Donaldson Company, Inc.
Year Submitted: 2006 |
Process: Manufacturing |
Industry: Industrial Equipment Manufacturer |
Wastes Reduced: Landfilled Waste |
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Location: Cresco IA |
No. of employees: 9000 |
Contact: Ryan Burnley |
Phone: 1-800-792-8135 |
Description:
The plant in Cresco evaluated reusing
scrap material several years ago, but was unsuccessful in finding an outlet for the large quantities
of media paper disposed of annually. Since the addition of the new PowerCore" filtration line
one year ago, scrap tonnage has increased. The company desires to reduce the amount of
landfilled media, through both diversion and source reduction, and to comply with QS9000
continuous improvement requirements, giving Donaldson reason to undertake a pollution
prevention project.
P2 Application:
Media Source Reduction -
The splicers on the main assembly lines account for an estimated $82,800 worth of wasted
media sent to the landfill annually. The cause of this loss is the lack of a secondary spray
counter on the splicer. The counter tells the operator the current runs progress; the only
counters currently installed are located on the pleater, about 25 feet from where the splice is
made. As a result, the operator must guess when to splice in a new roll. Adding a second
counter to the splicer itself will divert an estimated $82,800 worth of media from the landfill to production annually.
Selling OCC Scrap -
Currently, Donaldson recycles OCC (Old Corrugated Cardboard) containers with a local recycling
company, spending $9,130 annually on transportation costs. City Carton Recycling, the
company supplying Donaldson with the horizontal baler system, has offered to pay one-half of
Official Board Market (OBM) value for handling the OCC, which would create revenue of
$9,980. Switching recycling companies will result in a net annual savings of $19,110.
Plastic Recycling -
Various types of plastics are used in manufacturing processes as well as in finished products.
Due to process contamination on the plastic parts, normal recyclers and environmental burning
plants cannot use the plastics. Donaldson's plant in Frankfort, Ind., located a recycler that will
accept Cresco's plastic parts as well as Frankfort's. The scrap plastic is now shipped to the Frankfort plant weekly by Donaldson trucks already making the run, resulting in no additional
shipping costs and an annual savings of $2,700.
Element Dismantling Finished filter elements that do not meet company specifications comprise 20 percent of the annual landfill tonnage. Research is underway to design a machine to cut the end-caps from the elements, so that the middle section can be reused or sent to BFC. This would reduce annual tonnage by roughly 18 percent. Approximately one to two percent of the elements are scrapped per day; an automated machine should be able to dismantle this number of elements
in a short period of time. Initial capital costs will be about $15,000, and comparing labor costs
to landfill savings results in a net annual savings of approximately $10,500.
Media Landfill Diversion - Raw media makes up on average 70 percent of annual landfill tonnage. BFC Gas & Electric Companies in Cedar Rapids collects raw material and incinerates it to power an industrial steam turbine that generates electricity. Sending the scrap media to BFC will result in annual savings of $30,200.
- Total Cost Savings: $142,610.00
Details of Reductions
Additional Information :
Donaldson Company, Inc., headquartered in Bloomington, Minn., has more than 9,000 employees
at more than 30 manufacturing locations worldwide, including 14 plants in the United
States. The Cresco plant manufactures industrial air filtration products for companies such as Caterpillar, FMC, Ford, General Dynamics, John
Deere and CNH. Donaldson is also a supplier to the United States government of filtration systems for the Blackhawk helicopter and
humvee, and of Pulse Jet Air Cleaner (PJAC) filters for the M1 Abrams Battle Tank, Armored Personnel Carrier (APC) and Bradley Fighting
Vehicle.
Source:
P2RIC
