Hi Life Products – Ontario, CA

Leggett & Platt Hi Life Products (Branch 6008) in Ontario, California, is a manufacturer of high-quality rebond and specialty carpet pad, and became Eco Initiative-registered in April 2015. Without an operation like Hi Life Products, millions of pounds of used carpet pad and polyurethane foam would end up in the landfill.

The rebonded carpet underlay is made from recycled scrap foam from various industries, including used carpet underlay. Scrap padding is brought to the facility and staged for production. The scrap is then ground and mixed to the desired consistency and stored in hoppers. From the hoppers, the ground foam is sent to a blender where dyes and bonding chemicals are applied. The foam/chemical mixture is evenly applied to a conveyor line where it is steamed, extruded, trimmed, laminated, and rolled. Rolls are packaged and stored for shipping.

The prime foam carpet underlay is made from raw chemicals. A chemical mixture is formulated and applied to a conveyor between two laminating sheets and is sent through an oven that activates the foam. The foam is trimmed and stored for curing. Once cured, the product is rolled, packaged, and stored for shipping.

Hi Life Products has been working on the following impact reduction efforts:

  • Reduce binder chemical use by 1% by recirculating grinding dust back into the process as filler
  • Reduce waste sent to the landfill by an additional 15% in 2016 by continuing to add new recycling methods for cardboard tubes, e-waste, and wood pallets (Note: The facility was able to achieve a 27% reduction of landfill waste in 2014 compared to 2013)
    • This facility has experimented with a compost program for reducing waste to landfill
  • Reduce energy consumption by 10% in 2016 through the implementation of several projects such as:
    • Air compressors were replaced with newer models and system upgrades that use 23% less energy and decrease the amount of air leaks in lines
    • Office employees have been trained in better energy practices for computer usage – Sleep timers have been set to a maximum of 15 minutes on all office computers
    • Installing light sensors and LED lighting
    • Insulating boiler room heating pipes to prevent heat loss
    • Reduction in the amount of shrink wrap used on rolls that helps reduce the amount of energy required to reduce the rolls
    • Decrease air leaks found on manufacturing lines
  • Reduce water usage by 10% by regulating flush flow on urinals, toilets, and faucet aerators
  • The facility has improved its process of changing dyes for its Specialty line
  • Reduce air emissions by facilitating a ride-share program for employees
  • Reduce chemical waste usage by 5% with a change in its process of batch and dye changes