Issue link: http://cp.revolio.com/i/281113
actually a fairly expensive commodity, and demand for it is growing. Many EPS companies now collect their scrap foam in-house to be sold to other companies. Plasti-Fab, for example, does their own densifying in-house and sells the condensed material to a recycler that produces picture frames and other polystyrene products., Most regrind is put back into the process and excess regrind is either densified or sold for other uses such as toy manufacturing. Progressive Foam reprocesses some of their EPS manufacturing scrap to fabricate energy and cost saving billets to the pre-cast concrete panel industry. Progressive Foam even collects and densifies EPS dust from their factory floor for recycling. Energy Efficiency Utilities can be a large source of overhead costs for EPS manufacturing plants, and also a potential source of a surprising amount of waste. According to the U.S. Energy Administration, the industrial sector wastes more energy than any other U.S. entity, but there are a number of ways to reduce energy waste. Part of Progressive Foam's efficiency overhaul included revamping the way they consume utilities. A high-efficiency lighting system was installed throughout 100% of their manufacturing facilities, and the walls were painted white to provide maximum illumination for less electricity. The extra illumination creates the beneficial side effect of a more visible plant floor and a safer working environment. The same system that monitors Progressive's molding quality control also screens their energy use, as well as their compressed air system, and automatically distributes energy and air where it is most needed and reduces it where it is not. Progressive saw a return on investment from these upgrades within three years, a refund from their local energy company, as well as a carbon footprint reduction of 19%. Atlas EPS has also renovated the way they consume energy. Their lighting system was replaced with high-output T5 fluorescent fixtures, which were installed throughout their main manufacturing center in Byron, Michigan and have resulted in a 40% reduction in lighting costs. Boiler controls are scaled back on the weekends to match a reduced demand, and heat recovery systems on their block molds capture heat and return it as electricity to the grid. Curing rooms are monitored and timed to end their cycles precisely on time. In addition to hardware upgrades, Atlas EPS has promoted energy conservation practices in their professional culture. Employees are encouraged to turn off electric devices when possible and be aware of potential energy waste. Regular audits are conducted to look for any sources of energy waste. Having recently begun implementing their own energy efficiency practices, Plasti-Fab has also improved the lighting systems in their plants to reduce electricity use. They have begun soliciting their employees for ideas on how to improve their energy use and processes, and in 2013 they formed a Sustainability Committee to facilitate improvement of Plasti- Fab's Environmental, Social and Economic Sustainability. Compressed Air Compressed air is never free. Loss of compressed air can be caused by very small flaws in the manufacturing system, but can lead to lots of wasted money and resources. According to the U.S. Department of Energy's Compressed Air Challenge, 50% of compressed air used in industry is wasted, with most waste attributed to leaks and improper use. A 1/8" leak in the compressed air line can cost over $2,000 per year, an amount which increases exponentially the larger the leak. Regular inspection and maintenance of air lines saves money and resources, as well as lessening the strain on the air compressor. Jeff Nickerson, President of Concrete Block Insulating Systems, recommends getting employees involved in air system maintenance. As regular fixtures on the manufacturing floor, employees can notice leaks quickly and prevent loss. EPS dust and scrap beads can present a frustrating cleaning challenge at the end of the day, and using compressed air can seem an easy solution, but this is an improper use of valuable resources that can be addressed in other ways. Nickerson recommends using a gas or electric powered leaf blower, which operates at 64% less cost than using compressed air. Efficient and sustainable manufacturing is the goal of every EPS plant owner, but it can present a costly and time-consuming endeavor. By approaching the challenge systematically and addressing the most wasteful parts of the molding process, efficiency is being achieved in a relatively short amount of time and on a large scale. Despite however difficult it may seem, the results of optimization are a worthwhile reward. 3 continued from pg 2