Curbside collection programs used to be a function that a city or a hauling company just did. Now, however, garbage collection has become more and more of a science–and it requires a greater investment to keep customers and regulatory authorities happy.

By Joseph Lynn Tilton

Dwindling labor pools, rising insurance costs, and the public's demand to clean up garbage day are driving the industry away from manual collection and toward automated and semiautomated collection systems. Although this trend calls for more sophisticated collection vehicles, the most expensive element in an up-to-date collection system is still the curbside cart. Whether the operator must perform within budget or for a profit, care of the cart can make the dollar and customer service difference.

"The largest single investment for the hauler is the cart," declares Bill Birth, director of marketing-program development for Cascade Engineering Inc. "For example, if the customer base requires 20,000 carts, at $40 a cart you're talking an $800,000 investment. If we assume a five-day collection week, utilizing four trucks at $165,000 each, you're talking $660,000 for capital equipment."

Speaking from his Chicago, IL—based office, Birth comments that well-run residential waste collection operations must always keep the residential customer in mind. "A cart that looks substantial and is easy to clean is more readily accepted by the customer. But you also want a cart that is easy to handle, doesn't tip over, and isn't a chore to move." He adds that there are three other elements a hauler should consider when selecting carts: its size, durability, and ability to keep odors in and critters out.

"If a cart doesn't meet those criteria, the service provider, whether a city or a private hauler, gets the complaint. This can be a customer service issue for the city or the hauler. Customers don't see the truck three-quarters of the time, but every day they see the cart you provide." Speaking as a former city and county solid waste administrator and someone who has worked with municipalities to improve their collection programs, Birth emphasizes the need to maximize the cart's useful life. "It's important to have a program that is customer- and operator-service—oriented. Also needed is a commonsense driver-training and vehicle-maintenance program. Experimenting on-route is dangerous. If a driver knows fully what the equipment being operated can or cannot do and what to look for–in other words, how to troubleshoot–corrective action can be taken or maintenance can be informed."

Birth notes some industry-accepted yet often-forgotten standbys. "Maintenance schedules, especially when budgets are tight, need to be followed. Operations should avoid the temptation to exceed equipment operating parameters. For example, taking equipment that's designed for 1,000 pickups a day and building a daily route with 1,300 stops–unless maintenance schedules are adjusted accordingly–is playing with fire. Remember, those lifters or grabbers are built to lift only so much weight, lift so far, et cetera. Today's operation mangers, more than ever, must know what the service requirements are and what equipment is available to meet those efficiency and durability requirements."

Birth adds that customers also need to know the cart's limits. "The cart is not a 10-yard Dumpster. A 96-gallon container is designed to handle waste the family routinely generates in their home. Typically this doesn't include broken concrete, engine blocks, motor oil, hazardous waste, or whatever else is prohibited. Customer education is essential to avoiding cart problems."

When damage occurs, speedy repair or replacement is essential. "When carts have damaged wheels, lids, or handles or are worn through–which is rare–they can cause problems for the customer and for the hauler. These problems can be resolved and service efficiency and customer satisfaction maintained with just a little TLC. It may take 40 minutes or an hour to pick up and repair a cart, but it may take a week or more to pay off a workers' comp claim or sign up a new customer to replace the one that was lost because something went wrong due to ill repair."

Birt

h emphasizes that industry manufacturers are working together to help resolve issues, including the cart's compatibility with the collection vehicle's pickup system. "All components must be in sync for a collection program to work. We must work together with the truck-body manufacturers to ensure lifter and grabber systems are compatible. By working together we develop solutions, not excuses."

He recalls one situation when an operation had a new vehicle delivered–which damaged thousands of dollars in carts in a short space of time. "At first everybody–the vehicle manufacturer, the cart supplier, the route people–pointed fingers. Finally it was revealed after a month or so of go-around that the equipment or new-program orientation was a bit lacking, to say the least. The cart manufacturer, truck manufacturer, and local operator all dropped the training ball. A valuable, expensive lesson was learned. Once the operators and maintenance people were taught what to look for, what to expect, and how to calibrate the grabber, cart damage ceased." Thus, education and training upon delivery is another important element to protecting your cart investment.

San Bernardino Success

With 150,000 containers, 26 routes, and a three-can collection system, San Bernardino, CA (population 187,000), has a particular challenge in taking care of its 96- and 64-gal. Toter containers. "Everything's automated," declares Arlington Rodgers, solid waste manager for the city. "We have up to three trucks stopping in front of each house, and each picks up trash, greenwaste, or recyclables. Single-family homes have three 96-gallon containers, while those in mobile home parks tend to get only 64-gallon black and blue cans because greenwaste is at a minimum."

Rodgers explains that the vehicle's computerized pickup system is adjusted at the shop and is pretty much tamper-proof. Furthermore, a skillful driver can safely pick up a cart that's lying on its side without having to get out of the cab. "Our drivers average 900 to 1,000 stops on a given route, and we try to keep a route stop under 25 seconds. We strive to be productive, not hasty, so we do a lot of training through our fleet operations coordinator. We put older drivers on a green route because they're consistent, yet a blue route could have up to 2,000 containers of recyclables."

San Bernardino handles cart repairs through two part-time employees with a service truck designed to make onsite repairs. Their equipment includes a flatbed trailer so there's room for carts. Started in 1998, the service logged a lot of lid repairs on the carts in use at the time. "We found that the PVC pipe that attached the lid to the container was not long enough. Our repairmen would get PVC pipe from Home Depot and cut it 4 to 6 inches longer to prevent lid drop-off." He adds that the manufacturer has addressed the problem by designing a cart that eliminates the PVC hinge, and lid repairs at this time are greatly reduced.

One challenge is deciding when it's better to replace rather than repair the cart. Rodgers says, "The only thing we don't repair is holes. If the hole is from normal wear and tear, nothing's said. If we get a burn-through, we send the customer a letter cautioning them not to put in coals, fireplace tinder, et cetera. Burn-throughs peak around the Fourth of July, when there are a lot of barbecues in use. Then we'll get maybe 15 to 20, which is not bad with 36,000 residences."

When the carts are too difficult for the resident to handle, the city implements its Special Assistance Program, Rodgers explains. "Our driver will go into the backyard, get the can, empty it, and put it back in place. The cycle time for that is two to three minutes, and though it may slow us a bit, it's a program that won't go away."

Nor will the city's attitude that residents are customers and should be treated as such. "We make no profit, but the rates cover all costs. The last time we changed rates was four years ago. This is a business. We are taking people's checks, so we treat them as a customer, not as someone who has to have our business."

Looking to the future, Rodgers comments, "What I'm really interested in right now is something to buy that can handle the Santa Ana winds. They'll get up to 80 miles per hour, and the wind is unpredictable. While our windy season is from November until February, we never know when winds are going to blow."

Wind Resistance Makes a Difference

Cart manufacturing process

In Cheyenne, WY, Dennis Pino, superintendent of the city's sanitation and landfill division, doesn't have that wind problem. "We're at the end of the Front Range of the Rockies, and our winds start in late October and don't quit until sometime in April. I've seen it hit 100 miles per hour here, with 70 miles per hour not unusual." That's why Pino's people tested 13 different brands of carts before they made their last major cart purchase. They set them out empty in their yards, then rotated locations to ensure a more thorough analysis.

"We used the Day Weather Services at the airport 4 miles away to get daily readings on velocity, and we used a Skymate handheld machine to check velocity on the site. We clocked at what speeds the different brands' lids first popped open, when the cart fell, and how far it moved after the fall. Then we put in 35 pounds of compost to see how those carts performed with what is a fairly typical load weight for households. Just three or four fell over, and none traveled after the fall."

Pino reports that the Rehrig never fell and was one of the three brands selected for homeowner testing, which the department conducted in spring and early summer following the windy-season test. "That's our heaviest time of year because of yardwaste. We found the residents adjusted to the new carts very quickly, and after the test we got calls because they wanted them back."

But Cheyenne was on a manual collection system, and the move to a fully automated system didn't start until a year after the homeowner test. "Then we got 5,000 Rehrigs right off the bat. They cost more than the truck, but we got both the main truck and the backup vehicle secondhand from the City of Boulder, Colorado. They had used them less than six months and had fewer than 10,000 miles, so those trucks were just barely broken in." He adds that the phase-out from manual to automatic will total four years. "We're hoping to save on workers' comp claims most of all. Back and shoulder injuries are killing us. Plus, people don't want to be garbagemen anymore, which is why we had 113% turnover in 2001." Pino believes that newer vehicles with air conditioning, radios, comfortable cabs, and the technology associated with automated pickups will help reduce employee turnover.

He notes that the city, which has an estimated population of 50,000, anticipates a double-digit population growth in the next five years. "Business is booming, with small and large businesses coming in, and the city's expecting 900 new homes per year."

Despite projected growth, the combined work force in collection and at the landfill is expected to drop from 63 employees down to 30-35, and he expects the city to save $2 million in workers' comp claims and labor costs over a 10-year period. Pino concludes, "The City of Cheyenne Public Works Department was instrumental in helping the Sanitation Department organize the public meetings, making the public aware of these changes, calculating the homeowner testing surveys, and making this program a success."

Even in cities such as Nashville, TN, where the climate tends to be more moderate, testing helps ensure the best decision. Chace Anderson, director of the Divisions of Waste Management and Fleet Repair for Nashville, adds, "Because of our humid summers, we thought of minimizing the temperature by going to a white lid. We decided against it, though, because white shows dirt readily, and that color seemed weaker. Nor were the inside temperatures significantly lower."

The upside, however, is after Nashville concludes its current changeover–and it's just at the beginning phase of a massive program coordinated with Stringfellow Inc. and Toter–then 70% of its 130,000 stops will be automated. "We will have a uniform collection system. The trucks will be fitted with Toter-approved lifts so as to minimize damage to the carts, and citizens will have 96-gallon carts with lids that will help keep litter from blowing out of the containers and keep animals from strewing refuse," maintains Anderson. The change also will help the city realize a nearly $2 million-a-year savings in solid waste collection.

Compatibility Is Prime

As mentioned earlier, today's cart manufacturers are striving to have their carts interface with all brands of collection vehicles to help ensure maximum cart life cycles. Jeff Nadeau, executive vice president for Otto Industries in Charlotte, NC, comments, "The major issue comes when the lifting mechanisms are not compatible or not properly maintained to lift the cart. For example, if the grabber is not properly designed or not properly maintained, the pressure can become so great that it can crush that cart as it picks it up. It's rather similar to crushing a Styrofoam cup in your hand when you squeeze it too tightly."

Nadeau, who has nearly 20 years in the industry, notes that the latest models of fully automated grabbers, such as the Heil Tricuff, use 1,000 psi. "Sometimes drivers increase the pressure to accelerate cycle times, yet over the long term, any money saved is lost in cart replacement expense. Operators need to strike a balance with the right pressure that's efficient yet safe for long-term performance of the cart." Another problem he sees is that operations that tend to have long route times have less time for preventative maintenance.

"Moving from a semiautomated system to a fully automated one can double collection productivity yet eliminate one or two helpers. When you do that, you save not only the cost of employing those helpers but [also the cost of] their benefits, which can be another 30%–with less risk management."

Still, when that change comes, homeowners need to be educated regarding their role in helping the new system succeed, which also ensures longer cart life cycles. "One problem with residents is using the cart for purposes other than trash. Construction material is a popular thing. Otto carts come in 96-, 64-, and 32-gallon sizes, with the 96-gallon model rated to hold 335 pounds. But collection carts are not designed to be used as a dolly or wheelbarrow for moving building materials."

He adds that drivers also need to be prepared to get out of the truck in case the cart has been placed backward to the lifting mechanism or is overloaded with lengthy material such as lumber or other construction materials. A little bit of extra time then can help ensure the cart is not abused when it's picked up. "When companies or municipalities first introduce the new cart on the street, they need to include an information package for the user concerning the appropriate collection day and the proper care of the new cart, including washing, correct placement at the curb, avoiding loading with flammables, et cetera."

Nadeau concludes, "In the long term, fully automated systems are the solution to higher productivity and less risk management and overall are a better system for collecting household solid waste."

Design, Material, Construction, and Support All Count

When it comes to actual cart design, Michael Schwalbach, national manager of environmental products and services for Rehrig Pacific Inc. in Los Angeles, CA, reports that there are three main elements: the material and additives that make up the cart, the processing involved, and the design. "If you don't start with good material, you're going to get a cart with poor integrity. Consistent high-quality material makes a world of difference in longevity and integrity of the cart. When you're in the market for a cart, ask the manufacturer for references on the materials supplier. There's less risk when there's a long-term relationship between the manufacturer and the materials supplier."

Concerning processing methods, Schwalbach notes there are but two: injection molding and rotational molding. "The biggest reason that we believe injection is superior is it allows us to place plastic where we want to. If we want extra plastic at the bottom to resist abrasion, we can do that. If we want extra plastic at the gripping area, we can do that. We have control of where plastic goes. This allows us to put only extra plastic, and extra weight, where it's actually needed."

He also counsels checking for consistency of construction, especially on the walls or bottom or on the gripping area. "Visit the plant. See how the company operates, how it conducts its quality control. Follow the process from when the material is pulled off the rail or truck and taken to the machines and how it's handled during and after processing." He notes, for example, that if a cart is pulled from the mold too quickly, warping is a problem. If streaking or fading is a problem, then it's likely the mixing process isn't working correctly. Look for consistency of care every step of the way.

"The other area is design. You want a cart that is durable, user-friendly, and attractive." Sound design also enhances stability, which is especially important with automated systems. "If the cart gets knocked down or blown over, the driver has to get out, and full automation is defeated. An easy test is to raise the lid to full vertical position, then drop it so it swings down behind the cart. If the cart falls over, then it's not very stable."

Another point Schwalbach raises is homeowner education and accountability. "You need to be fairly strict on your rules, including what's allowed in the cart. If the driver notices any variance, he should tag it, whether it's abuse, wrong things in the cart, or putting the cart where it can't be reached, such as under a tree. If anything affects the operation, it's worth tagging the problem, spending a few minutes in communicating with the end user to save time in the long run."

While some manufacturers stress the benefits of injection molding, others point out the advantages of rotational molding. "We think the key to a long life cycle is to start with the toughest material possible, then take that raw material and make it into the strongest cart possible, using a stress-free molding process," declares John Scott, vice president of sales and marketing for Toter Inc. in Statesville, NC. His firm uses linear low-density polyethylene, which carries the highest environmental stress crack—resistance rating available and will stretch, bend, or flex longer than traditional high-density polyethylene.

"When picked up by an automated arm, the cart gives instead of cracks. Then when it's placed back on the curb, it returns to its original shape," Scott continues. He adds that some of Toter's carts have been on the street for nearly 20 years and that the audited warranty failure rate is a bare-bones 0.2 of 1%.

He comments, "Regulating operating pressure is essential for avoiding cart abuse, but it's unrealistic to think a fleet of trucks will always have the optimum operating pressure at all times. Maladjusted hydraulics is a challenge, and cart flexibility is the only way to minimize damage to the container." Scott adds that with carts typically carrying 10-year warranties, the likelihood is that sometime during those years the operator is going to get new vehicles or look at a new collection system. Thus, purchasers should consider carts that can easily be upgraded to new collection systems.

"Each Toter EVR cart is capable of being used in five major different collection programs, including semiautomatic, fully automated, weight-based, volume-based, and co-collection."

Co-collection is the latest technology advancement for handling both waste and recyclables. "The cart is divided down the middle and has two lids. When the truck picks up the cart, garbage goes in one side and recyclables in the other. It's possible to have one truck per route and just one cart per household. In addition to the obvious operational efficiencies, the program is more user-friendly. The more user-friendly the system, the higher the participation rate."

Scott concludes, "There are really two costs for carts: the initial price and the life cycle price. When you have to repair a cart, you dramatically increase the cost of that container. So start with a tough cart that has a proven track record so you don't expose yourself to a lot of hidden costs."

Residential Learning Curves

As cities have looked at possible changes in their waste pickup programs, residential education has been a concern. Gerald L. Edwards, administrator for the Divison of Refuse Collection for Columbus, OH, points out that education includes notifying the user that no material outside the container will be picked up. "If there is a bulk item, it must be at least 4 feet away so the gripper can grab the container. We also warn them that the container must not be next to a parked vehicle or else we can't pick it up." Keeping the resident accountable ensures a shorter learning curve, and tagging containers to let the resident know it ensures that the problem is solved by the next pickup day.

Operations Manager John Johnson adds that his division has 118 positions and that turnover and operator cart abuse have been low. "We talk to our drivers. They understand that carts are an expensive part of a fully automated collection system. We also do our own cart repair and keep an inventory of lids, wheels, and other parts, but we try to limit the inventory so we don't take up a lot of space."

Columbus not only has 155,000 residential carts but also has another 22,000 300-gal. containers for alley collection in inner-city neighborhoods. Edwards comments, "We're a general fund agency; we don't handle money. Citizens pay for the service through property tax and income tax, and we're given a percent of the general fund. We have to justify the dollars we're asking for."

That includes documenting any special collection needs. "If a doctor certifies there's a medical reason a resident can't place the container on the curb, then we have a crew that services that home. The crew handles all such exemptions throughout the city. This keeps from slowing the regular operator."

In Mesa, AZ, Willie Black, solid waste administrative supervisor, reports that despite the high ratio of senior citizens, this city of 400,000 has just 71 assisted pickups in a curbside program similar to San Bernardino's. "A large part of that population is in mobile-home parks or apartments, and they use large metal bins or compactors. We also offer a 60-gallon cart, rather than a 90-gallon, at a lower cost. But where a homeowner needs special assistance, our driver will move the container from the door to the truck and back to the door. Our challenge is when the home changes hands. Just the other week a driver met a new resident who thanked him for the terrific personal service." Black reports that Mesa is considering making an annual contact with those assisted to make sure they still need the service.

In Mesa, citizens pay for each element of collection, with the blue barrel being no extra charge. "Ours is serviced-based, no taxes involved. We return any extra money to the general fund. We also do our own cart repairs. If the repair is easy, such as a wheel or a lid, our staff can do it at the home, but if needed they'll leave a replacement and bring the damaged cart to the shop for repair and fix it for future use. We get very few burnout calls, but people do run them over. In either case, we salvage what we can, such as wheels or axles, but typically the body and lid are gone."

While wind is not a problem, few residents put a cart straight to the curb. So as part of the testing process, Black and his crew set carts at 45º either way to the curb and facing backward, doing a total of 35 lifts per cart, to discern which brands neither slipped into the hopper nor to the wheels. Black knows that carts that fall to the wheels or into the hopper can be damaged during normal operation. They also worked out the multiyear contract so schools, government agencies, and even other cities could buy the services, thus ensuring a larger order for their supplier and better prices for all involved. This cooperation eases the economic crunch associated with cart buying, which also is like extending a cart's life cycle.

Joseph Lynn Tilton is a frequent contributor to MSW Management.