This report analyzes ways for Kreysler & Associates (K&A) to reduce waste from their use of expanded polystyrene (EPS) in producing fiberglass reinforced polymer parts. Currently, 100% of EPS purchased goes to waste. The report evaluates process changes and alternative materials. It finds that using a dust sheet to prevent contamination along with selling clean EPS chunks for reuse can reduce waste while being feasible. Continuing EPS and resin use is also recommended until better alternatives are identified.
Extraction of Carbon Black from Organic CompoundIRJET Journal
This document discusses carbon black, including its production, properties, and applications. It is produced through the incomplete combustion of organic compounds like petroleum products or coconut shells. There are three main production methods that produce carbon blacks of different sizes and surface properties: channel, furnace, and thermal. Carbon black is used primarily as a reinforcing filler in tires and other rubber products, comprising 70% of its usage. It is also used as a pigment in plastics, paints, inks, and other applications due to its ability to absorb UV light and impart color. Some key properties that make it useful include its high surface area to volume ratio and ability to conduct heat and electricity when compounded with other materials.
Expanded polystyrene (EPS) rigid insulation manufactured by PermaTherm is a sustainable product with several environmental benefits. It requires little energy to manufacture compared to alternatives, can be up to 25% recycled material, and is fully recyclable at the end of its life. PermaTherm's manufacturing process does not use ozone-depleting chemicals, toxins, or solvents. Their EPS insulation provides maintenance-free performance for about 20 years and improves indoor air quality and energy efficiency in buildings.
1) DuPont Packaging Graphics conducted a lifecycle assessment to compare the environmental impacts of flexographic and rotogravure printing processes for packaging.
2) The assessment found that flexographic printing results in a 51% reduction in greenhouse gas emissions and a 48% savings in non-renewable energy consumption compared to rotogravure printing.
3) To help consumer packaged goods manufacturers quantify the environmental benefits of different printing options, DuPont developed a calculator comparing flexographic, rotogravure, and thermal flexo platemaking technologies.
IRJET- Fabrication and Characterization of E-Glass Fiber Epoxy and Fly Ash Co...IRJET Journal
This document discusses the fabrication and characterization of E-glass fiber, epoxy, and fly ash composites for use in automobile applications such as helical coil springs. Three helical coil springs were fabricated with different compositions of E-glass fiber, epoxy, and fly ash. The spring made with 70% E-glass fiber, 20% epoxy, and 10% fly ash (Composition C1) showed the highest compressive strength and stiffness. The composites were produced using a filament winding technique and were found to have higher stiffness than conventional steel coil springs, while reducing weight. The document reviews composite materials and their properties, and selects E-glass fiber, epoxy resin, and fly ash
Rockline Industries, a manufacturer of paper products, replaced their metal halide lighting fixtures with LED fixtures to reduce energy consumption and costs. The LED conversion reduced energy use per fixture from 400 watts to 150 watts, cutting costs significantly. It also improved light quality and reduced maintenance needs. This qualified Rockline for $48,000 in energy rebates. Employees also appreciate the cooler and brighter light from the LEDs.
The document discusses trends in the thermoset supply chain including:
- Molder/material supplier partnerships that enable specialization and material agnosticism.
- Increasing outsourcing of tooling to China requiring molders' involvement.
- Molders playing an important logistical role as hubs that maximize efficiencies.
- A material supplier discussing rising costs and identifying areas where thermosets offer value.
- Advancements in precision technology like process monitoring, tool design standards, and using data to improve controls.
This document summarizes a presentation about using UV-curable powder coatings on MDF substrates. UV powder coatings can finish MDF faster than liquid or thermally-cured coatings, in as little as 20 minutes. They use less energy and plant space, increase productivity, and provide environmental benefits like being solvent-free. UV powder coatings produce a durable finish that seals in formaldehydes and allows MDF products to meet CARB emissions standards. The presentation provides examples of MDF applications that benefit from UV powder coating and concludes it is a high-speed, high-quality, and environmentally friendly finishing option.
CT OCT 12 Automotive High-Temp Thermoplastic Composites LayoutMichael Legault
- Longer vehicle warranties and stricter fuel economy standards are driving demand for thermoplastic composites that can withstand higher underhood temperatures over longer periods.
- Automakers are seeking parts that can operate continuously above 200°C and withstand peak temperatures over 230°C, compared to the 170-190°C capabilities of earlier thermoplastic parts.
- Thermoplastic suppliers are developing new high-temperature materials like polyamides, nylon 4/6, and polyphenylene sulfide that allow parts to withstand temperatures from 180°C up to 220°C continuously and higher temporarily.
Extraction of Carbon Black from Organic CompoundIRJET Journal
This document discusses carbon black, including its production, properties, and applications. It is produced through the incomplete combustion of organic compounds like petroleum products or coconut shells. There are three main production methods that produce carbon blacks of different sizes and surface properties: channel, furnace, and thermal. Carbon black is used primarily as a reinforcing filler in tires and other rubber products, comprising 70% of its usage. It is also used as a pigment in plastics, paints, inks, and other applications due to its ability to absorb UV light and impart color. Some key properties that make it useful include its high surface area to volume ratio and ability to conduct heat and electricity when compounded with other materials.
Expanded polystyrene (EPS) rigid insulation manufactured by PermaTherm is a sustainable product with several environmental benefits. It requires little energy to manufacture compared to alternatives, can be up to 25% recycled material, and is fully recyclable at the end of its life. PermaTherm's manufacturing process does not use ozone-depleting chemicals, toxins, or solvents. Their EPS insulation provides maintenance-free performance for about 20 years and improves indoor air quality and energy efficiency in buildings.
1) DuPont Packaging Graphics conducted a lifecycle assessment to compare the environmental impacts of flexographic and rotogravure printing processes for packaging.
2) The assessment found that flexographic printing results in a 51% reduction in greenhouse gas emissions and a 48% savings in non-renewable energy consumption compared to rotogravure printing.
3) To help consumer packaged goods manufacturers quantify the environmental benefits of different printing options, DuPont developed a calculator comparing flexographic, rotogravure, and thermal flexo platemaking technologies.
IRJET- Fabrication and Characterization of E-Glass Fiber Epoxy and Fly Ash Co...IRJET Journal
This document discusses the fabrication and characterization of E-glass fiber, epoxy, and fly ash composites for use in automobile applications such as helical coil springs. Three helical coil springs were fabricated with different compositions of E-glass fiber, epoxy, and fly ash. The spring made with 70% E-glass fiber, 20% epoxy, and 10% fly ash (Composition C1) showed the highest compressive strength and stiffness. The composites were produced using a filament winding technique and were found to have higher stiffness than conventional steel coil springs, while reducing weight. The document reviews composite materials and their properties, and selects E-glass fiber, epoxy resin, and fly ash
Rockline Industries, a manufacturer of paper products, replaced their metal halide lighting fixtures with LED fixtures to reduce energy consumption and costs. The LED conversion reduced energy use per fixture from 400 watts to 150 watts, cutting costs significantly. It also improved light quality and reduced maintenance needs. This qualified Rockline for $48,000 in energy rebates. Employees also appreciate the cooler and brighter light from the LEDs.
The document discusses trends in the thermoset supply chain including:
- Molder/material supplier partnerships that enable specialization and material agnosticism.
- Increasing outsourcing of tooling to China requiring molders' involvement.
- Molders playing an important logistical role as hubs that maximize efficiencies.
- A material supplier discussing rising costs and identifying areas where thermosets offer value.
- Advancements in precision technology like process monitoring, tool design standards, and using data to improve controls.
This document summarizes a presentation about using UV-curable powder coatings on MDF substrates. UV powder coatings can finish MDF faster than liquid or thermally-cured coatings, in as little as 20 minutes. They use less energy and plant space, increase productivity, and provide environmental benefits like being solvent-free. UV powder coatings produce a durable finish that seals in formaldehydes and allows MDF products to meet CARB emissions standards. The presentation provides examples of MDF applications that benefit from UV powder coating and concludes it is a high-speed, high-quality, and environmentally friendly finishing option.
CT OCT 12 Automotive High-Temp Thermoplastic Composites LayoutMichael Legault
- Longer vehicle warranties and stricter fuel economy standards are driving demand for thermoplastic composites that can withstand higher underhood temperatures over longer periods.
- Automakers are seeking parts that can operate continuously above 200°C and withstand peak temperatures over 230°C, compared to the 170-190°C capabilities of earlier thermoplastic parts.
- Thermoplastic suppliers are developing new high-temperature materials like polyamides, nylon 4/6, and polyphenylene sulfide that allow parts to withstand temperatures from 180°C up to 220°C continuously and higher temporarily.
The document provides instructions for uploading a splash screen image for a mobile app. It notes that every app must have a launch or placeholder image displayed when it starts up. It specifies that the splash screen size should be 1080 x 1920 pixels and can be either a PNG or JPEG file under 3 MB in size. It also includes a button to upload the splash screen image and preview what it will look like on a phone's home screen before proceeding to the next step.
El documento describe diferentes técnicas fotográficas como la velocidad de obturación alta, la profundidad de campo y el uso de teleobjetivos y angular grandes. La velocidad de obturación alta congela gotas de agua en el aire para capturar movimiento. La profundidad de campo hace que los objetos más alejados se vean difuminados. Los teleobjetivos permiten fotografiar objetos a distancias no alcanzables con un objetivo normal y el angular grande deforma el paisaje abarcando un gran campo de visión.
This document provides guidance on scriptwriting for a game trailer. It recommends using Courier New font sized 12 points and including a title page with the script title and author. Scene headings should use capital letters and include location, time of day, and characters. Each page should represent one minute of screen time. The first scene should fade in and include a scene heading and setting explanation. Character names should be in caps when mentioned and dialogue should be centered and move the story forward. The script should capture subtext and reflect characters' personalities. Students are tasked with turning their story into a properly formatted script.
El etanol es un líquido incoloro con fórmula molecular C2H6O. Tiene un punto de ebullición de 78.4°C y es totalmente miscible en agua. Es inflamable y se utiliza comúnmente como combustible.
The candidate has over 10 years of experience in maintenance, testing, deployment, and operation of blow out preventers (BOPs) and various drilling tools. They have a degree in mechanical engineering and training in offshore drilling equipment. They are seeking a position as a maintenance engineer where they can utilize their skills in planning, scheduling, and maintaining drilling equipment to ensure efficiency and eliminate downtime. They have experience working on various offshore drilling units and maintaining compliance with regulatory codes. A highlight of their career was leading a team to perform a turnaround and re-certification of BOPs on a drillship, which was completed on time. They believe their skills in project management and resource allocation would help promote operational efficiency in the role.
This document discusses SingTel's use of social media to engage customers and promote its brand. It describes SingTel's social media team structure and roles. It provides examples of successful social media campaigns including a concert with K-pop group 2NE1, a campaign to get feedback on 4G speeds called #Need4GSpeed, and a campaign called #HawkerHeroes where Gordon Ramsay challenged local hawkers to a cook-off. The #HawkerHeroes campaign was a major success, generating significant engagement, traffic to SingTel's website, and positive press coverage.
This will help you in grasping the concept about Balance Sheet. It is very helpful especially for economists and engineers as well. In case of any confusion you can contact me on linkedin. Thanx!
The document announces the MVP Challenge 2012 hosted by Expansion Bridge to help tech startups. It invites teams to create a mockup and pitch video of their minimum viable product by November 8th for a chance to win prizes, including having their mockup developed professionally. Finalists will present to investors on December 5th for feedback and the opportunity to win cash and advisory prizes to help launch their startup.
El documento trata sobre el potencial forrajero y la estimación de la capacidad de carga en agostaderos. Describe los factores a considerar para evaluar el potencial de producción de forraje, como la cobertura y tipo de vegetación. Explica cómo estimar la producción forrajera disponible mediante la identificación de sitios, estimación de superficies, especies forrajeras clave y producción por hectárea. Resalta la importancia de dividir el agostadero en potreros y rotar el pastoreo para mejorar la producción y evitar el sobrep
The document provides guidance on creating a personal development plan with mentoring. It recommends identifying development needs and strengths, creating a rolling 1-year plan with detailed 6-month objectives. The plan should be SMART (Specific, Measurable, Attainable, Relevant, Time-bound). The plan should support clear objectives through a variety of training and development activities, with 25% focused on training and 75% on other methods. Mentoring involves a long-term relationship where the mentor provides help, guidance, and support through roles like coaching, counseling, and networking. An effective mentoring relationship progresses through phases from initially establishing trust to the mentee gaining independence.
This project aims to recycle carbon fiber composite materials for use in automotive manufacturing. Researchers are developing methods to extract carbon fibers from end-of-life components and manufacturing scrap using fluidized beds or supercritical fluids. The recycled carbon fibers will be used to produce bulk and sheet molding compounds for non-load bearing automotive parts. This recycling will help reduce waste and lower the cost of carbon fiber, allowing increased use in vehicles to reduce weight and emissions.
This document summarizes research from Scion, a New Zealand research organization, on biopolymers and chemicals from 2014-2015. It discusses how Scion is supporting manufacturers through research on sustainable and biobased resources. Key points include Scion developing an eco-friendly bioplastic alternative to polystyrene foam called ZealaFoam, research finding that a biocomposite reinforced with wood fibers can be highly recyclable, and industrial extrusion trials being assisted by computer simulation to optimize natural fiber compounding processes.
Production Fuel From Waste Plastic By Pyrolysis (Theoretical part)Alitek97
In our experiments, commercially available shredded plastics were procured and washed before pyrolysis. Pyrolysis it is one of the most favorable and effective disposing methods, the process is an environmentally friendly and efficient way to eliminate the effect of plastic. Pyrolysis is the thermal degradation of solid wastes at high temperatures (250- 325℃) in the absence of air (and oxygen). The main process given below:
1. Identification of waste plastics. (PE/PP/PS/LDPE/HDPE)
2. Crash and cut the plastic for the pyrolysis process
3. Condensation of the gas to obtain raw fuel.
4. Collect the sample and perform tests to identify the kinds of fuel produced.
Green cast demonstration of innovative lightweight construction components ma...eSAT Publishing House
This document describes the GREEN CAST project which aims to develop an innovative, sustainable construction material made from recycled fly ash as an alternative to autoclaved aerated concrete (AAC). The material is produced using a geopolymer process with fly ash activated in an alkaline solution and foaming agent. Testing found the material has similar mechanical, thermal and acoustic properties as AAC but with lower environmental impact. Two full-scale demonstrator buildings were constructed using the new material and AAC blocks to compare performance, finding the new material performs similarly as an insulating material.
HP provides many free green resources for organizations looking to reduce their environmental impact and carbon footprint, including a carbon footprint calculator, green IT action plan guide, and Smart Web Printing tool. KYOCERA developed the first printers to use amorphous silicon drums instead of OPC drums, increasing drum lifespan and reducing waste. Xerox introduced the first copiers and duplicators with automatic duplex printing in 1970, reducing paper usage. Toshiba offsets the carbon emissions from its printers through a program providing efficient cookstoves to households in Kenya.
Magna International, an automotive parts manufacturer, has developed a new wood fiber polymer composite called Concero for automotive parts through a 2.5 year research collaboration. Testing of the lighter and more sustainable Concero composite in Magna's production facilities shows potential to replace 20% glass-reinforced polypropylene parts. If adopted widely in the 60 million vehicles produced annually, the market for wood fibers in automotive composites could reach 800,000 tonnes per year.
This document discusses processes for separating, recycling, re-manufacturing and reusing carbon fibre from carbon fibre composites. It describes how pyrolysis is used to separate carbon fibres at high temperatures. The recovered fibres can be converted into pellets, powder or plates for reuse. Testing shows recycled carbon fibres have 10-20% lower strength than virgin fibres but offer 20-40% cost savings. Recycled fibres could be used in injection molding, additive manufacturing or to reinforce advanced materials like ceramics. Developing efficient recycling methods is important as carbon fibre use increases in industries like aviation and automotive.
Extraction of Carbon Black from the Coconut ShellIRJET Journal
This document summarizes the extraction and manufacturing process of carbon black from coconut shells. It discusses that carbon black is produced through the incomplete combustion of hydrocarbon materials. There are three main types - channel, furnace, and thermal - which vary in average particle size and surface chemistry. Carbon black can be extracted from coconut shells through pyrolysis or destructive distillation. The carbon black extracted from coconut shells is a fine carbon powder that has potential applications as an electromagnetic wave absorber or conductive material due to its high surface area.
The document provides instructions for uploading a splash screen image for a mobile app. It notes that every app must have a launch or placeholder image displayed when it starts up. It specifies that the splash screen size should be 1080 x 1920 pixels and can be either a PNG or JPEG file under 3 MB in size. It also includes a button to upload the splash screen image and preview what it will look like on a phone's home screen before proceeding to the next step.
El documento describe diferentes técnicas fotográficas como la velocidad de obturación alta, la profundidad de campo y el uso de teleobjetivos y angular grandes. La velocidad de obturación alta congela gotas de agua en el aire para capturar movimiento. La profundidad de campo hace que los objetos más alejados se vean difuminados. Los teleobjetivos permiten fotografiar objetos a distancias no alcanzables con un objetivo normal y el angular grande deforma el paisaje abarcando un gran campo de visión.
This document provides guidance on scriptwriting for a game trailer. It recommends using Courier New font sized 12 points and including a title page with the script title and author. Scene headings should use capital letters and include location, time of day, and characters. Each page should represent one minute of screen time. The first scene should fade in and include a scene heading and setting explanation. Character names should be in caps when mentioned and dialogue should be centered and move the story forward. The script should capture subtext and reflect characters' personalities. Students are tasked with turning their story into a properly formatted script.
El etanol es un líquido incoloro con fórmula molecular C2H6O. Tiene un punto de ebullición de 78.4°C y es totalmente miscible en agua. Es inflamable y se utiliza comúnmente como combustible.
The candidate has over 10 years of experience in maintenance, testing, deployment, and operation of blow out preventers (BOPs) and various drilling tools. They have a degree in mechanical engineering and training in offshore drilling equipment. They are seeking a position as a maintenance engineer where they can utilize their skills in planning, scheduling, and maintaining drilling equipment to ensure efficiency and eliminate downtime. They have experience working on various offshore drilling units and maintaining compliance with regulatory codes. A highlight of their career was leading a team to perform a turnaround and re-certification of BOPs on a drillship, which was completed on time. They believe their skills in project management and resource allocation would help promote operational efficiency in the role.
This document discusses SingTel's use of social media to engage customers and promote its brand. It describes SingTel's social media team structure and roles. It provides examples of successful social media campaigns including a concert with K-pop group 2NE1, a campaign to get feedback on 4G speeds called #Need4GSpeed, and a campaign called #HawkerHeroes where Gordon Ramsay challenged local hawkers to a cook-off. The #HawkerHeroes campaign was a major success, generating significant engagement, traffic to SingTel's website, and positive press coverage.
This will help you in grasping the concept about Balance Sheet. It is very helpful especially for economists and engineers as well. In case of any confusion you can contact me on linkedin. Thanx!
The document announces the MVP Challenge 2012 hosted by Expansion Bridge to help tech startups. It invites teams to create a mockup and pitch video of their minimum viable product by November 8th for a chance to win prizes, including having their mockup developed professionally. Finalists will present to investors on December 5th for feedback and the opportunity to win cash and advisory prizes to help launch their startup.
El documento trata sobre el potencial forrajero y la estimación de la capacidad de carga en agostaderos. Describe los factores a considerar para evaluar el potencial de producción de forraje, como la cobertura y tipo de vegetación. Explica cómo estimar la producción forrajera disponible mediante la identificación de sitios, estimación de superficies, especies forrajeras clave y producción por hectárea. Resalta la importancia de dividir el agostadero en potreros y rotar el pastoreo para mejorar la producción y evitar el sobrep
The document provides guidance on creating a personal development plan with mentoring. It recommends identifying development needs and strengths, creating a rolling 1-year plan with detailed 6-month objectives. The plan should be SMART (Specific, Measurable, Attainable, Relevant, Time-bound). The plan should support clear objectives through a variety of training and development activities, with 25% focused on training and 75% on other methods. Mentoring involves a long-term relationship where the mentor provides help, guidance, and support through roles like coaching, counseling, and networking. An effective mentoring relationship progresses through phases from initially establishing trust to the mentee gaining independence.
This project aims to recycle carbon fiber composite materials for use in automotive manufacturing. Researchers are developing methods to extract carbon fibers from end-of-life components and manufacturing scrap using fluidized beds or supercritical fluids. The recycled carbon fibers will be used to produce bulk and sheet molding compounds for non-load bearing automotive parts. This recycling will help reduce waste and lower the cost of carbon fiber, allowing increased use in vehicles to reduce weight and emissions.
This document summarizes research from Scion, a New Zealand research organization, on biopolymers and chemicals from 2014-2015. It discusses how Scion is supporting manufacturers through research on sustainable and biobased resources. Key points include Scion developing an eco-friendly bioplastic alternative to polystyrene foam called ZealaFoam, research finding that a biocomposite reinforced with wood fibers can be highly recyclable, and industrial extrusion trials being assisted by computer simulation to optimize natural fiber compounding processes.
Production Fuel From Waste Plastic By Pyrolysis (Theoretical part)Alitek97
In our experiments, commercially available shredded plastics were procured and washed before pyrolysis. Pyrolysis it is one of the most favorable and effective disposing methods, the process is an environmentally friendly and efficient way to eliminate the effect of plastic. Pyrolysis is the thermal degradation of solid wastes at high temperatures (250- 325℃) in the absence of air (and oxygen). The main process given below:
1. Identification of waste plastics. (PE/PP/PS/LDPE/HDPE)
2. Crash and cut the plastic for the pyrolysis process
3. Condensation of the gas to obtain raw fuel.
4. Collect the sample and perform tests to identify the kinds of fuel produced.
Green cast demonstration of innovative lightweight construction components ma...eSAT Publishing House
This document describes the GREEN CAST project which aims to develop an innovative, sustainable construction material made from recycled fly ash as an alternative to autoclaved aerated concrete (AAC). The material is produced using a geopolymer process with fly ash activated in an alkaline solution and foaming agent. Testing found the material has similar mechanical, thermal and acoustic properties as AAC but with lower environmental impact. Two full-scale demonstrator buildings were constructed using the new material and AAC blocks to compare performance, finding the new material performs similarly as an insulating material.
HP provides many free green resources for organizations looking to reduce their environmental impact and carbon footprint, including a carbon footprint calculator, green IT action plan guide, and Smart Web Printing tool. KYOCERA developed the first printers to use amorphous silicon drums instead of OPC drums, increasing drum lifespan and reducing waste. Xerox introduced the first copiers and duplicators with automatic duplex printing in 1970, reducing paper usage. Toshiba offsets the carbon emissions from its printers through a program providing efficient cookstoves to households in Kenya.
Magna International, an automotive parts manufacturer, has developed a new wood fiber polymer composite called Concero for automotive parts through a 2.5 year research collaboration. Testing of the lighter and more sustainable Concero composite in Magna's production facilities shows potential to replace 20% glass-reinforced polypropylene parts. If adopted widely in the 60 million vehicles produced annually, the market for wood fibers in automotive composites could reach 800,000 tonnes per year.
This document discusses processes for separating, recycling, re-manufacturing and reusing carbon fibre from carbon fibre composites. It describes how pyrolysis is used to separate carbon fibres at high temperatures. The recovered fibres can be converted into pellets, powder or plates for reuse. Testing shows recycled carbon fibres have 10-20% lower strength than virgin fibres but offer 20-40% cost savings. Recycled fibres could be used in injection molding, additive manufacturing or to reinforce advanced materials like ceramics. Developing efficient recycling methods is important as carbon fibre use increases in industries like aviation and automotive.
Extraction of Carbon Black from the Coconut ShellIRJET Journal
This document summarizes the extraction and manufacturing process of carbon black from coconut shells. It discusses that carbon black is produced through the incomplete combustion of hydrocarbon materials. There are three main types - channel, furnace, and thermal - which vary in average particle size and surface chemistry. Carbon black can be extracted from coconut shells through pyrolysis or destructive distillation. The carbon black extracted from coconut shells is a fine carbon powder that has potential applications as an electromagnetic wave absorber or conductive material due to its high surface area.
Green manufacturing aims to make products and processes safer for the environment and human health. It focuses on using less toxic materials, post-consumer recycled content, locally sourced materials, and renewable energy. Interface, a carpet manufacturer, has transitioned to using bio-based raw materials, sources over 27% of its energy from renewables, and has eliminated 50% of waste costs. Deconstruction is the careful dismantling of structures to maximize reuse of materials and minimize landfill waste. Reuse keeps goods out of the waste stream by redistributing still-usable items, while recycling collects, sorts, and reprocesses used materials into new raw materials. Remanufacturing disassembles worn equipment to reuse sound parts and build new products
This document presents a life cycle assessment (LCA) of a standard promotional ballpoint pen to develop a more environmentally friendly version. The LCA analyzes the pen's materials, manufacturing, transportation, use, and end of life. It finds that plastic components like the polystyrene barrel have the greatest environmental impact. To reduce this, the study switches the barrel material to recycled aluminum, which significantly decreases greenhouse gas emissions and water usage. Some metal components must remain the same for strength and durability. The document considers replacing petroleum-based ink with soy-based ink as another environmentally friendly modification. In summary, the LCA identifies plastic as the primary contributor to the pen's environmental impact and recommends switching to
This document presents a life cycle assessment (LCA) of a standard promotional ballpoint pen to develop a more environmentally friendly version. The LCA analyzes the pen's materials, manufacturing, transportation, use, and end of life. It finds that plastic components like the polystyrene barrel have the greatest environmental impact. To reduce this, the study switches the barrel material to recycled aluminum, which significantly decreases greenhouse gas emissions and water usage. Recycled polypropylene is also used to lessen impacts from materials. The report considers alternative inks but finds soy-based ink to be the most practical option for maintaining usability while lowering environmental effects over the pen's lifetime.
Second CELLUWOOD Newsletter (published in September 2014)
CELLUWOOD was a 4 years EU project, funded under the Eco Innovation research initiative. The project aims to develop a new range of structural elements made of wood by introducing innovative production elements and includes the use of cellulose instead of petroleum-based glue in the lamination of the timber products. The ‘physical’ results will be the strong eco-beams and columns and their most sustainable manufacturing technologies, in addition to significant environmental and cost benefits of the innovation. These are achieved by the introduction of the (new) technologies from other sectors (e.g. cellulose velvet, biocomposite reinforcement and bio-resin) for innovative uses in the defect removal and repairing, facilitating innovation in the use of nano/micro cellulose and bio-resin technologies in timber reengineering, and the development, testing and demonstration of the novel initiative products.
Coordinator and responsible of the project at AIDIMA: Miguel Ángel Abián
In the case of AIDIMA, this project is co-funded by IVACE (Instituto Valenciano de Competitividad Empresarial) and by the European Regional Development Fund (ERDF).
The document discusses applying circular economy principles to power cable design. It outlines Alliander's goal of having 40% of purchased goods integrated into the circular model by 2020. Prysmian Group supplies cables to Alliander and is working on circular design innovations like reusable insulation materials. The document advocates analyzing cable design using a "LIDS wheel" framework considering material selection, production, distribution, lifetime, and recyclability to create a closed-loop circular product life cycle.
ECO-FRIENDLY AND SUSTAINABLE SOLUTIONS PROGRESSING CIRCULAR ECONOMYiQHub
Budenheim offers sustainable solutions for the life science and materials science markets, including circular economy solutions. They have expertise in polymer processing and formulation. Their products include masterbatches, flame retardants, and additives that provide benefits such as lightweighting, energy efficiency, and improved performance while reducing CO2 emissions. Their foaming agents can reduce part weight by over 10% through cellular structure formation. They also offer color masterbatches that maximize recyclate usage and enable detection and sorting of colored plastics for recycling.
Testing of Coconut Shell Reinforced Brake PADSIJSRED
1) The document describes research into developing coconut shell reinforced brake pads as a safer alternative to asbestos brake pads. Various samples of brake pads were created with different compositions of coconut shell powder, graphite, alumina, and epoxy resin.
2) The samples were tested on a wear testing machine at various speeds to measure the wear rate and coefficient of friction. Sample four performed the best with the lowest wear rate.
3) The research demonstrated that brake pads created with coconut shell reinforcement can be a viable non-toxic alternative to asbestos brake pads and perform well under testing.
This document discusses using plastic waste as an alternative fuel source. It begins by outlining the growing problem of plastic waste and its negative impacts on soil quality and the environment when dumped on land or in oceans. The study then examines the calorific (energy) value of different types of recycled plastics, finding their potential energy is comparable to fuels like pet coke and coal. The document goes on to describe a experiment where plastic waste was "co-processed" as an alternative fuel in a cement plant. Results showed using plastic waste along with pet coke as fuel increased the heat required for cement production only slightly. Emissions from the plant were also still within prescribed limits. The study concludes that plastic waste has potential to be
Prepreg technology has enabled the evolution of high-speed transportation like trains and ships. This document explains prepreg technology, including how prepregs are made and their properties. Prepregs consist of fibers reinforced with a resin or matrix. They are used in aerospace, marine, sports, and other industries due to benefits like lower weight, higher strength and stiffness than conventional materials. Common prepreg processing methods include vacuum bagging and autoclaving.
IRJET- Novel Way of Manufacturing a Carbon Fiber Monocoque ChassisIRJET Journal
1. The document describes a novel method for manufacturing a carbon fiber monocoque chassis. 2. The proposed method eliminates the mould making process from the existing three step process of pattern, mould, then product. 3. By directly producing the carbon fiber product from the wooden pattern, the proposed method saves both time and money compared to the existing method, reducing costs by Rs. 15,000.
This document provides an overview of major carbon capture technologies, including post-combustion capture, pre-combustion capture, and oxy-combustion. It discusses the technology readiness levels of different approaches, advantages and challenges of each type of capture, and the need for large-scale commercial demonstrations of integrated carbon capture and storage technologies. Key points covered include a description of different capture technologies, the importance of improving power plant efficiency to reduce carbon emissions, current status of different technologies in terms of readiness levels, and factors important for commercial deployment of carbon capture systems.
IRJET- Experimental Investigation of Mechanical Characteristics of Natural Re...IRJET Journal
The document experimentally investigates the mechanical properties of natural fiber composites made from groundnut shell, rice husk, and coir fibers reinforced with epoxy resin. Two composite plates were fabricated - one with groundnut shell and rice husk fibers, and one with groundnut and coir fibers. The tensile, flexural, and impact strengths of the plates were then tested according to ASTM standards. The results showed that the plate with groundnut and coir fibers exhibited better mechanical properties than the plate with groundnut shell and rice husk fibers, indicating natural fiber composites have potential as an alternative to synthetic fiber composites.
Similar to Kreysler & Associates Field Study (EPS Reduction) (20)
Main Java[All of the Base Concepts}.docxadhitya5119
This is part 1 of my Java Learning Journey. This Contains Custom methods, classes, constructors, packages, multithreading , try- catch block, finally block and more.
Walmart Business+ and Spark Good for Nonprofits.pdfTechSoup
"Learn about all the ways Walmart supports nonprofit organizations.
You will hear from Liz Willett, the Head of Nonprofits, and hear about what Walmart is doing to help nonprofits, including Walmart Business and Spark Good. Walmart Business+ is a new offer for nonprofits that offers discounts and also streamlines nonprofits order and expense tracking, saving time and money.
The webinar may also give some examples on how nonprofits can best leverage Walmart Business+.
The event will cover the following::
Walmart Business + (https://business.walmart.com/plus) is a new shopping experience for nonprofits, schools, and local business customers that connects an exclusive online shopping experience to stores. Benefits include free delivery and shipping, a 'Spend Analytics” feature, special discounts, deals and tax-exempt shopping.
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Chapter wise All Notes of First year Basic Civil Engineering
Syllabus
Chapter-1
Introduction to objective, scope and outcome the subject
Chapter 2
Introduction: Scope and Specialization of Civil Engineering, Role of civil Engineer in Society, Impact of infrastructural development on economy of country.
Chapter 3
Surveying: Object Principles & Types of Surveying; Site Plans, Plans & Maps; Scales & Unit of different Measurements.
Linear Measurements: Instruments used. Linear Measurement by Tape, Ranging out Survey Lines and overcoming Obstructions; Measurements on sloping ground; Tape corrections, conventional symbols. Angular Measurements: Instruments used; Introduction to Compass Surveying, Bearings and Longitude & Latitude of a Line, Introduction to total station.
Levelling: Instrument used Object of levelling, Methods of levelling in brief, and Contour maps.
Chapter 4
Buildings: Selection of site for Buildings, Layout of Building Plan, Types of buildings, Plinth area, carpet area, floor space index, Introduction to building byelaws, concept of sun light & ventilation. Components of Buildings & their functions, Basic concept of R.C.C., Introduction to types of foundation
Chapter 5
Transportation: Introduction to Transportation Engineering; Traffic and Road Safety: Types and Characteristics of Various Modes of Transportation; Various Road Traffic Signs, Causes of Accidents and Road Safety Measures.
Chapter 6
Environmental Engineering: Environmental Pollution, Environmental Acts and Regulations, Functional Concepts of Ecology, Basics of Species, Biodiversity, Ecosystem, Hydrological Cycle; Chemical Cycles: Carbon, Nitrogen & Phosphorus; Energy Flow in Ecosystems.
Water Pollution: Water Quality standards, Introduction to Treatment & Disposal of Waste Water. Reuse and Saving of Water, Rain Water Harvesting. Solid Waste Management: Classification of Solid Waste, Collection, Transportation and Disposal of Solid. Recycling of Solid Waste: Energy Recovery, Sanitary Landfill, On-Site Sanitation. Air & Noise Pollution: Primary and Secondary air pollutants, Harmful effects of Air Pollution, Control of Air Pollution. . Noise Pollution Harmful Effects of noise pollution, control of noise pollution, Global warming & Climate Change, Ozone depletion, Greenhouse effect
Text Books:
1. Palancharmy, Basic Civil Engineering, McGraw Hill publishers.
2. Satheesh Gopi, Basic Civil Engineering, Pearson Publishers.
3. Ketki Rangwala Dalal, Essentials of Civil Engineering, Charotar Publishing House.
4. BCP, Surveying volume 1
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Kreysler & Associates Field Study (EPS Reduction)
1. EPS
WASTE
Field
Study
for
MS&E
264
REDUCTION
AT
K&A
Submitted by:
Veronica Chau
Kalpana Kumar
Dangfun Pornnoparat
Abrash Pervaiz
2. Executive Summary
Kreysler & Associates (K&A) is a company that produces composite Fiberglass
Reinforced Polymer (FRP) for use in architecture, sculpture and industrial applications.
Currently, K&A uses Expanded Polystyrene (EPS) as the material for making FRP molds,
and Unsaturated Polyester (UPR) as the resin. EPS is widely used as a molding material in
FRP-making due to these properties: (1) light-weight, (2) heat-resistant, and (3) cheap.
However, the challenges with using EPS are: it is non-biodegradable; a significant portion is
wasted in creating the mold; and it cannot be recycled once contaminated with resins. Hence,
of the EPS purchased, 100% goes to waste. The objective of our project was thus to find
ways of reducing K&A’s EPS waste from 100% to as close to 0% as possible.
This report begins with an overview of K&A supply-chain for EPS use. An LCA of
EPS and UPR production is presented to show its impact on the environment. Analysis of the
potential solutions for K&A falls under the broad categories of process re-engineering and
assessing alternative materials. Process re-engineering focuses on changes in the current
processes that K&A can make to reduce or eliminate the various sources of EPS waste. An
LCA comparison of alternate materials to replace EPS and UPR is also carried out. This
comparison focuses primarily on four key parameters: energy consumption, carcinogens,
ozone layer depletion and greenhouse gas emissions.
Finally, the alternatives discussed are ranked on a matrix of sustainability versus
feasibility (the degree to which K&A can implement these changes). Based on the ranking,
the final recommendations to K&A are to (1) use a dust sheet/filter to prevent contamination,
(2) use advanced CNC machines such as 3D cutting to eliminate EPS dust while creating the
shape, (3) down-cycle the clean chunks of EPS by selling them for alternative uses, and (4)
continue using EPS and UPR as the foam and resin, respectively, until analysis into a more
suitable material can be done.
i
3. Table of Contents
1. Company Background and Motivation .............................................................................. 1
2. Project Description ............................................................................................................. 1
3. Description of EPS Supply Chain at K&A ........................................................................ 2
4. Life Cycle Analyses of EPS and UPR................................................................................ 3
5. Sustainability Assessment of Alternatives ......................................................................... 4
a) Process Re-engineering .................................................................................................. 4
b) Alternative Materials and Resins.................................................................................... 6
6. Recommendations .............................................................................................................. 7
7. Areas for further research................................................................................................... 8
8. Conclusion and Key takeaways.......................................................................................... 8
Appendix A: Financial Analysis.................................................................................................l
List of Exhibits
Exhibit A: EPS Pictures ..............................................................................................................a
Exhibit B: EPS Supply Chain at K&A..........................................................................................b
Exhibit C: Life Cycle Analyses of EPS and UPR........................................................................... c
Exhibit D: Process Re-engineering Options ..................................................................................e
Exhibit E: List of Contacted Companies ........................................................................................f
Exhibit F: LCA of Alternate Materials .........................................................................................g
Exhibit G: Recommendations Matrix ........................................................................................... k
ii
4. 1. Company Background and Motivation
Founded in 1982, Kreysler and Associates (K&A) is a custom fabrication shop
specializing in the design, engineering and manufacture of composite products, particularly
Fiber Reinforced Polymer (FRP) for architecture, sculpture and industrial applications. The
process of making FRP involves various combinations of fiber, polymer and resins that are
unique to each project. Currently, K&A uses Expanded Polystyrene (EPS)1 as the material for
making FRP molds and Unsaturated Polyester (UPR) as the resin.
EPS is widely used as a molding material in FRP-making because it has the following
properties: (1) light-weight (made from 98% air), (2) heat-resistant, and (3) cheap. However,
the challenges with using EPS are that it is non-biodegradable; a significant portion is wasted
in creating the mold, and it cannot be recycled once contaminated (See Exhibit A for pictures
of EPS and the waste generated). As an example, K&A purchases 3700 pounds of EPS on
average for each project, but only utilizes 1800 pounds for the mold. Additionally, this EPS
mold cannot be reused or recycled once contaminated with resins. Hence, of the EPS
purchased, 100% goes to waste.
2. Project Description
The objectives of our project are:
• To find ways of reducing K&A’s EPS waste from 100% to as close to 0% as possible
• To suggest potential alternatives to EPS and UPR that are more environmentally friendly
and sustainable in the long run.
1
EPS is commonly known as “Styrofoam”, which is a trademark brand developed by The Dow Chemical Company
1
5. 3. Description of EPS Supply Chain at K&A
Exhibit B gives a snapshot of the overall flow of the EPS supply chain. K&A
receives the EPS from its suppliers2 in the form of large, untrimmed blocks with dimensions
ranging from 36” x 48” x 96” up to 41” x 49” x 288”. In order to use the EPS for molding,
the large blocks are trimmed down to a rough size using a handheld hotwire. This initial
trimming results in scrap foam in large chunks (about 15% of the original block), which we
refer to as “clean chunks”. K&A disposes these chunks by giving them for free to companies
that want them3.
The trimmed blocks are then put on CNC machines and are cut into the required
shape for the mold. This machining process results in waste in the form of “foam dust”,
which is about 35% of the original block of EPS. There are two categories of dust: clean and
contaminated. The clean dust, which forms 14% of all EPS bought, is normally picked up by
the foam suppliers for reuse as they drop off new blocks at K&A. As other materials share the
same machining space with EPS, a major portion of the dust (around 21% of the original EPS
volume) becomes contaminated with urethane foam, wood dust and fiberglass composites
from other parts of the shop. Additionally, a vacuum system which helps with cleaning up
was removed last year due to shop expansion. Without this tool, cleaning and sorting dust is
difficult. Even though the contaminated dust has 98% EPS by volume, recyclers demand
100% purity and hence all the contaminated dust is landfilled.
Of the EPS bought, 50% is actually used for molding; which is again discarded to
landfill after use as it is contaminated with UPR. Therefore, 71% of EPS used by K&A
results in contaminated waste after taking into account both the initial and after-use scrap.
2
Currently, the two main suppliers for K&A are ACH Foam Technologies (http://www.achfoam.com/) and Insulfoam
(http://www.insulfoam.com/).
3
New Image Foam (http://newimagefoam.com/) and Right Way Recycling (http://www.rightwayrecycling.us/) are the two
companies currently picking up these chunks from K&A. “Craigslist” is also being used to find companies interested in
picking up these chunks, but this process is arbitrary and not standardized.
2
6. A very small amount of EPS is used for packaging, but it is negligible, so we have not
considered it in our analysis.
4. Life Cycle Analyses of EPS and UPR
With the given information, a life cycle analysis (LCA) was performed for EPS and
UPR using SimaPro 7.2. While all the impact categories are important for any type of LCA
or environmental consideration, this paper mainly examines greenhouse gas emissions, ozone
layer depletion, carcinogens, and energy resources for analysis.
Exhibit C(a) gives an overview of the energy resources needed to produce, assemble,
and dispose of EPS. The energy intensive stages lie in the raw materials acquisition and
production stages of EPS, (Exhibit C(b)) while transportation and landfilling contribute
minimally. Exhibit C(a) shows that the entire EPS life cycle requires 147,000 MJ. Putting
this number into perspective, it would require the heat energy from lighting 10 million
wooden matches to produce 1 lb of EPS.
1 p (1 production unit) of each is created and 1 p of each is disposed of, showing the
100% EPS waste that K&A currently follows. Similarly, when greenhouse emissions are
analyzed in Exhibit C(c), production of EPS accounts for almost 99% of the greenhouse gas
emissions (transportation excluded) at 4,810 kg of CO2. Putting this into perspective, one
complete life cycle loop produces about 1,200 kg CO2 more than a single car with 30 mpg
(Honda Fit)4 driving 12,000 miles per year.
Exhibit C(d) gives numerical data that corresponds to all impact categories in the
LCA. Because raw materials acquisition and production of EPS is most environmentally
impactful, Exhibit C(e) shows the total energy inputs and emission outputs of these two
phases in the lifecycle.
4
Source: http://www.cnbc.com/id/42326638/30_Cars_That_Get_30_MPG?slide=6
3
7. 5. Sustainability Assessment of Alternatives
Our analysis of the potential solutions falls under the broad categories of process re-
engineering and assessing alternative materials. Process re-engineering focuses on changes in
the current processes that K&A can make to reduce or eliminate the various sources of EPS
waste. A comparison of alternate materials to replace EPS and UPR was also carried out.
a) Process Re-engineering
Exhibit D gives an overview of all the options for process re-engineering. We briefly
discuss each option below:
• Customization at Suppliers: The first option to minimize EPS waste is to obtain
customized molds from the suppliers such as ACH. However, as K&A’s architectural
molds are heavily customized for each project, it would be difficult to communicate
precise mold patterns to suppliers; therefore, this is not a feasible option.
• Revenue-generation from clean chunks: Instead of giving away the clean chunks for
free, K&A can sell them. From our research, EPS can be down-cycled into a number of
other products such as coat hangers, picture frames and packing peanuts. We have
contacted many companies that are willing to pay for and down-cycle clean EPS. The list
of contacted companies is provided in Exhibit E.
• 3D CNC-cutting machine: To reduce EPS dust in the cutting process, 3D CNC cutting
tools (such as those provided by Streamline Automation5) can be used in place of a
traditional CNC machine. These tools provide automated foam carving and foam cutting
production processes, using state-of-the-art software and equipment that greatly reduces
the volume of dust produced in the cutting process.
• Shave-off contaminated surface: One alternative to increase the proportion of clean EPS
is to shave off the contaminated surface from the mold, possibly with a handheld hot
5
Streamline Automation (www.3dcutting.com) is a company that provides a full range of tools and services for CNC
cutting. The approximate cost of their equipment and services ranges from $40-240k.
4
8. wire. Due to the complexity of the customized shape, this would be difficult and labor
intensive. It is estimated that a 250 cubic feet mold would require 2 hours of labor,
costing $100/hour, to shave off its contaminated surface. Moreover, some amount of
foam would still end up in landfill.
• Revenue generation from contaminated chunks: There is a potential to sell
contaminated chunks to Avangard Innovation, a recycling solutions provider in Texas. A
sample of contaminated EPS scraps needs to be verified to see whether it can be recycled
and still have some value. If the sample passes the test, EPS chunks can be picked up by
Avangard’s partner warehouse located in California. K&A can earn the highest price if it
supplies at least 35,000 lb, or earn less at smaller volume. As K&A uses limited volume
of EPS, the amount of revenue that they can potentially earn from this source is restricted.
• Melt contaminated EPS into styrene: Since EPS is made by synthesizing pentane and
styrene, EPS can be melted in a process called thermal densification, after which styrene
is recovered. This process, however, is dangerous as it uses carcinogenic inputs.
• Compaction and disposal: K&A can save significant costs from transportation to landfill
by using a compacter that compresses the EPS waste bound for disposal. Although this is
not a revenue-generating option and requires investment in buying new equipment, this
will compact the foam by a ratio of 70:1, thereby reducing the volume of EPS that
requires transportation to landfill.
• Use a dust sheet: While the vacuum system is out of use due to shop expansion, a dust
sheet can be used to clean up dust during the cutting process to prevent dust from
contamination. This will help increase the ratio of clean dust that can be recycled.
5
9. To analyze the financial aspects of K&A’s EPS waste reduction efforts, we did a mock6 NPV
analysis to determine the “breakeven budget” for K&A for “x%” reduction in EPS waste. The
results are outlined in Appendix A: Financial Analysis.
b) Alternative Materials and Resins
As EPS is lightweight, commercialized, cheap, and heat resistant, finding alternative
materials (see Exhibit F(a) for the list of materials considered) that exactly suited these
characteristics, were not found. The biofoam from the company, Green Cell, is made from
corn starch, while polyurethane foam (PUR) is made from petroleum and vegetable
sources. Exhibit F(b) was partially referenced to consider possible resin alternatives.
According to Exhibit F(c), to fit K&A’s requirements, the foam is required to be
denser (37 lbs/cuft) than EPS. Exhibit F(d) compares all the materials against EPS as a
baseline. Considering the same impact categories as the LCA (energy resources, ozone,
carcinogens, and greenhouse gas), EPS performs the best against all the other viable
choices. Although both woods7 provide the best LCA results, they are not feasible options.
The lightest wood, balsa (density 7-9 lbs/cuft8), cannot compete with EPS produced at 2
lb/cuft. Additionally, while wood is a much better environmental option than foamed plastic
(biodegradability of EPS is over 200 years9), it is not a sustainable option to cut down the
equivalence of 3,700 lbs for each project that K&A pursues. Similarly, the alternative resins
considered perform extremely poorly against UPR (Exhibit F(e)).
Interestingly, the biodegradable biofoam performed the worst, and by a large margin,
in carcinogens and ozone layer. Exhibit F(f) shows that chemical additives and maize
production at the plant account for the majority of these emissions.
6
See Appendix A: Financial Analysis for model assumptions.
7
Basswood is also known as Linden (used this name in SimaPro)
8
Source: http://www.engineeringtoolbox.com/wood-density-d_40.html
9
Study of photocatalytic degradation of polystyrene (http://tinyurl.com/874mshq)
6
10. 6. Recommendations
To provide strong recommendations for K&A’s EPS problem, the alternatives discussed
above were ranked on a matrix of sustainability versus feasibility (the degree to which K&A
could implement these changes). Exhibit G shows this ranking:
● Options such as using a dust sheet/filter were ranked high, both in terms of feasibility and
sustainability, as we believe this is a cheap yet easy process change for K&A to
implement. This option will help eliminate contamination in EPS dust.
● Options that ranked high on sustainability, but low on feasibility (for example, selling
contaminated EPS to the Texas-based Avangard Innovation) were so, primarily because
of the uncertainty in implementation.
● Options that were high on feasibility, but low on sustainability (using epoxy and
polypropylene) fared so, because even though they were industry-standards, LCA showed
that they did not perform well in terms of energy consumption, and hence were not
sustainable in the long-run.
● Finally, options that fared low on both sustainability and feasibility (biofoam and wood)
did so, because they either performed very poorly in LCA, and/or were too expensive to
use as a molding material.
Based on Exhibit G, out final recommendations (in order of priority) are:
● Use a dust sheet/filter to prevent contamination.
● Use 3D CNC cutting machine to eliminate EPS dust while creating the shape.
● Down-cycle the clean chunks of EPS by selling them for alternative uses.
● Continue using EPS and UPR as the foam and resin, respectively, until more sustainable
alternatives are found.
7
11. 7. Areas for further research
While our team conducted a preliminary analysis of alternate materials for EPS and
UPR, given our limited knowledge in the chemical composition of materials, there is still
room for research into an appropriate replacement for EPS that is both biodegradable and
non-toxic. Recent research has been conducted into biodegradable and bio-based thermosets
that show potential to replace synthetic, fossil fuel-based thermosets. For instance, a team led
by Prof. Gadi Rothenberg and Dr. Albert Alberts of the University of Amsterdam have new
thermoset resins that are made from renewable sources, and display properties of
biodegradability and non-toxicity10. However, this research is still in its infancy, and it will
take some time before such products can be made commercially available.
8. Conclusion and Key Takeaways
The following are key takeaways that we learned from working on this project:
• EPS is everywhere: The use of EPS is so prevalent these days that it is an integral part of
our daily lives. Eliminating it from a key process is an extreme challenge.
• EPS is highly recyclable as long as it is clean: Despite our efforts, we found that
contaminated EPS has very little value. There is a need for process change to eliminate
EPS contamination in the first place (Design for Sustainability).
• Biodegradability does not imply sustainability: Many companies only focus on the
sustainability during the end-of-life of a product, rather than throughout the life cycle of
the product. The LCA results that we obtained on the biofoam were a classic example of
this. While the foam was biodegradable, it was the most environmentally harmful in
terms of ozone layer depletion and carcinogens. However, as we learned in the Herman-
Miller case, there is a need to incorporate sustainability in every aspect of the product life
cycle, beginning from its design.
10
Source: http://biopol.free.fr/index.php/new-biobased-and-biodegradable-thermoset-resins/
8
12. Exhibit A: EPS Pictures
(a) New EPS Blocks (b) Clean EPS Chunks
(c) Clean EPS Chunks (d) EPS Dust
(e) EPS Blocks before Molding (f) EPS Blocks after Molding
a
14. Exhibit C: Life Cycle Analyses of EPS and UPR
a) Energy Resources for EPS Production, Assembly and Disposal
b) Energy Resources for EPS Raw Material Acquisition and Production
c
15. c) EPS and UPR Greenhouse Gas Emissions
d) EPS LCA Data Table
d
16. e) EPS LCA Data for Raw Material Acquisition and Production
Exhibit D: Process Re-engineering Options
e
17. Exhibit E: List of Contacted Companies
No. Company Company Website Location Brief Description Distance
Name from
K&A
(miles)
1 Rastra www.rastra.com Scottsdale Build a high quality 782
Engineering ,AZ building material from EPS
2 Infiltrator http://www.infiltratorsystems.c N/A Use modified or fire- N/A
Systems Inc. om retardant EPS in drainage
applications
3 Rapac Inc. http://ringcompanies.com/rapac Oakland, Manufacture EcoSix, 2137
home TN which is recycled
Polystyrene foam
4 Timbron https://www.facebook.com/Tim Stockton, Timbron International 76
International bron.International?sk=info CA collects, recycles, and
converts waste Polystyrene
(Styrofoam) into building
products
5 Alliance of www.epspackaging.org Napa, CA AFPR provides a full list of 11
foam EPS recycling drop off
Packaging locations.
Recyclers
6 Plastic http://www.plasticsmarkets.org/ Multiple Connects recycled plastics N/A
Markets Dot locations buyers and suppliers
Org on
website
7 El Cerrito http://www.el- El Cerrito, Recycling Center 26
Recycling cerrito.org/index.aspx?NID=19 CA
Center 3
8 G.B. http://www.gbimcorp.com/inde St. Union Recyclers and Plastics 55
Industrial x.htm City, CA providers
Materials
Corp
9 Foam http://www.foamfabricatorsinc. St. Foam Providers 100
Fabricators, com/ Modesto,
Inc. CA
10 American http://www.americanrecyclingc St. Recycling Center, now 102
Recycling a.com/wpress/ Modesto, accepts EPS
Company CA
11 Tegrant http://www.tegrant.com/ Hayward, Provide thermal, protective 62
Corporation CA and consumer packaging
12 F.P. http://www.fpintl.com/ Redwood "Environmental" Packaging 65
International City, CA providers
13 Avangard http://www.avaicg.com/ Houston, EPS Recyclers N/A
Innovative Texas
14 Kurtz Ersa http://www.kurtz.de/ Germany EPS Recyclers N/A
15 STYROCYC http://www.styrocyclers.com Marietta, EPS Recyclers N/A
LERS, LLC Georgia
16 GreenMax www.intcorecycling.com China EPS Recyclers N/A
17 Streamline http://3dcutting.com Calgary, Providers of State-of-the-art N/A
Automation Alberta, 3D CNC Cutting
Canada
f
18. Exhibit F: LCA of Alternate Materials
a) Alternative Materials and Resins Considered
b) Comparison of Biodegradability of Bio-based Plastics
g
22. Exhibit G: Recommendations Matrix
Sustainability
Feasibility
• Green cells indicate the steps that K&A should undertake to reduce their EPS waste.
Yellow cells indicate further possibilities which require more work to ascertain their
feasibility. Red cells indicate steps that K&A should avoid due to lower sustainability
impacts and/or lower feasibilities.
• Items in ‘Blue’ indicate a material (as either a mold or a resin).
k
23. Appendix A: Financial Analysis
The intuition from the financial analysis is summarized in the following table:
Target Reduction Breakeven Budget Range
17%-50% 11 $0-$103,444
50%-100%12 $103,444-$258,159
It can be seen from the above table that in order to reduce the EPS waste (excluding
the contaminated mold), K&A can invest just over $100,000 in order to recover the
investment based on the savings that they can get from reduced buying of EPS and the
landfill costs. Any added investment can be termed as an investment in reducing the
environmental footprint of the company. This “breakeven budget” can be allocated to acquire
new equipment (such as the 3D CNC cutting machine) for re-engineering the processes
within K&A such that they result in minimal waste. Our argument is that it can be financially
feasible for K&A to reduce its waste by re-engineering their processes to attain a certain
waste-reduction target. Please refer to the next page for the complete analysis.
11
This range includes EPS waste in the form of clean chunks, clean dust and dirty dust. Anything below 17%
has negative cash flows and results in no savings.
12
This range considers the total EPS waste including the waste from contamsinated mold.
l
24. $300,000
$250,000
$200,000
Breakeven
Budget
$150,000
$100,000
$50,000
$0
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
($50,000)
($100,000)
%
EPS
Waste
Reduc:on
Sample Data from Spreadsheet Model:
Model Assumptions:
1) Only one laborer working 40 hrs in a week at minimum wage is running and maintaining
the machine.
2) Cost of Energy is 16 cents per kWh and the equipment is rated at 20kWh and runs for
1000 hours in an year.
3) The cost of one sheet of EPS was calculated using the minimum size given by K&A, and
by getting the price from the Internet (http://univfoam.com/pricing-calculators/eps-
pricing).
m
25. 4) Number of sheets used per project was calculated by assuming that K&A uses 1800 lbs
of EPS per project.
5) Transportation costs (costs to transport the EPS from ACH and other suppliers) are
proportional to the amount of EPS transported.
6) One trip (from ACH to K&A) costs $35 and there are four trips per week.
7) Landfill costs have been calculated using the information given by K&A.
8) 100% of the landfill costs will be eliminated using the machine (this is not entirely
reasonable though, there will still be some mold left).
9) Discount Rate and Corporate Tax Rate have been assumed at 10% and 30%,
respectively.
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