Flat metal rolling case study
Challenge
A fabricated aluminum manufacturer in Washington State was unable to handle high volumes of waste, posing environmental and financial risks. They required process optimization and wanted to reduce the cost of rolling oil while minimizing fluid waste to improve profitability.
Solution
Focusing on the process, CRS installed over 2,000 feet of underground, insulated and traced pipelines to provide the necessary fluid transport. The piping was also contained to prevent environmental degradation. Because the process produced extremely abrasive bottom materials, CRS used special materials for construction and an oversized pump with a reduced RPM output.
Ultimately, CRS designed, fabricated and installed a fixed, on-site, five-gallon-per-minute reprocessing unit and took sole source responsibility for recycling the entire inventory of rolling oil and solvents. In addition, CRS provided total technical support including lab assistance and analysis, inventory monitoring, maintenance support and ad-hoc resource coverage. The agreement included a full-time operator to run and maintain the unit and a CRS project capital investment to complete the operation.
Results
Currently reprocessing up to 70,000 gallons per month, the facility has eliminated off-site waste shipments.
CRS’ Optimized Reprocessing Management (ORM) has resulted in a $1.5 million annual cost savings and a higher quality of reusable rolling oil. CRS has also helped this customer achieve:
- A waste fluid minimization target of 95%
- An acceptable additive recovery level of 95%
- Elimination of staining on production materials
- Recycling of solvent to a specified minimum flash point
- Elimination of off-site transportation costs
- A cleaner operation for the health and safety of plant employees
- A reduction in overhead
- Greater focus on the core business