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Energy consumption has long been a target for sustainability efforts at plastic processing facilities, as well as from the companies that supply equipment to those in the industry. Total energy consumption in the manufacturing sector decreased by 17 percent from 2002 to 2010, according to preliminary data collected in the 2010 Manufacturing Energy Consumption Survey. The manufacturing sector used over 14 quadrillion Btu of energy as a fuel in 2010, the report said, which is a decrease of 13 percent from the MECS 2002 level. Helping plastics processors cut energy use has been an objective of The Conair Group for many years, said Ray Kelly, vice president-engineering.
While noting not all auxiliaries are power hungry, Kelly said some processes, like resin drying, material handling and conveying, heat transfer systems and granulation for instance, can be very energy-intensive.
Although overall manufacturing output declined by three percent between 2002 and 2010, some manufacturing industries grew over the period, according to the MECS report.
Plastics Executives looking to make better decisions faster use the results of MAPP's benchmarking studies to determine where their organization stacks up to the rest of the industry.
1) Assess your existing equipment’s efficiencyTake a hard look at your welding shop and determine a time to make crucial upgrades that will increase overall productivity and quality as well as energy efficiency. Step 2 – Calculate input powerDivide the total output power by the power source’s efficiency, which is provided by the welding equipment manufacturer to yield input power in kilowatts (KW). Step 4 – Calculate the daily operating costs during idle periodsTo calculate the idle consumption per day, first take the input power multiplied by the idle hours per day.
Now find your power source’s input power idle number provided on the rating plate or in the instruction manual in watts and multiply it by the idle hours. Inverter-based power sources allow manufacturers to deliver more power output from new power electronics technology, resulting in a better performance-to-size ratio. 3) Closely track shop floor production and efficiencyAnother way to track energy efficiency, overall production efficiency and quality is to begin using production monitoring tools in your welding operations. As you may know or not know, Cerasis is not a manufacturing consultancy who provides direct services to manufacturers to improve direct manufacturing process. Over the years, machines and technology have developed to solve rapidly changing and complex manufacturing issues, and to meet consumer demand for better, faster, and higher-quality products all with the goal of lowering manufacturing costs still an important factor. With new technology comes the need for more knowledge and training to operate new, advanced equipment. To maintain control over the production process as new technology is developed, manufacturing executives are striving to get new information as quickly as possible, apply this information to existing infrastructure, and make better decisions, faster.
Look at your entire process as a whole, instead of focusing on just the products or manufacturing costs only that are associated with the whole. Balance your labor requirements and lower labor costs by taking a demand-calibrated approach, rather than a capacity-utilization approach to production decisions.
We've thoroughly enjoyed learning more and more about the "hyper productive workforce" and all of the other labor management capabilities after coming across the Easy Metrics blog. Second to labor, energy use is one of the highest manufacturing costs associated with running your operations.
The industrial sector accounts for approximately 31 percent of all energy consumption in the United States—consuming just over 21,000 trillion Btu annually—and much of this energy is used for manufacturing processes. To better manage your facility’s energy manufacturing costs, it helps to understand how you are charged for energy. Furthermore, the NIST, The National Association of Manufacturers, and The Manufacturing Institute put out a great white paper on how efficiency and innovation are improved when you reduce your energy manufacturing costs. With an improved, optimized system and real-time monitoring of how your production processes are operating and being managed, the manufacturing costs of regulatory compliance is expected to decrease. As stated in the beginning of this post, transportation costs can make up as much as 10% of total revenue.
Identifying common production process weaknesses can help manufacturers approach cutting manufacturing costs company wide, determine the best way to maintain ultimate operational visibility and control, and create a system for prioritizing ongoing optimization projects without failing to meet market demands.
Adam RobinsonAdam Robinson oversees the overall marketing strategy for Cerasis including website development, social media and content marketing, trade show marketing, email campaigns, and webinar marketing. Slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. How to reduce energy and water consumption in the preparation of raw materials in the ceramic tile manufacturing.
Dry and wet routes in the ceramic tile manufacturing process refer to two different technologies on how to prepare the raw materials for the forming stage. When the NRG power plant in El Segundo, Calif., was redesigned, two towers were demolished which caused extensive light from the plant to bother local neighbors.
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The environmental performance of products and processes has become a key issue to businesses and consumers, which is why many industries are investigating ways to minimize their effects on the environment. EPS-IA has conducted life cycle analyses for EPS insulation, and more specifically for structural insulated panels. EPS is capable of such a large return on investment because of its long life-span and ability to reduce energy consumption needs.
EPS-IA has also conducted analyses that evaluated the use of EPS as a shipping material compared to alternatives.
More specifically, the assessment—from raw material acquisition to processing, transportation and final disposition—shows that as recycling increases, atmospheric and waterborne emissions decrease by up to 9%.

A life cycle inventory commissioned by the Oregon Department of Environmental Quality (DEQ), with assistance from the U.S. A recent report from the US Energy Information Administration indicates those efforts are making an impact. It also indicated gross output decreased by only three percent over the same period, pointing to a significant decline in the amount of energy used per unit of gross manufacturing output. The overall decrease in energy consumption from 2006 to 2010 mirrors the slowdown in manufacturing production during the same period, as measured by the Federal Reserve Board and Bureau of Economic Analysis in separate annual manufacturing output indexes. The Cranberry Township, PA-based auxiliary equipment supplier has made a commitment to economic and ecological sustainability by developing equipment that helps plastics processors reduce energy consumption, make better use of raw materials, reclaim scrap and improve process yield. The reduction in employment and increase in gross output signals an increase in labor productivity during this same period. Available reports include the North American Plastics Industry Study, Quarterly Economic Study, Human Resources Benchmarking, Plant Management Statistics and Quality Studies. Even if they’re running in like new condition, older welding power sources lack the energy-saving capabilities of newer technology. These models also deliver smooth operation with greater efficiency than many older, conventional welding power sources.
This pulsed, high-voltage, high-frequency DC then is fed to the main power transformer, where it is transformed into the low-voltage DC that’s suitable for welding. The latest welding power sources provide data collection capabilities through special weld data acquisition tools, allowing monitoring of weld performance, equipment condition and efficiency.
However, we have a great affiliation and special interest with the manufacturing community. So how does the modern manufacturing company focus on achieving all of these things effectively?
Many manufacturing companies are often finding it very difficult to adapt to market conditions while simultaneously optimizing production costs and efficiency. Modern manufacturing solutions can help executives manage assets in ways that both meet customer demand and help cut manufacturing costs. Directing your attention to process optimization may be the most important step in improving overall efficiency.
We encourage you to check them out as a way to control labor costs through data analysis driven by software implementation. Once you have optimized your process and your workforce, perhaps you can run at a slower pace to save energy. On average, manufacturing facilities use 95.1 kilowatt-hours (kWh) of electricity and 536,500 Btu of natural gas per square foot annually, though actual consumption varies widely depending on the subsector. Most utilities charge manufacturing facilities for their natural gas based on the amount of energy delivered, in therms.
Additionally, production mistakes will become less frequent, and the cost to correct these mistakes will be reduced.
As a manufacturer, consider the cost of storage, insurance, maintenance, and disposal – if applicable. We have often seen that of all the costs of doing business for a manufacturer transportation can make up 50% of manufacturing costs in the logistics category. As a result of both routes a granulated solid ready to be used in the pressing stage is obtained, but the characteristics of these granulates are strongly influenced by preparation route. In an effort to get rid of this light pollution and update old, lighting fixtures at the same time, NRG turned to LEDtronics, Inc. Several have found it advantageous to explore ways of moving beyond compliance using pollution prevention strategies and environmental management systems to improve their environmental performance. Credibility demands that when a claim is made about a products exceptional performance, exceptional evidence should be presented. Each study discovered that the use of EPS as insulation yields a positive energy benefit that exceeds the energy required for its production and transportation (also known as “investment). A large amount of power that is produced is dedicated to maintaining the internal environmental quality of buildings (e.g. Life Cycle Inventory (LCI) database, maintained by the National Renewable Energy Laboratory of the U.S.
While sometimes EPS is not necessarily the best choice for packaging, the study concluded that the benefits of EPS are significant. Simultaneously, energy use can achieve a 14% reduction depending on the level of recycled content and the actual recycling method. EPA, illustrates an important environmental caveat: recyclability and recycled content are not always good predictors of environmental burdens. In fact, welding annually consumes at least $15 million worth of electricity in the United States and about $99 million worldwide.
While the upfront cost of upgrading might seem a bit daunting, the payback on upgrades may be faster than you think. A metallic transformer changed it from the relatively high input voltage to 60 Hz current at a lower voltage. The new inverters also have a much smaller footprint than traditional welding power sources.Inverters also feature advanced input voltage protection – a must for high-performance use on job sites where power supplied to the welding power source isn’t always necessarily robust or reliable, and instead can be more erratic. No computer hardware is required – saving on both capital expenditures and the energy to run such equipment – and the welder information can be viewed anywhere, anytime, and with any web device, without any special software. Careful assessment of your plant’s needs and power usage is the first step in generating savings. Because our shipper customers, whom we help in transportation management through freight technology and managed transportation services are mostly manufacturers, we like to write about best practices and tips that enrich and improve the operations of a manufacturer.
Take a close look at even the smallest details of your production process, and how the tiniest characteristics play a part in the bigger picture.

Making production decisions based on demand, you can save on energy costs without sacrificing output or customer satisfaction.
Electricity, on the other hand, can be charged based on two measures: consumption and demand. Typically, when you employ technology, as is the case with our transportation management system, you often have built in automation that keeps you compliant. With that large amount, having a handle on transportation management is a must for manufacturers to remain competitive.
Robinson works with the business development department to create messaging that attracts the right decision makers, gaining inbound leads and increasing brand awareness all while shortening sales cycles, the time it takes to gain sales appointments and set proper sales and execution expectations.
Historically, the dry route was firstly developed, however when the quality standards and the size of the tiles increased, the wet route was successfully introduced into the manufacturing process, and from 1990 decade it is the most widespread technology to prepare the body raw materials in the world. One such tool is life-cycle analysis, which considers the environmental impact of the entire life of a product. The EPS-IA is dedicated to accurately promoting the facts about EPS and its effect on our world, and has conducted several extensive EPS Life Cycle Assessments and Analysis Reports to provide convincing information on EPS environmental impacts and sustainability benefits.
In fact, EPS insulation can return up to 200 times the amount of energy required to produce it, and reduce emissions by up to 100 times the volume produced during the manufacturing process, representing an energy payback period of less than 17 months and a recapture of green house gas emissions in less than 10 months.
EPS not only offers a safe, lightweight option for packaging material, but is also a fully recyclable material with low environmental impact. The study, conducted by Franklin Associates, Ltd., takes a close look at 26 different packaging options to better understand environmental and natural resource impacts. The latest welding power sources offer many benefits on the production line – from increased weld quality and deposition to increased energy efficiency. This current then was rectified by a device known as a rectifier bridge to get a DC welding output, which was controlled by relatively slow control systems.Older industrial power sources built on this technology are typically heavy and large, weighing in at 400 pounds or more. Lincoln Electric worked with some large end user customers to develop the latest inverter technology so that it is capable of surviving as much as 1000-volt input spikes on the job, and their welding equipment has survived and continued to operate.Portable and lightweight, inverter-based welding power sources provide precise arc-starting capabilities and advanced output controls that allow welders to fine tune their welding output to desired parameters. With SaaS, the software application is not installed on a client computer or server like traditional licensed software. From that point forward, you can decide to upgrade, streamline and monitor your welding equipment in the way that best suits your shop’s needs and overall savings goals. You don’t want to optimize only part of your system and potentially interrupt or damage another part of your process down the line.
Monitoring your production process and operating conditions in real time is essential to managing how much energy – and cost – is expended.
The consumption component of the bill is based on the amount of electricity (in kWh) that the building uses during a month.
Adjust your manufacturing operations to respond directly to customer demand to avoid excess inventory or underproduction. If you are not using a Transportation Management System or aren't employing all the best practices in transportation, you could be doing all the preceding things correctly, but still hemorrhaging money at the bottom line. The reports quantifies resource use, taking into account all the benefits, energy costs and emissions to air, water and soil required to produce and manufacture EPS from cradle-to-cradle and from cradle-to-grave. Proper insulation increases a building's R-value, which is a measurement of the amount of thermal resistance of the building’s exterior. Polystyrene loosefill and molded pulp loosefill were among the void fill materials analyzed.
All tend to heat up during use and have limited ability to pulse any faster than 120 pulses per second due to control inefficiencies.
The technology behind these units provides manufacturers with a power source that can perform high- and low-amperage flux-cored, stick, TIG and MIG welding, not to mention arc gouging and even CV submerged arc. In this way, you can see how it's important that we speak about overall improvements for a manufacturer, and not just in the logistics space, although, with transportation costs making up on average 10% of sales, logistics improvement is a huge way to lower total manufacturing costs. The demand component is based on the highest (or peak) usage in kilowatts (kW) occurring within the month, or, for some utilities, during the previous 12 months. If you are struggling to maintain costs in transportation, reach out to use for a consultation to discuss your current transportation management strategies and tactics to see if we can help you improve today and thus put more back to the bottom line.
The company is a certified GSA and Minority-Owned Small Business and has grown into one of the worlda€™s leading suppliers of innovative LED lights, lamps, clusters, and arrays. EPS insulation significantly increases R-value, thus reducing the amount of energy necessary to heat and cool a structure. The report concludes that just because a packaging material is easy for consumers to recycle doesn’t guarantee that it has lower environmental burdens, and that high post-consumer content materials are not guaranteed to have lower burdens. With SaaS, up-front expenses are minimal because of the subscription-based pricing model; implementation is quick, and software upgrades are easily accomplished. Before you try to make any changes or improvements, consider how change will affect the process as a whole. LEDtronics now employs over 300 people with sales representatives worldwide and prides itself on delivering LED lighting solutions and products of consistently high quality to exceed customer expectations.
EPS insulation can be expected to last for decades, and at the end of its life, much of it can be recycled.
The study also determined that a box shipped with polystyrene loose fill requires less energy over its life cycle and stresses that high post-consumer recycled content should not be the primary driver for selecting a packaging material. Because energy costs can be a considerable percentage of your bill, care should be taken to reduce peak demand whenever possible. View the Oregon DEQ study summary, Packaging Options for Shipping Soft Goods in E-Commerce and Catalog Sales, for more details.

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