Students develop zero-waste solutions in industry-backed program

GAF Cedar City’s Eric Lewis and Josh Mecham (left)  Winning proposals included SUU business major Matt Cherry’s (center) idea to repurpose shredded foam for wall insulation, retired engineer Matt Lindsay’s (right of center) concept to use waste in highway impact materials, and Launch High School’s Thomas Daniels’ (right) proposal to incinerate waste for energy. 

CEDAR CITY, Utah — A cohort of students from Southern Utah University (SUU) and Southwest Technical College (STECH) has completed the GAF Zero Waste Cohort, a work-based learning program focused on sustainability and waste reduction in manufacturing. The initiative, supported by The Nucleus Institute and Talent Ready Utah, was developed in partnership with GAF, the nation’s largest producer of polyisocyanurate (polyiso) insulation.

The project began with a community-wide ideathon in December 2024 to find new uses for polyiso waste, a byproduct of roofing insulation production. Winning proposals included a method to repurpose shredded foam for wall insulation, a concept to use waste in highway impact materials, and a proposal to incinerate polyiso for energy recovery.

“At GAF, our goal is to make the production process as efficient and sustainable as possible,” said Eric Lewis, general manager at GAF Cedar City. “Big changes require fresh ideas and new perspectives.”

A faculty-led cohort of SUU and STECH students representing multiple academic programs worked in the lab with GAF engineers to develop solutions for reducing and repurposing manufacturing waste materials.

Following the ideathon, nine students from SUU and STECH joined the SUU Industry Challenge Lab on March 3. Guided by faculty, GAF mentors, and corporate engineers, students developed two solutions: a lightweight cement alternative using ground polyiso waste, and a combustion-based energy recovery model aimed at reducing electricity costs at GAF’s plant. Both concepts were presented to GAF engineers this summer and received positive feedback for further development.

“This collaboration helped us identify solutions outside of our normal considerations and think about broader opportunities,” said Josh Meacham, plant engineer at GAF. “One of the most valuable things a student can do is to participate in an industry project, internship, or research opportunity.”

The Nucleus Institute launch in August celebrated SUU industry connection, commercialization, and applied research opportunities for faculty and students, including the GAF Zero Waste lab. Pictured with Nucleus Insitute Executive Director Jefferson Moss (center) are SUU’s Dean Ken Hall, Dixie L. Leavitt School of Business, and Assistant VP of Workforce and Educational Opportunity Melynda Thorpe.

Students received academic credit and stipends through The Nucleus Institute, with tuition sponsored by GAF. Final technical documentation has been submitted for ongoing review and potential implementation.

“By engaging with industry partners, our students are shaping a stronger, more sustainable future,” said SUU President Mindy Benson. “In applied research settings, students worked side-by-side with workplace experts and leaders, demonstrating how higher education, government, and industry can unite to deliver real-world innovations that strengthen our local communities.”

More information on The Nucleus Institute is available at nucleusutah.org.