This article appeared in 'On the Farm' in June 2003.

The rapid adoption of the use of poly irrigation tubing throughout the Delta is proof enough that decision makers in row crop agriculture realized early on that the product's benefits would outweigh any drawbacks. Poly tubing is easy, convenient, offers multiple uses and allows for spur-of-the-moment irrigation and water movement decisions.

However, the rapid influx and widespread use of poly tubing did create at least one nagging problem for farmers: what to do at season's end with the tubing left in the field? Usually it was piled at the edge of fields, buried, burned or ended up in landfills, which was inconvenient and expensive. The method for moving water was new enough that few farmers gave much thought to effective disposal, but as the seasons of use grew so did the piles of used poly tubing

As the search for answers began, an environmentally- and farmer-friendly solution was proposed by the same industry leaders who were selling the tubing. Farmers needed a way to turn the pipe back in, and the industry needed a method for recycling it.

That's where Delta Plastics of the South, headquartered in Stuttgart, Ark., took the lead.

Delta Plastics is a national leader in the manufacture of poly irrigation tubing. From its plant in Stuttgart, the company produces a full line of high-quality tubing that is sold through a network of dealers throughout the region. Their manufacturing process involves a proprietary blend of virgin poly resins, which are formulated for strength and to resist cracking and the harmful effects of the sun. Delta Plastic's focus during the entire manufacturing process is on providing a consistently high-quality product to the end user.

In some respects, that was the easy part. Making the tubing proved easier than getting rid of it.

Dhu Thompson, owner of Delta Plastics of the South, and his people faced some tough challenges in their effort to provide a practical disposal solution.

First, poly tubing used in an agricultural application is going to end up dirty. Any material in the outdoors becomes laden with soil, vegetative matter and other contaminants. In their first attempts at various recycling methods, they quickly found dirt was their nemesis. They simply couldn't get the tubing clean enough to recycle it into a usable form, at least not with a method that was feasible.

Enter the persistence of plant manager Lon Busick. He, with vital input from other Delta Plastics employees, integrated equipment commonly used in other industries with some innovative ideas of his own and found a solution to the cleaning obstacle. The solution turned out to be unique and profitable enough to eventually receive a U.S. patent. Seven years of tinkering, redesign and trial and error finally resulted in a perfected system.

Today, Delta Plastic's recycling operation runs 24 hours a day, seven days a week. The recycled material is called certified post consumer resin. This resin is not of the quality necessary to use in new poly tubing, but it is highly desirable for use in the manufacture of garbage bags and agricultural or construction films.

The obstacle of logistics
While Thompson, Busick and a team of other persistent employees were working on the cleaning and recycling process, efforts were also underway to solve another major obstacle: logistics.

The tremendous acceptance and success of the use of poly tubing resulted in an immense volume of used tubing scattered throughout the Delta. Thompson needed to accommodate growers with ease and convenience, but he had to do it economically.

He began by meeting the growers on their own turf. He set up collection sites where growers could bring the used tubing and leave it for pick up by the Delta Plastics' recycling unit.

At first, the sites were widespread but targeted for the areas of highest poly tubing use. Today, more than 100 collection sites are available for farmers to return their used tubing. Farmers must absorb some small costs of transportation to the sites, but if the tubing was originally sold by Delta Plastics of the South, the hauling away and recycling of the tubing is a free service to growers.

Tubing from other manufacturers is welcomed for recycling, but growers are charged a small fee for the service.

A fleet of specialized trucks runs throughout the region picking up tubing at the collection sites. In addition, on-site collections can be arranged at the farmers' locations for a minimal fee. The trucks run five to six days per week, and last year alone hauled almost 18 million pounds of waste plastic from the region. Since 1998, more than 83 million pounds of used poly tubing have been collected for recycling.

"Delta Plastics is very deserving of any recognition they receive," says Steve Martin, chief of Solid Waste Management with the Arkansas Department of Environmental Quality. "They decided they were going to make this recycling thing work and pulled through when it probably would have been easier for them to go in another direction."

Delta Plastics of the South passed its 10-year milestone in 2002. The company was founded in 1993, but didn't find its current stability until 1996 when it was acquired by an investor group under the leadership of Thompson, a former Louisiana banker.

With his wife, Mary Ellen, keeping the operation's books, Thompson left the banking business and dove into the operations of the company. As it became evident recycling the tubing would be integral to the continued success of selling it to growers, he divided the company into two distinct but complementary businesses; manufacturing and recycling.

No turning back now
In the rural community of Stuttgart, where for decades agriculture provided the stability of the area's economy, Delta Plastics of the South has been a success story and a saving grace. Delta Plastics has about 60 employees, and Thompson is clearly excited about the company's prospects.

"We have a big future in front of us. Where else could you be a part of something that can be commercially successful, while still having such a positive affect on the environment?" says Thompson. "Our operation is pretty simple. We make and sell poly tubing that helps the farmer put water in the field for the crops. After the season, we pick it up and haul it off. We are the only company in the United States doing what we are doing, and we are very proud of that."

Is his wife still keeping the books?

"No," he laughs. "We recently added a controller to our staff, but she still keeps an eye on things."

Giving back reaps rewards
Delta Plastics is the 2003 recipient of the Crystal Award from Keep Arkansas Beautiful, a state agency charged with litter reduction, the promotion of recycling and the encouragement and support of community beautification efforts.

"We are very proud to have Delta Plastics as our 2003 award recipient in only their second year of consideration. We applaud their leadership and the example they set for businesses in the field of recycling and litter reduction in our state, as well as the other states of the region," says Jack Singleton, staff member at Keep Arkansas Beautiful. Michelle Gillham, a recycling coordinator with ADEQ, says "Arkansas is fortunate to have a company like Delta Plastics call our state home. They are a jewel for our state."

Delta Plastics of the South has also been honored by the Arkansas Recycling Coalition and the Arkansas Wildlife Federation.

(To learn more about Keep Arkansas Beautiful, contact the agency at 888-742-8701.)

Reprinted with permission from 'On the Farm' Magazine © 2003