Transforming Waste into Innovation: ACRE’s Circular Journey

As consumers increasingly prioritize sustainability—66% of all and 75% of millennial respondents shared that sustainability influences their purchasing decisions according to a survey by McKinsey & Company. Materials like ACRE by Modern Mill are revolutionizing how buildings can become more eco-friendly, one of the planet’s largest carbon-emitting industries on the planet.

Modern Mill is at the forefront of sustainable and circular manufacturing with the use of a zero-waste process that transforms rice hulls into ACRE products. Below, we’ll explore the journey from rice hull to ACRE board, showcasing the eco-friendly process behind this remarkable product.

Upcycling Rice Hulls

The manufacturing process of ACRE begins with its primary ingredient, rice hulls. Commonly referred to as rice hulls or “husks,” they are a waste byproduct of the food production process. Each year, the United States grows over 20 billion pounds of rice, and while nearly half of the grains are exported, all hulls are destined for landfills. 

Modern Mill operates in Fernwood, Mississippi, and sources rice hulls from local farms. The hulls are ground down into a compound that serves as the base of ACRE products. These hulls are an excellent source of building materials given the durable aspects they provide and are a sensible replacement for old-growth wood species. Using resources like rice hulls which are harvested within months is a practical replacement to cutting down old-growth trees which take hundreds of years to reach maturity.

Innovative Manufacturing for Zero Waste

The manufacturing of ACRE is based on zero-waste principles. Modern Mill’s circular manufacturing process allows all ACRE scraps and shavings to be reused and recycled with lower-impact production methods such as looped systems to recycle water. 

By utilizing every piece of ACRE material, the process minimizes environmental impact and maximizes resource efficiency. Approaches like this are essential to promoting healthier production of materials and emphasizing the importance of saving carbon emissions, trees, and diverting global waste.

For a visual look at our manufacturing process, watch a tour of the facility here!

Strength and Durability Through Circular Economy

ACRE boards offer a high level of durability, compared to traditional wood, without the environmental drawbacks. Through circular manufacturing, the rice hulls are transformed into a material that is resistant to water, weather, pests and rot making ACRE ideal for both indoor and outdoor applications. This resilience means fewer replacements and less resource consumption over the product’s lifecycle.

Measurable Results

Consumers are demanding sustainable practices from their brands because they make a positive impact on the environment. Modern Mill’s manufacturing process has diverted over 20 million pounds of rice hulls from landfills and the use of ACRE has saved over 38,000 softwood trees. 

Using waste materials to create innovative products is a beneficial way to preserve natural resources, better the health of the environment, and promote zero-impact manufacturing processes.

Conclusion

From start to finish, ACRE represents a breakthrough in sustainable building materials, supporting both environmental health and high performance. Ready to explore how ACRE can transform your project? Order samples today or fill out the contact form below, and we’d be happy to start the conversation!