Plastics Technology

JUN 2013

Plastics Technology - Dedicated to improving Plastics Processing.

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injection molding need an interested and motivated volunteer leader in your plant, but it also helps to have a full-time corporate-level sustainability leader. Top management must be willing to give fnancial and moral support to the sustainability program and should encourage and support education and training in "green" concepts. Nypro Mebane formed a Sustainability Council of about a dozen members from every level of plant operations. They meet at least monthly to discuss progress on on two dozen open projects, small and large, at any given time. One key activity for any plant's sustainability team, Cathey advises, is to take the time to investigate available government and utility company incentives for "green" programs. The Mebane plant took advantage of such programs in implementing two types of renewable energy generation—solar and wind. As pictured on the cover of this issue, Nypro Mebane installed a $1 million, 0.25-megaWatt solar photovoltaic system on its roof, which went "live" in May 2010. "Our cost of electricity from Duke Energy is 6¢/kWh. In peak months, Duke pays us 12¢/kWh for our solar power. That generates about $40,000 a year in green energy." With that revenue plus federal and state incentives, he adds, payback for the solar system is about six years. The system should last up to 25 years. Government incentives stand to repay about 85% of the $1 million initial cost. The federal government reimbursed half of the initial cost in one year, while the state of North Carolina will pay up to 35% of the cost over fve years. Similar incentives apply to the installation of a $60,000, 6-kW wind energy system in May 2010. This generates about $4000 a year in green energy and will pay back within fve years, limited mainly by the state's 5-yr payout program. All told, these renewable energy projects defray only a fraction of the plant's energy bill, which amounts to $100,000 a month. In addition, Nypro has worked to reduce energy consumption inside the Meban plant. In 2010, the original metal halide, warehouse-type lighting was replaced with high-effciency fuorescents for $47,000. The result was both energy savings and a safer and more productive workplace with better illumination. Payback is estimated at two years. In the last three years, the Mebane facility replaced 22 of the plant's injection presses (165 to 750 tons) with energy-saving allelectric models from Milacron, Netstal, and Engel. "Based on our experience," Cathey says, "I can't imagine a better investment for a molder than moving to all-electric machines, versus hydraulic or Nypro Mebane's Sustainability Council has around a dozen members from all levels of plant staff, down to machine operators. It meets at least monthly to discuss around two dozen open sustainability projects. Nypro spent $60,000 on a 6-kW wind energy system that generates about $4000 a year in renewable energy. That revenue, plus state and federal incentives, will pay back in fve years. BLEND IT BLEND IT BLEND IT BLEND IT L T MONITOR MORET L T L L T COOEYIIT COOEYIIT COOEYIIT COOEYIIT V V V V N N N N CO HO CO CO CO FEED IT FEED IT FEED IT FEED IT T REAW CAN RESI LLY SU I BE RE N IS DRY MY ? Only the Conair Drying Monitor tells you what's happening in your drying hopper in real-time. Now monitoring multiple hoppers. Even non-Conair hoppers. t GRIND I GRIND IT GRIND IT GRIND IT Watch the Conair Innovation video at promotions/innovation/ or scan this QR code with your SmartPhone. I I I I DRY E T DRY E T DRY E T DRY E T D IT XTRUD IT XTRUD IT XTRUD IT XTRU E E E E STORE IT STORE IT STORE IT STORE IT 724.584.5500 l l Plastics technology june 2013 29

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