Circular Innovation: Andrew Franzone Of Allen Field Company On The Role of Zero Waste and Efficiency in Shaping Future Businesses
An Interview With Martita Mestey
Commitment from Leadership: Sustainability initiatives must be prioritized from the top down. As president, I openly support and encourage investments in circular solutions, setting a clear standard for the entire organization.
As businesses face growing pressure to address environmental concerns, the principles of circular innovation have become increasingly vital. By focusing on zero waste and efficiency, companies can not only reduce their ecological footprint but also unlock new opportunities for growth, resilience, and profitability. How can businesses successfully incorporate these strategies to shape a sustainable future? In this interview series, we are talking with industry leaders, sustainability experts, innovators, and entrepreneurs about “Circular Innovation: The Role of Zero Waste and Efficiency in Shaping Future Businesses.”
As part of this series, I had the pleasure of interviewing AJ Franzone, President of Allen Field Co., Inc.
Andrew “AJ” Franzone is the CEO of Allen Field Co., Inc., a global leader specializing in sustainable, reusable, and high-performance packaging components. With extensive experience in business strategy, sustainability, and operational innovation, AJ guides companies in adopting circular economy principles to enhance efficiency, reduce waste, and drive profitability. His leadership emphasizes practical, scalable solutions that help businesses transition toward more sustainable practices without compromising quality or performance.
Thank you so much for doing this with us! Our readers would love to get to know you a bit better. How did you become involved in the circular economy and zero waste initiatives?
Well, we started seeing more customers asking about alternatives to virgin plastics, especially the big players like Amazon and Apple. They were pushing hard for single-stream packaging and looking to eliminate plastic wherever possible. That started to influence the rest of the industry, even companies that didn’t have the same margins or infrastructure to make big shifts overnight. For us, it was a wake-up call. We knew we couldn’t flip a switch and be zero waste, especially with products that need to carry weight and meet strict performance standards. But we could start pushing in the right direction. What really drove it home was when the price of recycled materials came down enough to make it a feasible option. Once the cost gap narrowed, we started building it into more of our product line without having to pass on major price hikes to customers. That’s when it became something we could really scale.
Can you share your professional background and how it prepared you to innovate in this space?
My background is rooted in running a manufacturing business, so I’ve always been focused on making things work better. That includes improving processes, reducing waste, and building stronger supply chains. Over the years, I’ve seen how small changes in materials or design can lead to big improvements in cost, efficiency, and environmental impact. As sustainability became a bigger focus for our customers, it became clear that the most effective solutions are the ones that don’t require a trade-off. That’s what led us toward circular innovation. Not because it’s trendy, but because it’s a smarter and more resilient way to operate.
What drives your commitment to promoting efficiency and zero waste in business?
First, I want to be really clear that in packaging it is really difficult to talk about zero waste.
We make components that need to perform under real pressure. They carry weight, survive rough shipping, and protect high-value products. Some materials are just necessary for that. That said, the concept of reducing waste and being more responsible absolutely applies to other parts of our business, and I think it’s important to continuously try to improve. That includes our sustainability efforts.
Even before people focused on a company’s sustainability, we were always trying to find ways to cut down on waste anywhere we could. It’s just bad business to waste anything — whether it’s material, time, or labor. So what really drives my commitment is knowing that efficiency and sustainability aren’t just theoretical ideals. They go hand in hand with good operations.
I’ve seen firsthand how even small improvements in packaging design can significantly reduce waste and cut costs, making a noticeable impact on both the bottom line and the environment. Over the past few years, we’ve worked hard to incorporate post-consumer recycled materials across our product line. We’ve also introduced paper and cloth alternatives for customers who need single-stream packaging. These aren’t just marketing claims — they’re the result of customer demand, rigorous testing, and a practical mindset.
I think we approach every project with a combination of passion, care, and deep industry expertise. We’ve been solving real problems like product damage, wasted materials, and inefficient shipping for decades. It’s motivating to see customers experience tangible benefits, whether it’s lower freight costs, fewer returns, or a stronger sustainability story.
As I’ve mentioned in other interviews, our work with post-consumer recycled (PCR) materials isn’t driven by trends or buzzwords. It’s driven by the clear, practical benefits PCR brings. Using recycled materials extends the life cycle of plastics and cuts down reliance on virgin resources. That saves our clients money and reduces overall waste. Seeing those results and hearing the positive feedback from customers who see measurable gains from these innovations fuels my passion for promoting greater efficiency across industries.
How does your organization incorporate the principles of the circular economy into its business model?
We’ve built our business around circular thinking. That means designing components that are made to last, easy to reuse, and straightforward to recycle. The goal is to reduce waste at every stage — during manufacturing, in transit, and at the end of a product’s life.
One of the most effective ways we support a circular system is by using post-consumer recycled materials. It’s a way to give plastic a second life in products that aren’t single-use. Instead of relying entirely on virgin resin, we’re offering components that are both high-performing and part of a larger effort to close the loop. We’ve also introduced paper, cloth, and bamboo elements where possible. For example, some of our clients have transitioned to cotton cloth or kraft paper handles to meet single-stream packaging requirements. These shifts aren’t always easy, but they’re important.
Can you provide an example of how zero waste practices have improved your business operations or profitability?
A great example is our shift to post-consumer recycled plastic. At first, it was too expensive and hard to source, but now that supply has improved, we’ve been able to meet customer goals without huge cost increases. It’s even given us more supply chain stability. That’s helped us stay on schedule, meet performance standards, and avoid material delays. That kind of consistency is a big win, especially in uncertain markets.
What role does innovation play in advancing zero waste initiatives, and how do you foster that innovation within your company?
Many of our best product changes originate from within. Our teams constantly ask: Can we use a different material? Can we reduce weight without losing strength? We’ve built our innovation process around those questions. And it’s not just engineers — it’s operations and customer service, too — everyone’s part of it.
We foster that kind of thinking by making innovation part of everyone’s job. We conduct regular internal reviews, where cross-functional teams can raise challenges and propose new solutions. Some of our best ideas — such as testing bamboo for specific components — have originated in this way. It’s not about flashy breakthroughs. It’s about constant, practical improvements.
What are the key challenges to implementing circular economy principles in mainstream business models, and how do you address them?
One challenge is simply getting access to good recycled materials. Quality PCR isn’t always easy to find, especially if you’re not near a strong manufacturing region. We’re lucky — we’ve built relationships with reliable suppliers and we test everything in-house.
Another challenge is shifting mindsets. Many companies still operate on linear models built around one-and-done packaging. Moving toward reuse or recycled content requires them to rethink design, sourcing, and even how they communicate with customers. It takes time.
Measuring impact can also be difficult. If sustainability goals are vague, they’re hard to implement. We track clear metrics like the percentage of PCR used in a product or the number of components converted to paper-based alternatives.
How do you see circular economy and zero waste practices evolving in the future, and what role do you want your organization to play?
I think we’re headed toward a future where circular economy practices won’t be optional. They’ll be expected not just by regulators, but by customers, partners, and the next generation of workers and leaders. What’s considered forward-thinking today will eventually be seen as the bare minimum. That’s a good thing, but it also means companies need to start making changes now if they want to stay relevant.
I see the circular economy becoming more integrated into core business strategy, not just something tied to sustainability departments. It’s going to influence how products are designed, how materials are sourced, and how value is measured across the entire lifecycle of a product. Efficiency, durability, and reusability will carry more weight than they have in the past.
Our role is to make that shift easier. We’re not trying to push trends. We’re focused on creating solutions that are durable, practical, and measurable — solutions that help companies move toward circular systems without disrupting their operations. If we can be the partner that makes circular design feel like common sense instead of a heavy lift, then we’re doing our job right.
What are your “5 Things A Business Needs In Order To Successfully Adopt Zero Waste And Circular Economy Principles”?
- Commitment from Leadership: Sustainability initiatives must be prioritized from the top down. As president, I openly support and encourage investments in circular solutions, setting a clear standard for the entire organization.
- Clear Metrics: Businesses need measurable goals to track progress. When we introduced PCR components, we closely monitored waste reduction, cost impact, and performance data.
- Cross-Functional Collaboration: Circular practices require input from all departments. We’ve made innovation everyone’s responsibility, fostering better solutions and deeper employee buy-in.
- Reliable Supply Chain Partnerships: To ensure steady materials flow, we proactively established relationships with trusted domestic PCR material suppliers, helping us avoid disruptions and maintain quality.
- Customer Education and Engagement: Transparency with customers about sustainability goals and practices creates loyalty and shared commitment. Regular communication about the benefits and performance of our sustainable products has significantly strengthened customer relationships.
Who or what has been the biggest inspiration in your pursuit of creating a more sustainable, circular business model?
My inspiration comes from companies and leaders who successfully integrate profitability and sustainability without compromise. Leaders who innovate practically, solving real-world problems while maintaining a clear vision for a sustainable future, continually inspire me.
If you could implement one big change across industries to accelerate the adoption of the circular economy, what would it be and why?
If I could make one big change, it would be to expand and modernize the infrastructure that supports recycled materials across industries. A lot of companies want to use more PCR, but they don’t always have access to a reliable, high-quality supply. That’s especially true outside of major manufacturing and shipping hubs.
We’ve seen how having a strong manufacturing presence and access to regional suppliers on the East Coast, including in Pennsylvania where we operate, can make it more feasible to use recycled content in durable components.
When there’s local investment in recycling, sourcing, and manufacturing, it shortens supply chains, improves reliability, and reduces environmental impact. It also makes circular practices more practical, not just for packaging, but for any product that needs to perform in rigorous conditions. If more regions had this kind of infrastructure in place, it would accelerate adoption across the board and make it easier for companies to commit to circular solutions with confidence.
How can our readers further follow your work or your company online?
Readers can follow our work and innovations on our website at www.allenfield.com, where we regularly update our latest solutions, case studies, and sustainability progress. Additionally, connecting with me on LinkedIn is a great way to stay updated and engage directly.
This was great. Thanks for taking time for us to learn more about you and your business. We wish you continued success!
Circular Innovation: Andrew Franzone Of Allen Field Company On The Role of Zero Waste and… was originally published in Authority Magazine on Medium, where people are continuing the conversation by highlighting and responding to this story.