1. Introduction

Despite the rise of digital manufacturing in prosthetics and orthotics globally, traditional manufacturing still remains the viable and preferred choice in many developing nations.

South Africa is no different, with bulk of manufacturing government hospitals relying solely on traditional manufacturing. Similalrly with private sector, who operate at small scale rely on traditional manufacturing, and Ludada and Associates Orthopaedic Service is no different. However, at Ludada and Associates Orthopaedic Services (LAOS), we recognized the environmental challenges posed by the traditional manufacturing methods.

To which we decided to keep our manufacturing waste from the beginning of our manufacturing in 2020.

In an era where sustainability is a priority for organizations worldwide, we sought to evaluate the environmental impact of our traditional manufacturing. By conducting a four-year waste audit covering the period from 2020 to 2024. The purpose of the audit is to identify the type of waste and the quantities thereof, in order to identify sustainable alternative that will reduce waste towards the landfill.

This article therefore will present the findings of our waste audit, our ambitious sustainability targets for traditional manufacturing, through our commitment to adopting circular economy principles in prosthetics and orthotics manufacturing.

LAOS 4-Year Waste Audit

2. Understanding Environmental Impact

The manufacturing of prosthetic and orthotic devices involves several processes that generate waste material. By identifying, quantifying and understanding these materials, we can develop effective strategies to minimize waste and improve our overall sustainability.

I. Method of waste collection 

In 2020, we made the decision not to dispose any of our manufacturing waste, in order to have clear and quantifiable environmental impact measurement. The accumulated waste is categorized by material type and quantified by weight and counting of items where appropriate.

II. Types of Waste Generated:

   a. Plaster of Paris Bandage waste: (Negative Cast)

• • Use: These bandages capture the shape of the affected body part, forming a negative cast.
  • Waste: The negative cast contributed 95.6 kg of total waste, the third-highest source.

Plaster of Paris Bandage Waste Collection at LAOS

b. Plaster of Paris Powder waste (Positive Cast):

• • Use: Plaster of Paris powder is mixed with water and filled into the negative cast to create a positive model, which serves as the basis for manufacturing the orthotic and prosthetic device.
  • Waste: The positive model was the largest waste contributor, amounting to 881.5 kg or 38 bags of sack.

• • 

    Plaster of Paris Model Waste Collection at LAOS

C. Plastic HDPE waste:

• Use: High-density polyethylene (HDPE) and Polypropylene are heated and formed against the positive model to take patient shape.
• Waste: Plastic waste accounted for 108 kg, making it the second-highest contributor

d. Carbon Copy waste:

III. Waste weighted distribution 

Over four years, LAOS accumulated a total of 1,096.8 kg of waste. The breakdown of waste by material is as follows:

• Plaster of Paris Model (Positive Cast): 80.3% (881.5 kg)
• Plaster of Paris Bandages (Negative Cast): 8.7% (95.6 kg)
• Plastic HDPE: 9.3% (108 kg)
• Carbon Copy: 1% (11.2)

V. Environmental Sustainability Goal 

As the saying goes, “What you cannot measure, you cannot manage.” This waste audit has provided us with valuable insights to guide our sustainability efforts. Our goal is to reduce waste directed to landfills from 89% to 50, to 25% and below 5% by 2030. The audit findings will inform our ongoing efforts to create a zero-waste ecosystem, emphasizing waste reduction, reuse, and recycling.