Embracing Plastic Sustainability: Transforming Waste into Durable Products

In a warehouse in Southeast Dakota, a plastic “upcycling revolution” is underway. Machines are churning through 6,000 pounds of plastic waste per hour, transforming discarded materials into durable fence posts. This sustainable product approach not only addresses the plastic waste problem but is also the perfect example of upcycling via the creation of new, higher-value products with strength and longevity.

A Visionary Approach to Recycling

Avery Zahn, owner of ZahnTech (formerly known as Sustainable Products), has made significant strides since starting this plastic fence post business. In the first three months, he used 369,000 pounds of plastic waste to create infrastructure that is ten times stronger than wood. His innovation eliminates the possibility of fence posts rotting, a common issue with traditional wooden posts, especially for cattle farmers. Joy Nelson, owner of the Joy Ranch retreat center, experienced the benefits of Zahn’s creation firsthand, when she replaced her wooden posts with Zahn’s recycled plastic ones - particularly effective in areas prone to moisture and drainage issues.

ZahnTech: Leading the Charge

Zahn’s plastic posts are designed to be user-friendly. They can be cut with a normal saw and take screws, staples, or nails just like wood. However, unlike wood, which expands and contracts with heat and humidity, causing staples to work loose, these plastic posts remain stable, ensuring long-term reliability.

With positive feedback surrounding his design, Zahn and his team knew they had a valuable product and began mass-producing these posts in late summer 2023. Today, they are spreading the word about their benefits by attending trade shows, engaging in community conversations, and more. Zahn notes that all plastic and metal for his posts are sourced for free, keeping prices relatively low for customers seeking a sustainable fencing solution. Contributions come from various industries, such as pet food bag manufacturers and auto body repair shops and through advanced recycling technologies and processes, the company has achieved a 98% waste transformation rate, with a goal of reaching 100%.

The Call to Innovate and Recycle

As most of our posts indicate, the United States generates a significant amount of plastic waste. In 2018 alone, the country produced 35.7 million tons of plastic waste, accounting for 12.2% of municipal solid waste (MSW) generation [1]. Despite the large volume of plastic waste, the recycling rate remains relatively low and plastic containers and packaging are the main sources of plastic waste, contributing over 14.5 million tons in 2018. By embracing innovative recycling technologies and supporting companies like ZahnTech – which embodies the principles of upcycling, we can make a substantial impact on reducing plastic waste and promoting sustainability.

Let's drive change together and support initiatives that turn waste into valuable resources, contributing to a cleaner, greener planet.

[1] Plastics: Material-Specific Data | US EPA