DaVinci Roofscapes Recycles 1.2 Million Pounds of Polymer Scrap

DaVinci Roofscapes has kept more than 1.2 million pounds of polymer scrap out of landfills in 2016. The recycling effort includes the remolding of more than 696,000 pounds of grinded scrap into starter tiles and the transfer of 567,000 pounds of scrap to an end-user who makes pallets, crates and totes.

“Our goal is zero percentage of scrap going into a landfill,” says Bryan Ward, vice president of operations at DaVinci Roofscapes in Lenexa, Kan. “We are always looking for ways to recycle and reuse every piece of waste in our plant.”

“We made a capital investment in regrind machinery in recent years that’s paying off. Over the past two years we’ve decreased our trash generation by more than 50 percent annually. That’s a number we’re proud of and hope to improve upon even more in the future.”

DaVinci Roofscapes produces polymer slate and shake roofing tiles in 50 standard colors, plus custom colors. Each time the manufacturing operation changes color runs, there is a transitioning between colors. Those transition tiles are off spec and are recycled. The tiles, which are 100 percent recyclable, are segregated by color and then ground up and molded into starter shingles, which are generally unseen on the roof.

“We view Earth Day as a time to evaluate the progress of our recycling operations and share the good news about our efforts,” says Ward. “Our operation is efficient. Between reusing the regrind polymer and selling off additional scrap, we’re excited to prevent more than 1.2 million pounds of scrap from sitting in a landfill this year.”

The team members at DaVinci Roofscapes develop and manufacture polymer slate and shake roofing systems. DaVinci leads the industry in the selection of colors, tile thickness and tile width variety. The company’s products have a limited lifetime warranty and are 100 percent recyclable. All DaVinci roofing products are made in America where the company is a member of the National Association of Home Builders, the National Association of Roofing Contractors, the Cool Roof Rating Council and the U.S. Green Building Council.

300,000 Pounds of Polymer Roofing Tile Scraps Are Recycled Annually at DaVinci Roofscapes

The 45th anniversary of Earth Day in 2015 puts a shining spotlight on recycling efforts around the country—including at DaVinci Roofscapes in Kansas. That’s where more than 300,000 pounds of polymer roofing tile scraps are recycled each year.

“Most manufacturing operations have scrap materials,” says Bryan Ward, vice president of operations at DaVinci Roofscapes in Lenexa, Kan. “The difference here is that every roofing tile we create is 100 percent recyclable, so we are able to reuse every pound of scrap that comes off our production line into our roofing material’s starter shingles. This saves a significant amount of material from going to the landfill, along with making us an efficient, environmentally friendly operation.”

With more than 300,000 pounds of scrap recycled annually, DaVinci doesn’t stop there. The polymer slate and shake roofing manufacturer offers two recycling programs that provide a way for roofers to return scraps, cuttings and unused synthetic roofing material to the company’s facility for recycling.

Waste products from a job site can be returned to DaVinci’s Kansas plant for recycling (with shipping paid for by DaVinci within a 500-mile radius of the plant) and expired tiles (those older than 50 years old) can also be returned for recycling. Ward estimates that almost 5,000 pounds of product are returned from field projects each year for recycling.

Selecting polymer roofing tiles also helps save trees and energy. “Every time someone chooses a DaVinci roof instead of wood shakes, trees are saved—often young growth cedars that are difficult to harvest, produce low-quality shingles and further deplete our limited resources,” says Ward. “Natural slate roofs present other problems. The quarrying process consumes large amounts of labor and fuel and can be harmful to the local ecosystem. Up to 15 percent of natural slate tiles crack or break up during installation, so waste is significant. Because DaVinci tiles weigh one-third as much as natural slate of comparable thickness, transportation energy costs and carbon emissions are lower.

“Just as it’s important to us that all our sustainable roofing products are Made in America, it’s also vital that we keep our earth as clean and healthy as possible for future generations,” says Ward. “We’re a company that celebrates Earth Day every day of the year. By creating roofing products that meet Leadership in Energy and Environmental Design (LEED) certification process standards, we’re taking a step toward saving valuable resources.”