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Process Efficiency

Ophir Optics, LLC - Lean Manufacturing and Six Sigma. 2011.

  Ophir Optics uses lean manufacturing to achieve significant VOC reductions Download PDF file (315.07 kB)

US Pack- Process Improvements Reap Large Rewards. 2019

  US Pack in Leominster, MA, is a custom formulation blending and packaging facility, specialized in a wide range of custom liquid specialty products, primarily for the automotive aftermarket sector, and household and industrial markets. The company received a grant from TURI in 2017 to install a new, more efficient filling line, including a 10-head pressure gravity filler with dedicated air-actuated diaphragm pumps. The new equipment is predicted to reduce use of of acetone, ethylene glycol, and methanol by as much as 19,000 pounds total each year, and provide other efficiency and worker safety benefits. Download PDF file (820.42 kB)

Cranston Print Works Company - In-process Acid Recycling, Process Control Charting, Carbon Dioxide Wastewater Treatment. 2009.

  An employee-owned company, Cranston Print Works Co. (CPW) achieved annual savings of over 110 million gallons of water and over $350,000 in costs by implementing 25 water conservation projects. These savings are attributed to the CPW's Water Conservation Team, which was formed in response to the company's commitment to continuous quality improvement. Download PDF file (114.45 kB)

South Coast Technical Products - Filtration and Wastewater Compliance. OTA 2007.

  SouthCoast Technical Products made changes to their operating processes which brought the company into compliance with Massachusetts environmental regulations and led to significant reductions in water use. By switching from an elaborate ultra filtration unit to a simple bag filtration process, the company was able to reduce more than 200,000 gallons of water and save $37,000 per year. Download PDF file (123.20 kB)

Olympic Manufacturing - Recycling Coolant. OTA 1999.

  By installing a recycling system for the coolant used on their roll threading machines, Olympic Manufacturing was able to reduce coolant disposal by 75% and solid waste disposal by approximately 88%. Prior to installation and operation of this recycling system, Olympic was discarding machining coolant after two days of use, generating roughly 600 gallons of waste coolant and two 55-gallon barrels of solid waste each week. The reduction in waste saved the company about $38,000 annually. Download PDF file (21.11 kB)

Korber Hats - Elimination of Hazardous Air Pollutants. OTA 1997.

  Korber Hats of Fall River, Massachusetts, a maker of custom straw and felt hats, has reduced emissions of volatile organic compounds (VOCs) by 80,000 pounds, 44,000 pounds of which was eliminated through process changes and chemical reformulation. The company, which was using 52,000 pounds of toluene and 17,200 pounds of methyl ethyl ketone in 1994, permanently eliminated the use of these hazardous air pollutants in 1995. Korber has successfully substituted a water-based stiffening process in its straw hat dipping operation. Once the company and its vendor reformulated a stiffener to a waterbased acrylic lacquer, Korber was able to eliminate the use of a solvent thinner which consisted of 30% methyl ethyl ketone and 60% toluene. Korber worked with its supplier to analyze existing coatings and create a new formulation, which would replace the solvent coating. The company has since successfully switched to an entirely water-based process with some process changes and minimal capital investment. After adjustments are made for production levels, this project has saved Korber a minimum of $36,000 annually in reduced chemical purchases and permitting costs. Download PDF file (26.38 kB)

Poly-Plating Inc. - Chemical and Water Waste Reduction. OTA 1997.

  Poly-Plating designed and installed integral repurification equipment which filters, recycles and concentrates wastes for reclamation. This equipment reduced acid purchases to 1%of 1989 levels. Reclaiming and recycling has cut disposal costs by 98%. Additionally, water use has been reduced to 880 gallons per day, down from 78,000 gallons per day. Download PDF file (327.11 kB)

Lightolier - Elimination of Trichloroethylene and Reduction of VOC Emissions. OTA 1997.

  Lightolier has eliminated the use of approximately 1.25 million pounds of Trichloroethylene at their Fall River, Massachusetts plant. The company found less toxic alternatives and modified their production process, which eliminated more than 4 million pounds of air emissions, with savings of more than $2 million. Download PDF file (2.10 MB)

Kidde-Fenwal - New Coating Technologies Provide Big Payoffs. OTA 1996.

  By updating its coating operations with 1990s technologies including computer-programmed spray applications and ultraviolet (UV) curing, Kidde-Fenwal Incorporated reduced its air emissions by 75%, eliminated 20 drums per year of flammable waste, and reduced its production cycle by an entire day. The new system, which also reduced the amount of coating used per printed circuit board by 96%, is expected to save the company $300,000 annually, providing a payback on its investment in less than one year. Download PDF file (107.42 kB)

Novacor Chemicals, Inc. - Monomer Storage and Handling Improvements. OTA 1995.

  The U.S.-based polystyrene division of Novacor Chemicals, Inc. updated the equipment of their monomer storage and handling facility in order to demonstrate the company' s environmental awareness and to reduce overall potential liability. This project eliminated the volatile hydrocarbon emissions that previously emanated from the monomer storage tanks, spelling a 50% reduction in the facility's overall emissions. The change also reduced the risks of fire and groundwater contamination, while eliminating the potential liability associated with collapse of the aged tanks previously in use. Download PDF file (23.96 kB)