Leading the Charge in Energy Efficiency and Environmental Stewardship
Proactive Innovation

Reducing Energy Use and Plastic Waste

In an era where sustainability and environmental responsibility are more important than ever, Kaysun Corporation has emerged as a leader in energy efficiency and waste reduction. This 75-year-old custom injection molding manufacturer, based in Manitowoc, Wisconsin, has long recognized the environmental impact of the plastic waste their production process produces. Through its innovative and proactive approach, Kaysun is turning plastic waste into a valuable resource – energy.

Dedicated Green Team
Commitment to Environmental Sustainability
Kaysun Green Team

Kaysun understands the potential environmental consequences of its operations, particularly the generation of plastic waste. Rather than turning a blind eye, Kaysun is confronting the challenges head-on.

The company’s Green Team, a dedicated group of employees focused on sustainability, is at the heart of Kaysun’s environmental initiatives. Members of the Green Team routinely visit a regional landfill as a reminder and reinforcement of their commitment.

“We're a plastics company and we understand we generate landfill,” Ben Harrison Kaysun Corp. Owner/CEO said. “We know how catastrophic it is for the environment. So, we're doing everything we can to be a better environmental steward and to do our part to reduce landfill and improve energy efficiency.”

Turning Plastic Waste into Fuel
Landfill

Kaysun’s dedication to environmental stewardship extends beyond waste reduction. The company has also worked tirelessly to improve the energy efficiency of its operations. By installing energy-efficient equipment and partnering with programs like Focus on Energy and its utility, Manitowoc Public Utilities, Kaysun has continuously made strides in reducing its energy consumption.

The Green Team played a critical role since 2017 implementing more than 20 energy-saving projects aimed at reducing the company’s environmental footprint.

One notable initiative: the conversion of plastic waste into fuel pellets. These pellets are used by utilities, such as Manitowoc Public Utilities, to generate power, effectively turning waste into a source of renewable energy.

The impact is significant. By converting plastic waste into fuel, Kaysun has diverted more than 2.5 million pounds of plastic from landfills since 2017. To put this into perspective, this amount of plastic waste is enough to power the homes of 93 Kaysun employees for an entire year.

The 2023 Drying Oven Conveyor Project: A Game-Changer
Kaysun Dryer

One of Kaysun’s most impressive achievements to date is its 2023 Drying Oven Conveyor Project. This project, which involved upgrading the company’s equipment to more energy-efficient systems, has been a game-changer for both the company’s energy usage and its bottom line. The results of the project are staggering. Kaysun is now saving 1.5 million kilowatt-hours of energy each year, which is the equivalent of preventing the shipment of 270 tons of coal, or about two full railcars to a coal plant.

The environmental benefits of the project are clear, but the financial savings are equally impressive. Kaysun is saving approximately $109,000 annually on its utility bills because of the energy-efficient upgrades. These savings allow the company to reinvest in its operations and continue its growth trajectory.

Recognition and the Road Ahead
Kaysun Dryer

In recognition of its achievements in energy efficiency and sustainability, Focus on Energy honored the company with a 2024 Energy Efficiency Excellence Award. Kaysun’s partnership with Focus on Energy has been instrumental in its success.

Focus on Energy provides financial incentives and support to businesses that implement energy-saving projects, making it easier for companies like Kaysun to pursue sustainability initiatives. As Kaysun continues to grow, these incentives are crucial in enabling the company to invest in energy-efficient technologies and processes.

"I want to thank Focus on Energy," Harrison said. "We're a company that's growing rapidly, and there's a lot of investment going on. Financial incentives are very important for companies like Kaysun, and this has been a big deal for us."

A Brighter, More Sustainable Future
Kaysun Factory

Kaysun Corporation’s journey toward environmental sustainability and energy efficiency is a powerful example of how businesses can balance growth and profitability with environmental responsibility. By turning plastic waste into a valuable resource and investing in energy-efficient technologies, Kaysun has significantly reduced its environmental impact while enhancing its bottom line.

The company’s dedication to sustainability is not just a trend—it’s a core part of its mission. As a 2024 Energy Efficiency Excellence Award recipient, Kaysun is setting a high standard for other businesses in the industry. Their efforts show that it’s possible to make a positive impact on the environment while still achieving business success; proof that with innovation, dedication, and a focus on sustainability, businesses can make a lasting impact on both their communities and the planet.

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