What began as a challenge to reduce waste costs evolved into a complete operational transformation. Through implementation of two Orwak Power 3820 balers leading to smarter waste handling and improved recycling processes, Sonno Group Limited in the UK successfully reduced costs, improved efficiency, freed up valuable space, and created a sustainable new source of revenue from recyclable materials. Orwak Easi UK first offered a two-week trial, which resulted in a profitable baling solution with estimated savings of about £210,000 a year for the customer!
Clear objective to find a more efficient waste solution
Sonno Group Limited is a furniture manufacturer and online retailer headquartered in West Yorkshire in the UK. It produces hand-made and made-to-order beds and mattresses, and the production generates significant volumes of plastic and cardboard waste. While some materials were being disposed of through a RoRo (Roll-On, Roll-Off) skip, a substantial amount required transportation to a waste management facility, resulting in considerable costs.
The objective was clear, to find a more efficient and sustainable waste management solution that would reduce waste volumes, lower operating costs, and improve overall site efficiency.
To identify the best approach, Orwak Easi UK conducted a comprehensive site survey, reviewing the existing waste handling process, analyzing associated costs, and evaluating opportunities for improvement. Beyond reducing waste expenditure, the goal was also to help the business save valuable time, optimize space, and create long-term operational efficiencies.
High-performance balers eliminate costs
Following the site survey, Orwak Easi UK recommended Sonno Group Limited to install two Orwak Power 3820 balers: one dedicated to cardboard and the other to plastic.
These high-performance balers produce mill-size bales weighing up to 500 kg, making them ideal for collection and processing by commercial recycling partners. The impact was immediate. Following installation and a successful two-week trial period, transport costs associated with waste disposal were eliminated, and the volume of waste entering the RoRo skip was significantly reduced.
To further enhance the value of the solution, Orwak Easi UK connected Sonno Group Limited with a local recycling partner willing to pay rebates for their baled materials. As a result, what was once a waste expense became a new revenue stream.
Complete leasing package starting with a free trial
- Site Survey: The first step is to conduct a detailed assessment of the existing waste management operation, reviewing current processes, waste volumes, and disposal costs. This enabled us to design a tailored solution that met the site’s operational requirements and sustainability goals.
- Free Two-Week Trial To ensure complete confidence in the proposed solution, Sonno Group Limited was given the opportunity to trial the equipment free of charge for two weeks. This allowed the team to experience the benefits firsthand and validate the projected savings before making a commitment.
- Complete Package: Orwak Easi UK could deliver a transparent, all-inclusive leasing package, which includes: the baler, delivery and installation, operator training, annual service, callouts, labor and replacement parts.
- Ongoing Customer Support: The commitment extends well beyond installation, and the customer continues to benefit from dedicated support through Orwak Easi’s sales team, customer service, consumables specialists, and service department, ensuring long-term performance and reliability.
Convincing results
By eliminating transportation costs, reducing waste disposal expenses, and introducing a more efficient recycling process, Sonno Group Limited is now achieving estimated annual savings of at least £210,000.
Turning Waste into Revenue
The ability to produce high-density 500 kg bales has enabled the company to secure premium rebate rates from recycling partners. Instead of paying for waste disposal, they now generate revenue from their recyclable materials, transforming a cost center into a valuable business asset. Sonno Group Limited is recognized locally for sustainability initiatives, and the improved recycling rate as well, reduced transport and as a result reduced CO2 emissions provided by compaction and baling, harmonize with that.
Increased Efficiency and Reduced Labor
The new baling solution has streamlined daily operations by eliminating the need to manually break down cardboard and transport recyclable materials to an off-site waste facility. This has reduced handling time, improved workforce productivity, and removed unnecessary double handling of materials.
Space Optimization
Large skips and frequent waste collection trucks are no longer occupying valuable space. Compact, neatly stacked bales require significantly less storage area, creating a cleaner, more organized, and more efficient working environment.
Image source: Orwak Easi UK