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Summary
Traditional approach
Waste management
Cleaner production initiatives
Benefits
Where to find additional information
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August 1998
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| An example
of end result product facings. |
Summary
Cutler Brands installed new cleaning equipment and reduced the
use of thinners by 40% (from 15,000 to 6000 L per annum) and subsequently
reduced the disposal of ink soaked cleaning rags.
Total savings: $164,930 per annum with an investment of $45,000.
Business Profile
Cutler Brands is an Australian owned company employing
94 staff. Since its inception in 1946 the company has developed
into a diversified operation based on modern screen printing processes
that can perform a variety of product branding and enhancement
tasks.
Financial assistance provided
An interest free loan of $22,529 was provided by the EPA's
Cleaner Industries Demonstration Scheme.
Technology implemented
Installation of the CPS Ink Cleaner and the CPS Stencil
Cleaner.
Cleaner production motivators
Improve resource management, minimise environmental impact,
increase productivity.
Traditional approach
- Approx 2200 kg per annum of ink soaked rags generated from
cleaning screens.
- Each printer washed screens with thinners: large loss of production
time and high solvent usage, therefore both financially and
environmentally undesirable.
- Solvent fumes in the screenshop undesirable for printing personnel.
- High potential for operator to be exposed to chemicals from
open old solvent reclaiming unit (no air curtain).
- Hazard to employees during production by using thinners and
traditional reclaiming technology.
Waste management
| Waste stream |
From cleaning ink from screens |
From cleaning stencil from screens |
| The process generating waste |
Ink cleaned from screens after printing and
before storage for re-use. |
Stencil removed from the screen and replaced
at end of its life. |
| Disposal method |
Rags collected and transported to landfill. |
Fluid to sewer after screening solids. |
| Cost of disposal |
$700 per annum. |
Approx $9500 per annum. |
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Comparison
of the Cleaner Production investment ($ per annum)
and an annual financial return. |
Cleaner production initiatives
Benefits recommended and implemented
The new technology developed allows the complete washing
of screens in a central area by one operator, with the screens
being cleaned of ink, stains and stencils and looking all but
new by the end of the process. The units are connected to the
plant's exhaust system offering effective ventilation.
CPS Ink Cleaner
The CPS Ink Cleaner removes ink from the screens without using
rags. The screen wash is pumped and circulated from the upper
level of the tank providing for prolonged and improved cleaning.
It is then recirculated. Chemicals are used to make the ink soluble.
Filtration through the filter mat withholds larger particles preventing
pump blockages. The conical shaped bottom of the solvent tank
ensures effective collection of sediments and removal of sludge.
CPS Stencil Cleaner
The CPS Stencil Cleaner removes stencils. The spray dispenser
unit promotes quick and efficient spraying of a ready-to-use stencil
remover or degreaser.
Benefits
| Environmental |
|
| Storage, usage and handling of chemicals |
- Number of ink soaked rags used for cleaning screens
substantially reduced.
- Solvent recycling means a significant reduction in the
volume of solvent used and sent off site, from 15,000 L
to 6000 L per annum. Solvent now needs to be replaced
only once every 4-6 months.
- Less harmful and more efficient products now being used.
- CPS system far less hazardous than thinners or previously
used reclaiming technology.
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| Wastewater |
- Minimised volume of generated waste, reduced hazardous
content and reduced amount of waste needing disposal.
System also filters waste and controls pH of wastewater
discharged to sewer.
- Maximised biodegradability of waste in effluent.
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| Economic |
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| Investment |
- $45,000 (includes EPA contribution).
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| Productivity |
- Optimised effectiveness. Chemicals used more efficiently,
reducing consumption.
- Print machine down time reduced by 1950 hours per annum,
representing $105,000 per annum and an additional earning
capacity without additional labour costs, increasing gross
profits by $25,000 per annum.
- Printers and juniors now freed from tedious task of
cleaning screens can devote more time to production.
- Improvement in delivery to clients by increasing product
turnover.
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| Savings, outcomes |
(per annum)
- Savings in use of thinners $6190
- Savings in rag usage $3740
- Improved gross profit from capacity increase $25,000
- Additional earning capacity without additional labour
costs $25,000
- Reduced print machine down time $105,000
- Total savings $164,930.
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| Payback period |
Approx 4 months. |
| OHS |
- Significant reduction in operator exposure to fumes
from thinners and the danger of spillage due to reduced
usage.
- Small amount of airflow at the front edge of the machine
helps protect the operator from exposure to solvent vapours.
- Less frequent contact with solvents and chemicals from
reduced solvent usage and unit being enclosed.
- In the event of contact with chemicals, CPS system far
less hazardous by virtue of chemistry being very dilute.
- Fire risk substantially reduced by elimination of flammable
solvents.
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Where to find additional information
Mr Jack Walter
Managing Director
Cutler Brands Pty Ltd
33 Humpries Terrace
Kilkenny SA 5009
Phone: (+61 8) 8268 9888
This page was last modified 21-04-2006
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