C2759 - GUD (NZ) Ltd - Metal Processing - Auckland
Region
Summary
Many options implemented by GUD are simple no cost and low cost good housekeeping
and management options, while providing significant savings. Additional options
are being investigated and trialed currently and are likely to bring further
savings.
Business Profile
GUD (NZ) Ltd manufactures and assembles air and car filters for cars, trucks,
and heavy commercial, industrial and construction equipment vehicles. Processes
include sheet metal fabrication, metal cleaning, metal coating (painting)
and assembly. The company employs 93 staff.
Type of Project
Waste monitoring, stock management by labelling of raw materials, central light
and power switches, replacement of fluorescent lights with metal halide lights,
establishing an Energy Task Force, repair of compressor leakages, pressing
products from metal off-cuts, metal recycling, reuse of metal working fluid,
use of low energy filter paper, plastisol and polyurethane, use of air knives
to dry products, powder coating.
Reasons for Project
The company has established an ISO 9001 and the automotive specific QS 9000
quality management system. As part of this, resource consumption and waste
production have been addressed. GUD (NZ) Ltd participated in the project
because it wanted to further improve its environmental performance.
The Project
Waste monitoring
| Details |
Waste is continuously
monitored by staff and line supervisors to identify types,
quantities and causes of waste generated. Monitoring results
are entered in a computer and are processed by division managers,
the engineering manager and the production manager. A copy
of the monitoring results is circulated to all managers of
the plant and is displayed in the factory to encourage staff
to identify causes and solutions. |
| Economics |
Labour costs, but
these are paid back immediately as a result of waste reductions. |
| Benefits |
Measuring is knowing.
Reduced waste. Staff involvement and motivation. |
Stock management by labelling raw materials
| Details |
Metal rolls that
are supplied to GUD are labelled with different colours for
each month to ensure that oldest stock is used first. |
| Economics |
No costs. |
| Benefits |
Reduced wastage
of expired raw materials. |
Energy Task Force & repair of compressor
leaks
| Details |
An "Energy Task
Force" was formed comprising the Managing Director, Engineering
Manager, Production Manager, Engineering Supervisor and other
key managers in the plant. The group meets once a month to
discuss energy management. Specific projects have included
investigation of compressors, lighting, heating and curing
ovens. A good housekeeping option implemented was the immediate
repair of compressor leakages. |
| Economics |
Labour time involved.
Other costs are negligible. Already $7,000 per year are saved
through immediate repair of compressor leakages. |
| Benefits |
Reduced energy
consumption and costs. |
Central light and power switches
| Details |
A central light
switch and a central power switch is used to ensure all power
is turned off at night and in weekends. |
| Economics |
Switches were installed
when the plant was built. |
| Benefits |
Reduced energy consumption
for machines and lights, improved safety to plant equipment
and machinery. |
Replacement fluorescent lights with metal halide lights
| Details |
Approximately 70
fluorescent lights (77 W) have been replaced with 10 metal
halide lamps (427 W). The remaining lights were fitted with
a reflector to improve lighting efficiency. |
| Economics |
Investment costs
$1,400: Costs of 10 metal halide lamps:
$140 X 10 = $1,400 (excluding fittings and installation);
Nominal labour costs as lamps were installed by GUD staff. Energy savings
21%: Hourly energy consumption/hour of 10 metal halide lamps:
0.427 kWh X 10 = 4.27 kWh;
Hourly energy consumption of 70 fluorescent lamps:
0.077 kWh X 70 = 5.39 kWh. Savings on lamp purchase costs 28% (does not
include reduced replacement costs):
Lifetime of metal halide lamps:
11,000 hours, costs of 10 lamps = $1,400 ($140 each);
Lifetime of fluorescent lamps:
8,000 hours, costs of 70 fluorescent lamps = $1,400 ($20 each). |
| Benefits |
Improved lighting,
energy savings, longer life of lamps and lower capital costs
for replacement. |
Pressing products from metal off-cuts
| Details |
Details Tin plate
circles of approximately 20 cm in diameter are pressed from
larger plates. The circles are a waste product and used to
be disposed of as metal scrap. GUD is now using the circles
to manufacture other product components. |
| Economics |
No costs involved.
Savings are approximately $600 in reduced metal consumption. |
| Benefits |
Reduced tin costs
and waste. |
Metal recycling
| Details |
A total of 25 tonnes
of tin plate and mild steel are collected for recycling per
year. |
| Economics |
The total revenue
from scrap metal is $20,000 per year. This does not include
reduced disposal costs. |
| Benefits |
Income from scrap
metal. Reduced waste and costs. |
Reuse of metal working fluid
| Details |
Cutting oil is used
to reduce the friction between the cutting tool and base
metal that is cut. The oil also contains rust inhibitors.
GUD uses a water-based cutting oil which is collected in
drip trays located under the power presses. This enables
the cutting oil to be continuously recycled. |
| Economics |
Nominal costs for
purchase of drip trays. Savings have not been determined. |
| Benefits |
Reduced cutting
oil waste. Reduced costs of cutting oil. |
METAL FINISHING PROCESSES
Use of low energy filter paper and plastisol or polyurethane
| Details |
Filter paper and
plastisol are the main filtering components of a car filter.
The use of low energy filter paper, low energy plastisol
and polyurethane are currently being investigated. By using
these alternatives, curing of the filters is no longer necessary
as the filter paper and plastisol/polyurethane is already
pre-cured. It is expected that as a result only one rather
than two ovens will be needed at GUD reducing heating costs
by 50%. |
| Economics |
This option is still
being trialed but it is expected that investment costs will
be nominal or very low and savings could be high. |
| Benefits |
Reduced energy consumption
and costs. |
Powder coating
| Details |
GUD
are currently investigating replacement of traditional
spray painting techniques
with powder coating for the application of paint to metal
cases. In powder coating the metal case is electrically charged
which enables the powder to attach evenly to the surface.
The object is then heated to "melt" the paint onto the surface.
Because a powder is used, excess powder can easily be captured
and reused, which is not possible with liquid paint. |
| Economics |
This
option is still under investigation, but planned for implementation
in the future. |
| Benefits |
Reduced paint consumption
as surplus paint can be reused. More equal paint coverage
and better looking product. Reduced waste water quantities
and costs. Reduced solvent emissions. Improved health and
safety conditions for employees |
Use of air knives rather than compressed air to dry products
| Details |
Air knives are now
used for drying filters rather than compressed air. This
reduces energy consumption with no adverse effects on product
quality. Drying with compressed air required a warming up
period, whereas air knives provide instant heat. As a result,
products dry faster with improved product quality. |
| Economics |
Purchase costs for
one air knife are $7,000. Savings from reduced energy consumption
are $5,500 per year. The payback period is 15 months. |
| Benefits |
Reduced energy consumption
and costs. Improved product quality. |
For additional information contact:
Chris Wood,
GUD (NZ) Ltd,
PO BOX 19175,
Avondale,
Auckland
Ph 09-8287089
Fax 09-8282244
For further information about Cleaner Production in the Metal
Industry see:
Opus International Consultants (September 1997): Cleaner
Production Guide for the Metal Industry- Minimising waste,
reducing costs and caring for the environment.
|
