In Business, Creating Sustainable Enterprises & Communities

THE COMPANY THAT RECYCLES A ONCE-IN-A-LIFETIME ART EXHIBIT

In Business, May-June, 2005, Vol. 27, No. 3, p. 22

After millions toured the saffron-colored gates assembled in New York City by world-famous artists Christo and Jeanne-Claude, a Pennsylvania firm is processing the is mantled exhibit for varied markets.

Verna Fisher

AS WE SAID goodbye to this past winter's frigid temperatures and multiple snow storms, we also bid farewell to an art project that was 26 years in the making. Created and gifted to the city of New York by artists Christo and Jeanne-Claude, the $23 million art exhibit, “The Gates: Central Park, New York, 1979-2005” spanned 23 miles of pathways in Central Park to the delight of many locals and visitors from afar.
For 16 days the 7,503 bright saffron, fabric panels danced in the cool breeze on matching color PVC vinyl frames with steel bases. The frames varied in widths from five feet to 18 feet. Since the exhibit was displayed in February, the still bare tree branches only added to the warmth of the park as the sun glistened through the fabric and bounced off the frames.
Often referring to themselves as “environmental artists” - their medium involving both country and city locations, Christo and Jeanne-Claude are also preservationists in the sense that they do not harm the areas where their works are displayed, and exhibits are recycled after completion. Rather than digging holes in Central Park, the artists opted for saffron steel footings to hold “The Gates” in place. After “The Gates” was dismantled, Nicos Polymers & Grinding - a sprawling 180,000 square foot processing company in Nazareth, Pennsylvania - recycled the materials.
The connection between the artists and Nicos came about when “Celeste Johnson, a consultant to the steel processor involved in the project, mentioned our name,” says Bob Perrone, Sales Support Administrator for Nicos Polymers & Grinding, Inc. With 25 years experience in the business of pulverizing, processing, and recycling, Nicos came out ahead after several companies were researched.
Christo and Jeanne-Claude “had to be absolutely sure that when the materials were sent here they weren't going to see them up on Ebay,” says Perrone. He comments that Nicos regularly deals with “imperfect medical devices,” defective or out-of-print music CDs, software, and consumer products. All of their customers “need to be sure that materials were securely taken care of and did not leave the building, and are really gone.” The black market is a prime concern regarding medical devices so videotaping and on-site witnesses serve as proof that jobs are handled properly.
When it came to “The Gates” project, Nicos recycled over 750,000 pounds of PVC, 20,000 pounds of HIPS (the industry nickname for high impact polystyrene) and polypropylene, and 75,000 pounds of nylon fabric. (HIPS are used in products that require strength or a shatter resistant, unbendable quality similar to that found in office in/out boxes.) All of these materials were processed in “large capacity Cumberland grinders,” Perrone remarks. “These are very large grinders with 250-400 horsepower, and the machines are capable of processing thousands of pounds per hour of material. With our internal engineering department, we have designed methods which enable us to feed large parts into this equipment. All materials from “The Gates” were ground intact utilizing a feed chute which sent the material into the grinder,” he says. The screen size used was 3/8”. Anything smaller than 3/8” went through the screen and was air conveyed into Gaylord boxes that are about 4' square.
Nicos uses several different types of equipment for the pulverizing, blending and grinding process. Most pulverizing is handled with disk mills that use 400-600 individual blades that can reduce materials to a fine powder. For more fragile materials, a hammermill may be used. Depending on the desired consistency of the finished product, blending is completed in either a ribbon blender or auger/screw type.
MARKETING PHASE BEGINS
With all materials processed, the marketing facet begins. The unique color of “The Gates” makes it challenging to find potential customers; however, it's a perfect property for water and sewer PVC pipes. Nicos will be placing ads in trade publications as well as using their existing list of customer contacts to find a new home for the materials. Their contract with “The Gates” a project team, including Christo and Jeanne-Claude, does not allow Nicos to advertise the materials as the former product of “The Gates” because of security concerns. This means that the nylon 66 fabric that was shredded and baled could be remelted and respun into yarn turning up anywhere. Since it is possible for the yarn to be dyed brown or black, you'll never know if the socks or that jacket you're wearing were once part of a historical art exhibit. The same goes for the PVC vinyl. Perrone says, “If it is coextruded with more PVC material on the outside, it could be white;” its former life will remain a secret.
However, Nicos did receive a special approval from the artists to allow engineering rulers to be made for The Vinyl Institute. According to Perrone, the rulers will carry the disclaimer, “This ruler was manufactured using recycled products; made of “The Gates” vinyl material, processed by Nicos Polymers, compliments of the Vinyl Institute,” which will be giving them out.

HOW NICOS WAS LAUNCHED
With over 25 years in business, Nicos began as the brainchild of James and Tara Knicos in 1978. In the late 70s, companies were not as concerned with the environment or the idea of recycling; however “James and Tara saw an opportunity to not only grow a business by working with producers to reclaim their materials, but serve the environment as well. They saw an opportunity to reprocess PVC which back then was considered a problem material.” Today, the company processes over 90 million pounds of material per year, and with the current structure of shifts can bring that amount up to 120 million pounds. However, with more personnel, Nicos can even surpass that amount.
Nicos Polymer's main client base, 85 percent to 95 percent, is custom processing for producers of raw materials or plastic product manufacturers. Although naming company names would be a breach of professional confidentiality, Perrone explains that a company “producing resin or pellet where they need us to either change size or blend materials to make a new product, or strictly package it for them into bulk bags or super sacks” is frequently the procedure followed for raw material producers. With plastic product manufacturers, such as fence or window profile, it's the nature of extrusion to have rejects. However, an option for extruding, molding, or thermoforming companies is to have the material ground or pulverized back into a powder form so that the material can be given a second chance.
Custom processing involves a keen eye for detail. According to Perrone, they may need to “control temperature, grind size, and depending on the process, it can get fairly complicated. Some blending needs to have stabilizing ingredients added so that when the material is put under heat to make a molten part, it doesn't change color or physical properties to where its not doing its job.” In some instances, Nicos may need to follow a client's “recipe”.
A family run business, Nicos also has an extended family feel to it. Tara cooks lunch for the office staff four days per week, and she doesn't make sandwiches either. They are treated to lavish lunches that are more like meals such as roasted chicken breast, brown rice, mashed potatoes and gravy, and corn on the cob. Six times yearly, she also cooks for all 71 employees. Perrone says: “All employees are known by name, and Jim and Tara make a point to go through the plant frequently to say hello to everyone and get to know them personally.”
Servicing local, national and international clients, “The Gates” venture has been the favorite project for many at Nicos simply because of the historical significance that the company played in the artwork itself. Perrone comments that so many people wanted to know why the exhibit only lasted for two weeks. Christo told him he looks at his artwork “as a reflection of what life is like…you're only here for a limited time so make the best of it.” While he says that Jeanne-Claude added, “Think of it as a rainbow. It's here to enjoy and then it's gone.” Perrone sums up: “We helped them make “The Gates” disappear forever.”