Cooper Crouse-Hinds, Amarillo is an iron foundry that manufactures electrical fittings. The gray iron fittings are cleaned, machined, plated, painted, assembled, and packed for shipment. The fittings require machining and use a synthetic water-based coolant. The coolant becomes contaminated with tramp oils, metal fines and bacteria. The coolant was collected in 55-gallon barrels, transported to storage, and transported a second time for pickup.
The contaminated coolant was sent offsite at the cost of 50 cents per gallon, at an average of 1,100 gallons per month for $550.
In May 2002, a coolant recovery system was brought on-line. The system recycles the coolant by filtering out oil and debris, pasteurizes the recycled coolant to reduce bacteria, and adds a percentage of new coolant and water to maintain the required ratio.
1) Eliminated disposal of used coolant, collection & handling; 2) Plumbing water to the machines will further reduce coolant usage during 2003; 3) Pasteurization of the coolant reduces potential for dermatitis exposure.
Details of Reductions
Additional Information :
Total Savings - $29,264
1) Coolant Recycler Total Cost Savings is $28,912 annually; 2) Eliminated disposal of used coolant, collection & handling - Savings $10,000 year; 3) 41% reduction in monthly usage of new coolant which saves 1718 gallons & $18,912 annually; 4) Reduced the SPCC Plan inventory of areas for stored oil-containing chemicals.