Manufacturing’s ‘Missing Middle’ Is Compromising Financial And Sustainability Goals
Manufacturers excel at tracking what goes in (raw materials) and what comes out (finished goods and waste collection). But between those two touchpoints lies the “missing middle” the day-to-day processes where waste quietly builds, profits leak, and sustainability targets slip out of reach.
“Production is king, so waste often slips under the radar,” explains Carole Rogan, Manufacturing Waste Expert at Biffa. “But every blind spot has a price tag. In today’s climate of rising costs and tougher regulations, data-driven visibility into that missing middle is no longer optional – it’s a competitive necessity.”
Carole highlights three common challenges holding manufacturers back, and how they can be turned into opportunities.
Challenge 1: Packaging that isn’t what it seems
Packaging can be deceptively complex once it enters the waste stream. A tray that looks recyclable may actually be lined with plastic, while bulk deliveries often arrive wrapped in mixed materials that require specialist processing.
The result is a disconnect between expectation and reality. Materials assumed to be recyclable frequently end up in general waste, driving up disposal costs and undermining sustainability reporting. One manufacturer Biffa supported discovered that over 40% of its ‘recyclable’ packaging required specialist processing, a hidden cost running into six figures each year before corrective action was taken.
Challenge 2: Inconsistent visibility across sites
Large manufacturing businesses often operate multiple facilities, each with its own routines, staffing patterns, and local practices. These variations are natural in fast-moving environments, but they can make it difficult to see the full picture.
One site may capture recycling data in detail, while another records waste more broadly. Seasonal recruitment and staff turnover can add further variability. For head offices, this makes comparing performance and identifying improvement opportunities challenging, leaving potential efficiencies untapped.
Challenge 3: Waste seen as separate from operations
In fast-paced production environments, waste is often treated as a side effect rather than a focus. A run of defective product may be accepted as a start-up issue, or segregation can slip during time-pressured clean-downs.
Each of these moments carries a hidden cost: wasted ingredients, packaging, and labour. Contamination is another major blind spot. If clean packaging is stored near raw materials, even minor slip-ups can send otherwise recyclable material straight to general waste. Over time, these disconnects erode both environmental performance and profitability.
From wasted cost to wasted no more
Data – from blind spots to benchmarks
Smart waste partners can track metrics in real time – from bin contamination levels to waste volumes by shift. With expert analysis, manufacturers can identify inefficiencies, replicate best practice across sites, and act on trends rather than retrospectively reporting on them. Tools such as Smart365 provide live visibility while simplifying compliance and reporting.
Waste audits – the gateway to visibility
A structured waste audit is often the fastest way to uncover the missing middle. On-site specialists review the full waste lifecycle, from production through to outputs and logistics – to reveal where value is leaking. Audits provide clear visibility, evidence to support internal decisions, and a practical improvement plan focused on measurable savings. As Rogan notes, “An audit isn’t about blame, it’s about clarity and opportunity.”
Training and culture – the quick win
Clear signage, education on recycling symbols, and appointing ‘Waste Champions’ can quickly reduce contamination and embed good habits. Small behavioural changes often deliver outsized returns when supported by the right data.
Preventing waste at the source
Prevention is always more valuable than recovery. Waste data can highlight where recurring production events are generating unnecessary loss – such as start-ups, changeovers, or surplus product. By making these impacts visible, manufacturers can decide where to focus improvements and stop avoidable waste before it reaches the bin.
Why this matters now
Recent legislation – from Extended Producer Responsibility (EPR) to Digital Waste Tracking – has made waste visibility urgent. Manufacturers now need accurate, auditable data not just for efficiency, but for legal compliance.
“Waste is no longer a back-office issue,” Rogan concludes. “It’s front and centre of profitability, compliance, and sustainability. Manufacturers who tackle the missing middle will protect their margins and strengthen their position as leaders in sustainable production.”
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