Turning Waste Into Value - Dyersville’s Journey to Zero Waste to Landfill

Sustainable production requires innovative solutions – especially when it comes to reducing landfill waste. Dyersville, Iowa (USA), the central production site for Modernfold, has taken on this challenge and implemented a new process for waste reduction. Through close collaboration with a new partner and consistent efforts, Dyersville has made significant progress on its journey toward zero waste to landfill.

A persistent challenge and a game-changing solution

As the sole production site for Modernfold, Dyersville specializes in manufacturing operable and glass wall systems. For years, the site faced a significant challenge in managing its waste. In FY 2023/24, Dyersville was responsible for 44% of dormakaba’s landfill waste, more than 60% of which was gypsum – a key material in its products. The big problem: Despite the team’s five-year search for a solution, finding a suitable recycling partner in the state of Iowa proved difficult due to minimal state regulations requiring similar commitments from local manufacturers.

But their persistence paid off. In November 2024, Dyersville partnered with MDK ZeroLandfill, a company that repurposes gypsum for agricultural use. Today, MDK coordinates the removal of gypsum from our site that is then ultimately used to recondition soil for enhanced crop production – turning waste into a valuable resource.

Major milestone in waste reduction

Since the program began, Modernfold has recycled an average of 56 tons of sheetrock/gypsum each month – achieving a 63.4% reduction in waste to landfill. With standard production volumes, this equates to nearly 800 tons of sheetrock annually that no longer ends up in a landfill. Jesse Blad, Operations Director at Modernfold, praises the successful collaboration between Modernfold’s internal purchasing group and the operations team.

“The project has had a profound impact. We are not only addressing the massive need to reduce gypsum landfill but also paving the way to reduce landfill from other sources as well.”

‍A broader commitment to sustainability

Globally, dormakaba is committed to optimizing waste management across its 33 manufacturing sites. With a baseline of 3,443 tons of waste in FY 2020/21, dormakaba is working closely with our consulting partner Beyondly to develop waste reduction roadmaps for each site. These roadmaps include waste stream characterization, segregation to identify reusable materials, and finding local partners to help divert waste from landfills. These efforts are part of dormakaba’s broader commitment to achieve zero waste to landfill by 2027. We expect to reduce the amount of operational waste sent to landfill by approximately 44% vs. baseline by the end of this financial year. Our target is to achieve a 75% rate by the end of financial year 2025/26 and a 100% rate by the end of financial year 2026/27.

Just the beginning

In addition to the gypsum recycling project, Dyersville is making significant progress on its overall waste management action plan. Modernfold and MDK are now working together to recycle corrugated materials and reduce clear plastic packaging waste. Looking ahead, the team is also evaluating opportunities to improve steel and aluminum recycling.

These initiatives mark a significant step in Dyersville’s journey to become a more sustainable, waste-conscious operation. Modernfold serves as an inspiring example for other manufacturers in Iowa and for dormakaba’s global sites. Through these initiatives, Dyersville plays a vital role in driving the company’s larger zero waste to landfill initiative forward.