After World War II, the United States underwent a rapid transformation from an agricultural to an industrial society, marking the beginning of the modern environmental movement. In the first 25 years of this movement, the US has spent more than $1 trillion addressing environmental threats caused by commercial activities. Since that time, being environmentally responsible has been an ever-growing concern, with quantifiable results being paramount. Fortunately, many companies’ metalworking operations are motivated to ‘go green’ by a driver more significant than an environmentally friendly reputation.
Manufacturers are discovering that adopting a green philosophy and using green-engineered equipment can yield significant financial rewards, ultimately leading to sustainable manufacturing. Some examples of results that companies are achieving, as reported by the National Institute of Standards and Technology (NIST) include:
Like these companies, metalworking operations that consciously take steps to be environmentally friendly by using less energy, producing less scrap, or eliminating hazardous waste disposal will reap the financial rewards of sustainability by shifting to green-engineered equipment and processes.
An article published by the Environmental Protection Agency (EPA) states that there are many reasons why companies are pursuing a green approach to sustainability:
An April 2017 study published by the International Journal of Business and Social Science concluded that adopting green manufacturing practices has enhanced operational performance.
Green engineering is the design, commercialization, and use of processes and products that minimize pollution, promote sustainability, and protect human health without sacrificing economic viability and efficiency. Because of its many benefits, several international suppliers, including U.S.-based equipment manufacturer PRAB Inc., engineer and build all their systems with a green engineering philosophy.
PRAB’s entire metal scrap processing, fluid recycling, and wastewater treatment equipment product line are built to help manufacturers achieve their sustainability goals. They work with a wide range of industries within the metalworking sector to optimize operational performance by improving the management of their metal scrap and fluid waste streams, extending tool life, reducing new coolant purchases, and helping them to meet or exceed compliance to strict environmental rules and regulations.
Four important ways that metalworking operations can use green engineering to improve their environmental footprint and profit margin include:
One of the first areas to analyze is the waste stream. An article published by The Fabricator magazine, titled “Do you manage scrap properly?” states that scrap metal—in most instances—represents the second-largest source of revenue for a metalworking operation. That said, shops should determine the cost of hauling away metal scrap and the amount of cutting fluid used each month. Then, a monthly report with housekeeping numbers should be run to determine how much time and labor is spent on removing this waste, along with other maintenance and cleaning required in their current scrap and fluid management process. Next, they should quantify their monthly expenditures on new lubricants, cutting fluids, and metals.
When the metalworking operation knows its waste stream spending, it can solicit green engineering equipment suppliers to provide an efficient and reliable profit-building solution. With the right solution, these operations can:
• Reduce metal scrap volume. Shredders and crushers can cut the volume of hazardous scrap by up to 12 times. Briquetters can turn wet chips into compact briquettes that are easy to store and often yield a higher value when sold to scrap dealers. By reducing scrap volumes, shops can significantly lower the number of truckloads shipped to the recycler, significantly reducing haul-away costs.
• Separate metal scrap from fluid. Wringers/centrifuges and briquetters can separate cutting fluids from metal chips. Operations can reuse this easy-to-melt scrap (reducing new metal purchases) or recycle it, getting top dollar from secondary smelters. The extracted fluid can also be recycled for reuse or sale.
• Reclaim and filter fluids. Fluid separated from chips by a wringer or briquetter can be extracted through a centralized or machine-side fluid recycling system that filters and recovers up to 98% of valuable coolant. These filtration systems also automatically circulate the clean fluid back into the process. This significantly reduces the need to purchase new oil or coolant.
• Reduce energy consumption. Green-engineered equipment is typically designed to reduce energy consumption. One example is Eaton Corporation’s Fluid Power Division in Marshall, Michigan. After installing a new wastewater treatment system, Eaton experienced a drop in their wash water’s operating temperature, resulting in a 20% reduction in energy usage.
Metalworking operations can also improve their profitability and conserve resources by prolonging the life of their tooling. Filtering fluid with the proper recycling system has been proven to extend tool life by up to 25%.
In the United States, the EPA governs the generation and disposal of hazardous waste under Title 40 CFR, part 261 (Identification and Listing of Hazardous Waste) and 279 (Used Oil Regulations). Metal scrap containing free-flowing liquids is classified as hazardous waste.
Operators, maintenance, and other employees who handle these wastes are typically unfamiliar with non-compliance penalties. So, employees do not understand the financial repercussions when they take shortcuts or don’t follow proper waste-handling procedures. That is why it’s advisable to inform employees during orientation and training of the financial impact EPA and environmental fines can have on the company and their jobs. Managers and supervisors also need to know the costs associated with tracking and doing hazardous waste stream management paperwork.
Suppose there are pollution issues with water drainage coming from the business or leakage from containers filled with wet chips. In that case, there is another cost threat- the salability of the property. Proactive land and water protection can pay dividends in stable or increased property values. It can also help to avoid large clean-up and property rehabilitation costs and help maintain good community reputation.
Incorporating green-engineered equipment into metalworking operations can alleviate these threats. For example, conveyors, carts, and dumpers can help shops safely contain hazardous materials and prevent spillage and fluid leaks that can contaminate the ground and water. Horizontal screw presses can dewater hazardous grinding swarf or filter cake by up to 85% and the extracted fluids can be disposed of safely.
As metalworking operations look to increase their green profitability, ISO 14000 certification may provide a foundation for improvements. These internationally recognized standards and guidelines help companies comply with regulations and reduce waste, improve inefficiencies, and cut costs. The certification can also improve the ability to get capital, lower insurance rates, simplify labeling, get permits, defend against environmental litigation, and expand into global markets where the certification is requested or required.
Whether a manufacturer chooses to apply for ISO 14000 certification, use green-engineered equipment in its process, or both, the reduction of waste handling costs and the selling or reuse of what was once hazardous scrap metal and cutting fluid are proven to provide quantifiable results.
In this paper, we will explain how dirty coolant shortens tool life, identify primary and secondary tool replacement costs, clarify common misconceptions about the value of back-end investments, and explain how coolant recycling systems provide return on investment in multiple ways. Read our white paper.
(800) 968-7722
(800) 493-3462