The plastics processing industry often faces heavy criticism for causing environmental damage and industrial pollution. Processors are now taking this issue seriously and making efforts to ensure that production techniques do not result in heavy waste and high energy utilization. Avani Jain puts forth some of the best manufacturing practices to help reduce waste and optimize cost.
Waste is defined as any aspect of operations that fails to add value. It is a significant hidden cost for many plastics manufacturing companies and includes the costs associated with energy & maintenance, solid wastes, inefficient utilization of water, hydraulic oil and emissions into the atmosphere.
Increasingly, companies and organizations are taking an interest in waste reduction, which thereby results in optimizing cost. Rohan Shrikant Shahane, Regional Director-South East Asia, Machine Point Consultants SL, notes, “With rising energy costs, soaring raw material prices and the impacts of climate change, the need to monitor energy consumption and reduce waste is more important than ever. As with most industries, controlling costs is critical to sustainability and profitability. In order to remain competitive a business must adopt effective energy management process and waste reduction methods.”
Waste reduction strategies
Right from polymer processors to plastics processing machinery manufacturers, it seems that the industry is aware of their due diligence and is adopting various steps for reducing waste. M M Biswal, Business Head-Polymers, Loxim Industries Ltd, details, “In order to reduce waste, one has to have an appropriate system in place, as it helps in improving the overall efficiency of the company. In our company, the water consumed during manufacturing of engineering thermoplastic compounds is recycled and used for watering our plants in the garden. We also have a rain water harvesting plant as it is a low lying area and a lot of water accumulation happens.” He continues, Thus, we not only reduce waste but consume it as well. For example, we offer to our customers an eco range, which is made of recycled products. We believe that atomization and training of people is important because if the people are trained well, they would contribute more towards operating efficiencies.”
Reducing waste does not merely mean managing the solid and liquid waste, but also means preventing excessive energy use. “Energy efficiency is possible only through a good set of machinery that demands adequate investment. Cutting cost on infrastructure, in turn, would increase the cost of efficiency, so we always believe that investing in right machinery is important. The right machinery will result in cost and operating efficiency as well as waste reduction in the long run. At the same time, the product quality will be good,” Biswal opines. Apart from the plastics processing machinery manufacturers, the ancillary equipment manufacturers have realized the need for waste reduction.
The plastics processing machinery manufacturers have also started adopting novel methods for waste reduction. Earlier, in the injection moulding segment, hydraulic machines ruled the market, but now the all-electric machines with better energy efficiency are being employed. Shahane notes, “The use of all-electric injection moulding machines helps in substantial reduction in maintenance cost, as these eliminate the need for hydraulic oil. Further, a shorter product cycle makes these more productive than the hydraulic machines. These machines reduce losses by using high-speed servo motors to drive the processes.”
Supporting acts
The rotomoulding industry is also continuously adopting various strategies for reducing waste and energy. Bharat Mistry, Partner, Ash Win Engineers, says, “We make machines that help in reducing plastic wastes. For example, plastic wastes like the entire plastic tanks are cut into small pieces by a scrap cutter; these pieces are then fed into a solid granulator where their size is further reduced to 10 mm. These are then put into a recycling extruder in which fine plastic granules are obtained; these granules are used to make an entirely new product. Thus, we are not only making the machine, but also reusing the plastic waste.”
Mistry adds, “Further, as a responsible company we have taken a number of steps. First, while making moulds of different sizes, we are particular about the quantity and size of raw material used, which, in this case, is stainless steel. We ensure that we procure only that quantity of material that will be needed for the job because if the requirement is low, then the remaining steel roll will go waste. Second, we produce extremely energy efficient oven chambers, i.e., furnace that runs on Liquefied Petroleum Gas (LPG) as against diesel or petrol. This results in energy efficiency and reduction in the production cost.” He continues, “Third, we use standardized frequency drives of European origin for the rotation of the mould. It ensures jerk-free operation, which otherwise may lead to variation in thickness, thus causing wastage. For example, if 100 tanks are made and there is weight variation, then it is not acceptable and they go waste.”
At present, the company has employed some techniques, but in future it will also adopt novel measures for waste reduction. Mistry claims, “We are developing machines that ensure high production. These machines will have the capacity to produce 30-35 products in one and a half hour. They will have advanced oven chambers, with temperature sensors inside the mould. The machines will reduce the cost of production, improve speed and ensure quality production. In future, we also aim to use Programmable Logic Controller (PLC)-based microprocessor control, which will ensure repetitive production with exact thickness and, thereby reduce wastage.”
Understanding responsibilities
With the elimination of waste, the quality improves while production time and cost are reduced. Keeping in mind the ongoing efforts by various companies, the future of the plastics industry is to become more environment-friendly; further, with the latest machinery and methods making inroads to the country, energy efficiency and waste reduction will be yet another achievement by this industry.
Source – Modern Plastics Polymers (Infomedia18)
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