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Manchester Tank & Equipment Elkhart, Indiana

Manchester Tank & Equipment Elkhart, Indiana. Aluminum Draw Lubricant Replacement Indiana Partners for Pollution Prevention June 4 th , 2014. P2 Opportunity – Original Process. The facility was using a mineral oil draw lubricant ( TufDraw HPAL) to form aluminum heads.

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Manchester Tank & Equipment Elkhart, Indiana

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  1. Manchester Tank & EquipmentElkhart, Indiana Aluminum Draw Lubricant Replacement Indiana Partners for Pollution Prevention June 4th, 2014

  2. P2 Opportunity – Original Process • The facility was using a mineral oil draw lubricant (TufDraw HPAL) to form aluminum heads. • Formed heads were pre-cleaned with a detergent then rinsed with a caustic solution in a two-stage parts washer, which overflows to the Elkhart POTW. • Annual potential to eliminate: • 4,435 pounds of detergent (Additive 10W) • 2,741 pounds of draw lubricant (TufDraw) • 11,749 pounds of oil-soaked absorbent matting

  3. Original Process – Absorbent Matting

  4. Original Process – Absorbent Matting

  5. Original Process – Oily Heads

  6. Original Process – Pre-Cleaning

  7. Original Process – Oily Residue in Washer

  8. P2 Opportunity – Proposed Process • The facility had previously purchased aluminum blanks already coated with a food-grade polyethylene lubricant. During these attempts in 2007 and 2008, it was determined that the blanks coated prior to arrival would add too much cost to the product. • For the P2 Challenge, we decided to evaluate new options for in-house application.

  9. Aluminum Draw Lubricant Team • Steve Jacobson – Environmental Manager • Roger Morningstar – Operations Manager • George Quetot – Plant 2 Supervisor • Rusty Stoeckinger – Maintenance Supervisor • Matt Horvath – Plant 2 Maintenance • Honorato Diaz – Operator • Orlando Ramirez - Operator

  10. Dry Lube P2 - Timeline • July, 2011 • Evaluation visit to vendor and power equipment mfg. currently using this process • August, 2012 • Return visit to Baum • December, 2012 • Delivery of Dry Lube Applicator • January, 2013 • Conversion to Dry Lube Process

  11. Equipment Purchased • Blank Coater • Air Knife • Pin Pallets

  12. Blank Coater

  13. Coated Aluminum Blanks Dry-Lubed Blank in Press Formed Heads After Washing

  14. Pollution Prevention Positives • 72% Reduction in Oil & Grease discharges • Reduction in weld defects • Old process used mineral oil, glycol ether and caustic. • New process uses food grade polyethylene and glycol ether (all non-hazardous) • Reduced exposure to employees

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