Background
Olympic Manufacturing, a 200-employee company located in Agawam, MA, produces commercial construction fasteners (screws) of varying diameter and length. Roll threading machines are used to carve the appropriate thread into the screws. During this process, a water-soluble coolant is applied to the screws, primarily to help protect the threading tool from heat, which causes excess wear. The performance of this coolant is greatly reduced as it mixes with machine oil, various coatings on the screws themselves, and the fine metal powder (or "swarf") generated during the threading process.
Toxics Use Reduction Planning
Faced with excessive disposal costs for coolant and swarf, Olympic's engineering department, production personnel, and facilities manager began searching for a viable coolant recycling system. The company had already investigated various types of filtering media, as well as centrifuge and vacuum systems. All of them had ended up clogging or tearing under the weight of the coolant/swarf sludge.
The company finally settled on a system that was able to filter the paste-like sludge and produce highgrade, recycled coolant. This system combines a mobile sump cleaning device with a stationary recycling center. The mobile unit has two compartments, one for transferring dirty coolant and sludge from the roll threading machines to the recycling center, and another for delivering clean coolant back to the machines. The dirty coolant and sludge are vacuumed from the machines, larger solid particles are filtered out, and the remaining material is stored in the mobile unit. Clean coolant is pumped into the machines and they are ready to run again.
When full, the mobile unit is wheeled over to the recycling center and the dirty material is discharged into a settling tank. After allowing 24 hours for the remaining solids to separate out, the dirty coolant is sent through a magnetic drum to remove any metal particles, then through a series of oil separators, and finally “polished” using a 5 micron filter. The recycled coolant is then fortified with a fresh coolant concentrate and pumped back into the mobile unit.
Results
Reductions
The new system has reduced the need for coolant concentrate from four 55-gallon barrels per month to one barrel per month, providing monthly cost savings of $1,600. Disposal of liquid waste has decreased 75%, from 600 gallons per week to 150 gallons per week, saving Olympic $1,800 per month. Disposal of solid waste has decreased 88% from two barrels per week to 1/4 barrel per week, saving the company $1,365 per month. In addition, the recycling system has reduced the risk and liability associated with waste disposal.
Economics
Not only have the reductions, as mentioned above, resulted in savings , but the coolant recycling system has also eliminated the need for replacement vacuum heads, saving Olympic $300 per month. The total savings Olympic achieved by installing the system are an estimated $5065 per month.
Tabriz rug, Iran
On behalf of Noor, OTA contacted the maker of Encap Green to learn more about the product, noting that although the information provided addresses many concerns, some questions remained. For example, a biodegradable ingredient could be toxic, the claim of the technical bulletin that the product is nontoxic could perhaps be unsubstantiated, and although a number of constituents of concern were stated not to be present, others of concern could be. Encap’s maker responded by supplying OTA with information on the ingredients, relying on OTA’s promise of confidentiality. OTA noted that the ingredients were almost all essential oils and other plant-based products, many food-grade, with the exception of two constituents.
The company owner replied that one of the constituents was a common component of several products certified as environmentally preferable by Green Seal 2 , considered to be a reliable green certification because its standards are scientific, its processes are open, and its certifications are verified. He stated that the other constituent was listed in CleanGredients3 as a recommended green constituent. He stated that one of the ingredients had a zero health rating on the MSDS from its supplier. OTA noted that although one of the constituents is commonly referred to as an environmentally preferable ingredient, if used in large enough amounts it could pose exposure hazards to workers. The maker of Encap responded that the constituent was present in very small amounts. In use it would be diluted at 4 ounces per gallon of water, and then distributed over 300 to 400 square feet. After hearing about his efforts to develop a green product, OTA asked the company’s president why he did not certify his own product as green. The company president stated that the cost of obtaining them was prohibitive for his small company and particularly for this small product line. He said “If necessary, I can disclose what that product is to you, but I would rather not. It is not well known by my competitors and I certainly do not want to help them out.”
Using Natural Ingredients
After hand-washing and thorough rinsing, the rugs are dried naturally, with no artificial heat applied, to avoid alteration of natural dyes or shrinkage. Noor states that subjecting rugs to heat “can cause distortion and shrinkage, manifested as surface ripples and curling edges.” Wool rugs are treated with lanolin, the natural oil of wool, to restore luster and suppleness of fiber and increase the longevity of the rug. Moth proofing, deodorizing, and disinfection are performed using natural products such as eucalyptus oil, bicarbonate of soda, and vinegar, and by carefully monitored exposure to natural sunlight. All dyeing for restoration work is performed using the same natural mineral or vegetable dyes as have been used traditionally. No synthetic chemical dyes are used. Noor’s website provides examples:
“For instance, the villages of Hamadan, Lilian, and Sarouk in central Persia (Iran) are known for their sublime pinkish dye, which dominates their rugs and is produced by boiling madder root with yogurt. Lavar is known for its indigo dye. In some places such as Baluchistan, where dyestuffs are scarce, weavers have become highly skilled at combining yarns with different natural coloration. Most dyes from natural sources need a “mordant”, or fixative, in order to bind to the yarn. Common sources of red dyes are madder root and cochineal (exudate from insects feeding on plant sap). Blues are often derived from indigo or possibly aubergine skin. Yellows may come from the flowering native plant called isparak, or from saffron, turmeric, apricot leaves, or wild pistachio trees. Orange may be derived from grass root, plum tree bark, poplar leaves, or willow leaves; green from walnut leaves, olive leaves, or sweet violet; browns and blacks from tea, tobacco, mud, walnut bark, or wild pistachio leaves.”
Authentic restoration is performed using the highest quality wool or silk preferably sourced from the place the rug was created. After carefully evaluating every step in the process of cleaning OTA was able to report to Noor that it possessed substantiation for making the claim that its process is “greener” than those that use machine-washing, petroleum-derived soaps and dyes, and industrial disinfectants, deodorizers, and moth-repellants. Noor has taken steps to ensure its claims are as carefully and thoroughly sourced as the products it uses to repair and maintain fine rugs. The Noor website notes that “A fine Oriental rug is far more than a decorative floor covering or an exceptional work of craftsmanship; it can be a depiction of paradise itself, inspiring us to dream of a better world. That longing has inspired Mr. Nooraee also, who believes that, like the weavers who slowly and laboriously tie each knot as they work toward paradise, we too can craft a better world, and that everyone deserves such a hope.”
Published 2013