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Tyco Fire Protection Products

Year Submitted: 2011

Process: Metal Machining

Industry: Metal Fabrication

Wastes Reduced: Coolant

Location: Lubbock TX

No. of employees: 200

Contact: Mark Townsend

Phone: 806-472-2451



Description:

Tyco Fire Protection Products used a pucking machine to compress brass shavings into a puck for many, many years. During the pucking operation, cutting fluids were squeezed from the brass shavings, drained from the system and containerized for disposal. The brass pucks were collected in large scrap metal bins and sold for scrap metal. In 2010, Joel Watson (Mfg. Manager) evaluated the brass pucking operation and determined it was not an efficient system. The puck machine had to be manned 8 hrs. per day and broke down frequently. When the pucking operation was down, the chip bins would stack up in the pucking area, cause congestion problems and promote secondary problems at the machining centers. The coolant recovered could not be reused because the recovered product was soured and unfit for reuse. Material handling, housekeeping and waste disposal also posed issues.

P2 Application:

Mr. Watson designed and installed a simple weir system into the machining centers chip hoppers to separate the coolant from the brass shavings and pump the coolant back into the machining centers coolant tanks. The brass shavings were dry enough to dump into a large collection unit for recycling. The cost per machining center was $100.00 each.

  • Total Cost Savings: $30,200.00
  • Comments: Additional savings come from a reduction of 2,080 labor hours ($15,600) and coolant purchase ($8,000). The payback period was about 1 month.

Details of Reductions

  • 1,000.0 - Gallon of   Spent Coolant
  • 4,160.0 - kWhr of   Electricity
Source: TCEQ



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