Building a Zero Landfill Future: Inside VLS’ New Braunfels, Texas Non-Hazardous Waste Processing Facility

Manufacturers looking to go Zero Landfill now have the opportunity to meet Sustainability goals. VLS Environmental Solutions is building a unique non-hazardous waste processing facility in New Braunfels, Texas to help manufacturers achieve their Sustainability goals.

Strategically located between Austin and San Antonio, the facility – equipped with shredding and solidification capabilities – is on track to begin operations by early 2027. Once complete, it will give Central Texas manufacturers a proven, compliant path to Zero Landfill — processing byproducts for waste-to-energy, engineered fuel, and handling liquid waste through solidification, all under one permitted roof.

Central Texas is one of the fastest-growing industrial corridors in the country. Manufacturing activity along the I-35 corridor keeps rising — and so does the volume of industrial byproducts that need a responsible outlet.

New Braunfels positions VLS close to the manufacturers who generate that waste and to the cement kilns and gasifiers that can use processed fuel as a cleaner energy source. A shorter distance between waste source, processing site, and end user means fewer transport miles, lower logistics costs, and a smaller carbon footprint.

This isn't just an expansion — it's a commitment to building the infrastructure that Central Texas manufacturers need to meet their Zero Landfill goals.

A facility built to process waste reliably and safely starts with solid materials. VLS is sourcing locally and domestically wherever possible, supporting Texas and American suppliers while keeping supply chains short.

Crews are pouring more than 5,000 cubic yards of Texas concrete for the site's foundations, fuel bins, sawdust bin, floors, and walls. A standard concrete mixer truck carries about 10 cubic yards — that adds up to roughly 500 truckloads.

Local sourcing cuts hauling distances and keeps dollars in the regional economy. The concrete will form the structural backbone of the facility, including the containment systems that support safe material handling for both solid and liquid waste streams.

The structure is being built with 457 tons of American steel — more than 900,000 pounds. Steel frames the buildings and will support the heavy industrial equipment running around the clock.

Choosing domestic steel reflects VLS' commitment to quality and accountability at every stage of the project.

To power and connect the site, VLS is installing 37 miles of American copper and aluminum cable — longer than the drive from New Braunfels to downtown San Antonio.

This cable network will power the shredders, conveyors, and controls, and carry the communication systems that keep operations monitored and coordinated. Infrastructure of this scale is designed to support reliable uptime from day one — essential for clients who depend on steady, predictable waste outlets.

The core mission of the New Braunfels facility is simple: divert non-hazardous industrial waste from the landfill and recover its energy value instead.

Engineered Fuel isn't a single technology — it's a framework. At VLS, the process starts with careful evaluation, moves through processing, and ends with a finished product that replaces fossil fuels in industrial energy systems.

Here's how it works:

VLS' Zero Landfill programs already divert more than one million tons of industrial waste annually. The New Braunfels facility is being built to expand that capacity and bring these solutions closer to Central Texas manufacturers.

The facility is designed to accept a broad range of non-hazardous residuals, including:

All materials are reviewed for eligibility before acceptance, and the TCEQ permit defines the boundaries of what can be processed.

Under federal Non-Hazardous Secondary Material (NHSM) rules (40 CFR Part 241), qualifying processed material may no longer be classified as solid waste once it meets fuel specifications. That means:

For manufacturers with sustainability targets, this documentation directly supports the reporting you need to validate progress.

At the center of the waste-to-energy process will be three industrial shredders from SSI Shredding Systems, Inc. These machines will break down industrial byproducts into a precise engineered fuel — one of the most consistent specifications in the industry.

The engineered fuel produced here replaces carbon and natural gas fuels in cement kilns and gasifiers, directly reducing reliance on traditional fossil fuels while giving manufacturers a compliant Zero Landfill pathway.

Not all industrial waste arrives as a solid. That's why VLS' New Braunfels facility is also being designed with liquid waste solidification capabilities — a critical service for manufacturers managing wastewater, sludges, and other liquid byproducts that can't go directly into a shredder or a landfill.

Solidification converts liquid or semi-liquid waste into a stable, solid form through a carefully managed process. The result is material that:

For industrial clients generating both solid and liquid waste streams, having solidification and engineered fuel processing under one roof — at one permitted facility — simplifies logistics, reduces vendor complexity, and supports a more complete Zero Landfill strategy.

Organizations often make strong progress toward Zero Landfill by recycling high-value materials like metals and cardboard. The challenge comes with what's left — the non-recyclable residuals that are difficult to manage and tend to default to the landfill.

The New Braunfels facility is being built specifically for that "last mile" of waste. Between waste-to-energy processing, engineered fuel production, and solidification capabilities, VLS is building a facility that can handle the hard stuff — the waste streams that most programs can't fully resolve.

For manufacturers in the region, this means:

VLS' existing programs already divert over one million tons of industrial waste from landfills annually. The New Braunfels facility is the next step in scaling that impact across Central Texas.

Chief Strategy Officer Rob Wheatley shared the vision:

“New Braunfels is a strategic investment in the next stage of VLS’s growth. We are expanding our ability to take industrial materials that are difficult to recycle and manufacture engineered fuels that meet the demanding specifications of cement producers. That creates value on both sides of our business: manufacturers gain a dependable alternative to landfill disposal, and cement producers gain a fuel source that reduces their reliance on traditional fossil fuels. This facility strengthens our national platform and demonstrates how VLS is building long-term growth around the needs of our customers.”

With more than 1,500 employees across 50+ locations in North America, VLS delivers innovative solutions that support clients in achieving their sustainability goals.

What is waste-to-energy processing?
Waste-to-energy takes non-hazardous industrial residuals that would otherwise go to a landfill and converts them into a usable fuel. At the New Braunfels facility, those materials will be shredded and sized into an engineered fuel used by cement kilns and gasifiers to replace fossil fuels.

What is engineered fuel?
Engineered fuel means that your waste is no longer a waste. Our processing of solid materials for disposal meets 40 CFR 241 regulations that exempt your waste from RCRA regulations because VLS is producing a fuel from your discarded materials.

What types of waste will the New Braunfels facility accept?
The facility will process non-hazardous industrial residuals under its TCEQ permit — including plant trash, off-spec products, packaging, and liquid waste that can be solidified. All materials are reviewed for eligibility before acceptance.

What is solidification and why does it matter?
Solidification converts liquid or semi-liquid waste into a stable solid form. It opens disposal and diversion pathways for waste streams that can't be processed as liquids, and it reduces risk during storage and transport.

Who will benefit from this facility?
Manufacturers with non-hazardous waste streams looking to reach Zero Landfill goals, cement kilns seeking alternative fuel sources, and Central Texas communities that benefit from reduced landfill reliance and sustainable industrial investment.

The New Braunfels facility represents what's possible when sustainability, compliance, and smart engineering come together. Built with local and American materials and designed to handle everything from solid industrial byproducts to liquid waste streams, it will give Central Texas manufacturers the comprehensive tools they need to reach Zero Landfill.

Whether you're facing new regulations, mounting waste volumes, or sustainability commitments that demand more than recycling can deliver, VLS can build a solution around your needs.

Let's work together toward zero waste. Call (877) 861-8588 or email info@vlses.com to talk with our team about waste-to-energy, solidification, and landfill diversion solutions for your operation.