Injection Molding Facility Clean Room

Client Situation

A clean room medical injection molding facility invested more than $1 million to install five new molding machines, as well as a new packaged pumping and filtration system designed to increase production speed of manufactured parts. The facility was experiencing challenges. Filters were plugging with deposits and funneling cloudy water into the system, creating corrosion issues and lost production time. The overall cost of constant filter changes by employees was calculated in excess of $200,000 annually.


Project Consulting

The Earthwise Environmental engineering survey and inspection process found that while the new equipment was top-notch, the equipment upgrade did not include proper sanitation and anti-corrosion treatment of long sections of newly-installed black iron piping. The Earthwise Environmental engineering survey also found the overall system contained numerous ‘dead legs’ in piping runs as well as galvanic couples throughout the plant - factors contributing to system bacteria build-up. Other trouble spots in the review by the Earthwise Environmental team of Certified Water Technologists determined the system contained high iron and copper levels and a low pH. The survey also discovered possible cross connection/contamination between the cooling tower and the chilled water loop feeding water into the injection process.

Solutions

To solve the multiple issues and reduce unnecessary production downtime, Earthwise Environmental confirmed the need for sulfate-reducing bacteria (SRB) from the tower cross-connection and implemented on-line sterilization with a bio-dispersant and SRB biocide. Existing nitrite treatment procedures in place were replaced with silica treatment. Once the system was sterilized, Earthwise Environmental developed a program to automate the feed of biocide and likewise perform routine system water biological testing.

The facility review also resulted in equipment adjustments to improve overall efficiency and water quality. New dual filters were installed for the five new machines to eliminate downtime during changes as well as labor costs. The existing 125 micron filtration system with a screen-type backwash filter was eliminated in favor of 10 micron, bag-type full-flow filter vessel. The galvanized series couples were replaced with stainless steel manifolds, and a color-coded hose system was put in place to eliminate cross-contamination of the water tower and chilled loop system.

Benefits and Results

  • Immediate labor cost reductions through elimination of injection molding machine filter changes. Prior to implementation of Earthwise Environmental recommendations, facility employees spent an average of 20 minutes per filter change three times a week on five machines, totaling six hours of labor weekly at a cost of $750 per hour. New filtration translates to labor savings of more than $200,000 annually and a 60-day return-on-investment, plus additional production time.
  • The changeover from galvanic couples to stainless steel manifolds saves labor and capital costs associated with corrosion and piping replacement.
  • Long-term protection of the chilled piping system eliminates the future replacement need, a costly capital expenditure.
  • Energy costs are reduced through increased efficiencies at heat transfer by elimination of the bio fouling through the SRB biocide program.

"Earthwise is the expert that every facility should work with to reduce their water, energy and hazardous chemical usage. By working with us, Earthwise Environmental significantly cut our operating costs with minimal capital investment."

- Robert G., vice president of operations and maintenance for a large university in Chicago, Illinois.

"We searched for an alternative to handling and storing heavy 55-gallon drums of hazardous chemicals. Earthwise Environmental's Drumless Water Treatment System is exactly what we were looking for. The non-hazardous solid dissolver provides diluted water treatment solution on demand into our feed water piping."

- Dave G., environmental manager for Oshkosh Truck in Oshkosh, Wisconsin.

"Earthwise Environmental teamed up with our staff to identify the best solution for our needs."

- Bob T., chief engineer at Principia College in Elsah, Illinois.

"When our hospital released new corporate responsibility guidelines for sustainability and green practices, we partnered with Earthwise Environmental. Their highly experienced Certified Water Technologists conducted a thorough audit of our facilities. Earthwise Environmental's recommendations saved our hospital more than $7 million dollars and 20 million gallons of water a year."

- Dave S., director of facilities for one of the largest and most respected teaching hospitals in Chicago, Illinois.

"After equipment failure issues arose with our previous vendor, Earthwise Environmental implemented their proven water treatment technology to clean our system and provide us with far better protection. We have Earthwise Environmental to thank for keeping us running."

- George M., facilities manager for an injection molding facility in Cary, Illinois.

Find out how an Earthwise Environmental™ program can make a real improvement in your facility's environmental impact and operational costs. Contact us today!

©Copyright 2012 Earthwise Environmental Inc.

Site by littlegreencube.