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Cleaner Production Case Study

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Cleaner Production Case Study CLEANER PRODUCTION CASE STUDY CONTAINER RECONDITIONING SERVICES PTY LTD SUMMARY The installation of a new, fully automated drum laundering line has greatly decreased the company’s operating costs by reducing use and subsequent disposal of solvents, energy use and solid waste disposal costs while improving productivity.The far more efficient and safer process is saving the company over $10,000 per annum with a payback of only six and a half months. DEPARTMENT FOR environment and heritage CASE STUDY CASE STUDY CASE STUDY CASE STUDY CONTAINER RECONDITIONING SERVICES PTY LTD Business profile CRS Container Reconditioning Services Pty Ltd is one of South Australia’s largest drum reconditioners, holding approximately 50% of the South Australian market and a small portion of the Victorian, New South Wales and Northern Territory markets.The company proprietor began trading in used drums in 1991 as a sole operator before starting reconditioning operations at the present site in 1996.The company now employs 12 staff. Financial assistance provided An interest-free loan of $16,250 for purchase of the new equipment was provided by the EPA’s Pollution Prevention Fund. Technology implemented A fully automatic drum laundering line. Cleaner production motivators To provide quality products and services to customers while reducing wastage and associated environmental costs. TRADITIONAL APPROACH The reconditioning process cleans, and restores where necessary, 205 litre drums and 1000 litre intermediate bulk containers for re-use by the supplier or new customers.The open- and closed-head 205 litre drums had contained used oil, solvent, paint, surfactant, detergent, acid and caustic materials. The previous inefficient method of reconditioning drums for re-use exposed employees to undesirable levels of solvent fumes and manual handling. Only 130 drums could be cleaned each day and some drums, such as those that contained resin, could not be reconditioned. Solvent disposal, energy, caustic soda and waste costs were extremely high. WASTE MANAGEMENT Processes The used drums were first drained of residues and then placed on spickets to be generating waste washed with a strong caustic soda solution before a water wash. Solvent was then added to the drum to remove washing stains and used to wipe the outside of the drum to remove grease, oil and/or the label. Waste stream • solvent fumes description • used solvent • used caustic solution • wastewater • solid waste #1 CASE STUDY CASE STUDY CASE STUDY CASE STUDY Traditional Process New Process Drums drained Drums drained Inver ted onto spicket Drums lifted onto the for caustic washing conveyor of laundering line Drums fail Moved to second inspection spicket for water wash Automated process Section 1 Caustic washes interior and exterior of drums Drums inspected for cleanliness Section 2 Interior & exterior of Solvent poured into drums rinsed with hot drum and rolled on water and air dried ground to remove cleaning stains Section 3 Drum injected with steam for rapid drying Drum bungs removed and solvent extracted Drum shot blasted Drums moved to vacuum drum drying line Drums tested in accordance with Drums tested in Dangerous Goods Code accordance with Dangerous Goods Code Drum ends re-rolled Drum ends re-rolled Drum labels ground off Drum labels ground off Drum repainted ready for sale Drum exterior cleaned manually with solvent Drum repainted ready for sale CLEANER PRODUCTION INITIATIVES Benefits recommended and implemented The new automated drum laundering line provides higher pressure caustic and water washes, improving internal and external cleanliness. It can launder a larger variety of drums that were previously disposed to landfill. A further benefit of the EPA assistance has been that savings in running costs have allowed the purchase and installation of a fully automated shot blasting system for the removal of flaky paint.This equipment further improves productivity and quality while reducing manual handling. #2 BENEFITS ENVIRONMENTAL Solvents • Solvent usage reduced by 76% • Used solvent disposal reduced by 63% but likely to increase significantly now that old stock has been disposed Energy • Energy consumption reduced by 17% by incorporating the use of a maxi-therm boiler system rather than heavy-duty electrical elements Wastewater • Wastewater discharge reduced by 6000 L p.a. Solid waste • Solid waste to landfill reduced by 40% as a greater variety of drums can be reconditioned ECONOMIC Solvents • Solvent purchases reduced by $6000 p.a. • Solvent disposal costs reduced by $2000 p.a. Energy • Electricity cost savings of $1300 p.a. Solid Waste • Solid waste charges reduced by $800 p.a. Productivity • Drum reconditioning capacity increased from 130 drums/day to 400 drums/day Payback period • 6 months OHS • No wiping down of drums with solvent • Reduced fumes in factory from flammable solvent • No manual handling of drums full of solvent • Fewer repetitive strain injuries WHERE TO FIND ADDITIONAL INFORMATION Eco-efficiency Team Mr Pat Ryan Environment Protection Agency Director GPO Box 2607 CRS Container Reconditioning Services Adelaide SA 5001 3 Chamberlain Street Wingfield SA 5013 Phone (08) 8204 2027 www.epa.sa.gov.au Phone (08) 8244 4171 Totally Chlorine Free TCF Recycled R Content .
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