we’re doing. Our brand equity is enhanced by what we do and how we go about doing it — not just what, but how we go about doing it.
And our employee brand matters in the communities that we’re in, because labor is extremely competitive in this nation. And somebody that goes to work and feels the impact of what they’re doing is valuable to the community as well — is important to us, and helps us recruit. We have a lot of people that apply to Trex merely because we do things responsibly, we do recycle. So it doesn’t only matter to our consumers, it matters to our employees as well.
Mitch Ratcliffe 33:35
Does the board have a set of “we do the right things” heuristics that they apply to some of these decisions, when you come and say, “Well, we need to do this, and it’s going to be more expensive”? How do they, as a group, create a systematic approach to making the right decision?
Zachary Lauer 33:50
We’re looking at it on an enterprise level, Mitch, where we’re looking at that return on invested capital at an enterprise level. And we will more than offset with our efficiency projects and our cost savings projects and those items on capital that allow us to do these types of things. And so we, for lack of a better term, try to overachieve in some areas to make sure that we can cover our bases in other areas.
Amy Fernandez 34:22
And our nominating and corporate governance committee is the one that gets a sustainability report every quarter. So every meeting we’re reporting on these metrics. Some of these metrics being very important — like our 95% recycled and reclaimed content in our composite decking — maintaining that is something that we report to them every quarter. We also report to them what we just talked about, our energy use, so there’s various metrics that we’re reporting to them.
And so it’s not only just that board-level oversight of our capital, it’s also the nominating and corporate governance committee oversight of our sustainability targets. So you’ve got two lenses looking at it.
Mitch Ratcliffe 35:04
Do you tie executive compensation to success on those metrics as well?
Amy Fernandez 35:08
We do not. We do not. Our executive compensation — it’s in our proxy statement, but no, there is not a modifier or a target for that. No, it’s overall company performance.
Mitch Ratcliffe 35:22
One of the changes that I noticed recently is that between 2022 and 2024, the NexTrex program recovered six times as much material as it did just two years before. What drove that growth, and where do you see a ceiling, potentially, in what NexTrex can deliver?
Zachary Lauer 35:42
Yeah. So when it comes to the NexTrex program, in 2025 we collected over 4 million. In 2026 we’re on trend to get pretty close to 6 million. You know, as we continue to expand the opportunity to rural communities and other avenues to capture this material, it’s just part of our supply chain. As you mentioned before, as competition enters in the space, we’re already moving into the future on different collection points and then different materials.
And where we see — just this grassroots reference that you’re talking to — non-grocery, non-distribution, non-traditional space, this could get to 20 million pounds or greater for us over the next 10 years.
Mitch Ratcliffe 36:33
As extended producer responsibility laws come into effect in various states, does that represent competition for the material, or could Trex even become part of the producer responsibility organization solution to collection and processing of materials within the state?
Amy Fernandez 36:49
Yeah, I mean, we’re in conversations with some of those folks about what they think they might be doing in the states that are starting to implement some of these, or, you know, discussing implementing some of this legislation. But we haven’t really seen that we’re going to have significant impact at all to Trex. There’s just, you know, given where we source our materials from, we’re not really seeing competition resulting from that legislation.
Mitch Ratcliffe 37:18
How do you see the NexTrex model continuing to evolve? Do you want to expand geographically, or is there potential for collecting other materials?
Zachary Lauer 37:18
Yes, I mean, we’re continuously working on the next-gen and the gen-after-that materials. We have a very extensive materials program here to evolve that. But we will continue to reach out to rural communities and those communities that aren’t served as strongly with collection points, and continue to expand those collection efforts nationally.
There’s probably only five to six states that we don’t even have a grassroots collection point in — we’re almost nationally covered in every state with these. And we set targets every year for this team to grow those programs. We have specific people that are dedicated to establishing these programs in underserved collection areas, and they have aggressive targets, and they’re passionate people.
Mitch Ratcliffe 38:25
Let me ask about the other side of the recycling equation here, which is, with many of the earliest Trex decks coming to the end of their expected life, reaching replacement age, what do you have to do in terms of policy partnerships and pricing to create a closed-loop solution to recycle those materials as well, so that old Trex decks become new Trex decks?
Amy Fernandez 38:49
So we have the manufacturing capability to reuse our material, so that isn’t the hurdle. The hurdle is at that collection stage. And when you have a contractor that is replacing a deck, they don’t want to sort, so they want to just have everything in there. And right now that is the hurdle — it’s the sorting piece of it, because we can recycle our own decking, but we can’t take — we talked about metal earlier, right? That’s something that we’re not going to be able to use. So that’s where the challenge is.
And what we’ve done is we’ve partnered with, for example, one of our distributors. We partnered with them to bring back truckloads of material back for recycling. So we’re trying to work with our distribution network. We do merchandising, and so for those, we’re able to get that back from our merchandising vendor to send scrap back to us. And then we’re also able to implement some communication around — if there is a big job, let’s start trying to get that product back to Trex so that we can recycle it.
That being said, anecdotally, I hear from friends that have had their first-gen Trex deck, and it is still looking beautiful. So although the warranties are 25 to 50 years, you know, we don’t —
Mitch Ratcliffe 40:15
It could go longer.
Amy Fernandez 40:16
It could go much longer. And so it’s a matter of, you know, starting to see, well, how can we start to put in place a program for when these do start to get replaced or age out?
Zachary Lauer 40:28
But we would use our network to do that reverse collection, right? The network that distributed would be the means to recollect it back.
Mitch Ratcliffe 40:39
That makes complete sense. For years, Earth911 has worked with Owens Corning on driving collection of shingles, but it’s interesting because shingle collection has spikes — extreme weather events, hurricanes, and so forth. And so they focus on communities and regions that are subject to disaster. It gives them the opportunity to get people to sort at a time when there’s a vast volume of material. Have you analyzed opportunities for that kind of optimized, focused geographic collection? Maybe a little ticky-tacky question, but I’d be curious.
Amy Fernandez 41:17
I hadn’t thought of it, and now that you mention it, I will.
Zachary Lauer 41:20
We’ve typically looked at our partners in the value chain for that versus external, you know, for those opportunities. So, and taking advantage of those backhauls and those types of situations, we already have trucks delivering. Can we have trucks collecting? The other thing — as we talked about the rural communities too, we’ve looked at offering the opportunity at those rural collection sites to take back product as well, because we already have trucks and trailers there.
Mitch Ratcliffe 41:49
If you were speaking with a manufacturer in another category, say textiles or electronics or other kinds of building materials, and they asked you what the single most important thing Trex got right early on, what would you tell them?
Zachary Lauer 42:04
We designed the manufacturing process, and we designed the supply chain to support it, from the very onset. And we had the mindset from the very onset that the variation was going to be there — figure it out. And through the decades we have refined the ability to do that. So we always had that end in mind: no matter what, we were going to figure out a way to do this. And we specifically designed our manufacturing processes and our collection processes to support that end-to-end supply chain to do that.
And the other thing that’s unique, and what I would recommend, is we’ve never depended on a middle partner or middle player in this chain. So as our collection may change over time, as our material streams change, I don’t have to go find somebody that can do that for me, right? I’m just modifying what I do today to a different material stream.
Mitch Ratcliffe 43:08
Are there moves you made that you wouldn’t recommend that others copy, because maybe it worked only because of where Trex was at the time? Are there ways to get into a blind alley and get stuck there?
Zachary Lauer 43:19
I really can’t think of any. You know, regardless, we’ve always tried to locate our facilities close to our raw material streams that allow us to maintain our 95% recycled content of materials in our decking. And so we specifically saw where we locate our plants to optimize that feed of material.
Mitch Ratcliffe 43:50
Well, Amy and Zach, this has been a fascinating conversation. How can folks keep up with what Trex is doing?
Amy Fernandez 43:57
We’ll be publishing our sustainability report as usual, probably sometime in that July timeframe, so be on the lookout for that next one. Our website — NexTrex is on our website as well, so those are probably the best places.
Zachary Lauer 44:10
Yeah. I mean, our website, and especially the NexTrex link there, has, you know, great videos and just great learning for people, and social media, right, is powerful too, for our NexTrex and our branding. So those are all platforms that we utilize to inform and educate, so that people can participate in the value chain and participate in this endeavor.
Amy Fernandez 44:36
Yep. So trex.com, Why Trex? The first link under that is sustainability.
Mitch Ratcliffe 44:41
Well, we will point folks to that. This has been a fascinating conversation, and really so impressive — what Trex has accomplished. Thanks so much for your time today.
Amy Fernandez 44:50
Thank you, Mitch. It’s our pleasure.
Zachary Lauer 44:52
Thank you.
Mitch Ratcliffe 44:53
Welcome back to Sustainability In Your Ear. You’ve been listening to my conversation with Amy Fernandez, Chief Legal Officer and Chief Sustainability Officer, and Zach Lauer, Chief Operations Officer at Trex Company, the largest manufacturer of wood-alternative composite decking in the world. And you can learn more about Trex and NexTrex collection programs at trex.com — that’s T-R-E-X, folks, trex.com.
You know, for the second time in less than a month, we’ve spoken with a company whose leaders chose to do the right thing regarding their environmental impact, and as a result, built a successful business from it. Kevin Kelly, CEO of Emerald Packaging, explained how they use recycled polyethylene in food packaging just a couple of weeks ago. But Trex got there in 1996, before “circular economy” was a phrase that anyone used in a boardroom, or, well, almost anywhere outside of a small cadre of design and architectural thinkers. Three decades later, it’s upcycled more than 5.5 billion pounds of plastic film and runs roughly 95% recycled and reclaimed content into its products. And I think, most impressively, operates one of the largest plastic film recycling operations in North America.
The sustainability work and the business are the same thing. It’s not a different choice to become sustainable — it’s part of the underlying philosophy of the company, and that’s the headline here. The structural insight is that Trex designed its manufacturing processes around variations in feedstocks, instead of trying to standardize and therefore eliminate the use of most of the material that they would receive. Zach described a rolodex of thousands of recipes that the production lines run through, swapping feedstocks the way that a baker swaps wheat flour for almond flour, for instance. And machine intelligence is making it easier to read the stream in real time and adjust temperatures and speeds on the line.
Most manufacturers spend their time narrowing input tolerances, but Trex developed tolerance for inputs that nobody else wanted and made it profitable. That’s a different theory of operations, and it explains why the company can go deeper into contaminated film streams — the dunnage returns that we heard about, the industrial trimmings, the bubble mailers that went to landfill before. Other recyclers walk away from this stuff, but Trex embraces and uses it. The lesson for any building products, textile, maybe electronics manufacturer thinking about recycled content is that variability is the design constraint. Solve for that first, or the supply chain will keep breaking on you.
Trex’s poly feedstock isn’t priced off a barrel of crude, which means in a period of reshoring, tariff uncertainty, and due to the war in Iran, oil-price swings, the recycled-content company holds a competitive advantage the virgin-material companies cannot match. And this is the version of the climate story that doesn’t get told often enough: recycled supply chains can be more stable than virgin ones in a volatile economy, not less.
So it’s refreshing to hear Trex acknowledge that the loop isn’t closed yet. The first generation of Trex decks is reaching replacement age — though I have to admit that my deck is looking pretty good at almost 20 years old — and the manufacturing side can reabsorb this material, but the recycling bottleneck is contractors pulling up those old decks who don’t want to sort the screws from the boards. And Amy named this directly. That’s the kind of candor that builds trust with the audience, and it points to the next phase in the circular economy work that requires leaping into the messy human logistics of deconstruction, sorting incentives, and reverse-haul economics.
Trex’s instinct to use its existing distribution backhauls is the right one, and it’s the model that other durable-goods manufacturers will need to copy if extended producer responsibility laws keep expanding state by state.
Two interviews this month with companies that chose the harder path early and now hold more defensible market positions. That isn’t a coincidence. It’s a leading indicator of which businesses get to keep operating in the climate economy that’s arriving right now. We’ll keep tracking the manufacturers building the infrastructure before the regulations force them to, because they’re the ones writing the playbook that everyone else will be reading in five years.
So stay tuned, folks. And hey, if today’s conversation gave you something to think about, share this episode with someone in your life who’s wondering whether sustainability and business strategy can actually be the same thing. And it turns out, in some companies, they already are. Folks, you’re the amplifiers — to spread more ideas to create less waste. And there are more than 550 episodes in our archive waiting for you on Apple Podcasts, Spotify, iHeartRadio, Audible, and other purveyors of podcast goodness, whatever you prefer.
Thanks for your support. I’m Mitch Ratcliffe. This is Sustainability In Your Ear, and we will be back with another innovator interview soon. In the meantime, folks, take care of yourself, take care of one another, and of course, let’s all take care of this beautiful planet of ours. Have a green day.
The post Sustainability In Your Ear: Trex Makes Circularity Work appeared first on Earth911.
https://earth911.com/podcast/sustainability-in-your-ear-trex-makes-circularity-work/
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