Industrial Energy EfficiencySustainable ManufacturingTraining

Project Summaries

Sustainable Manufacturing Project Summaries

Samples of what you can expect by working with us.

Our average Return on Investment is 300%, meaning, on average, we save our clients three times as much as our services cost.

We increase your competitive advantage. Period.

PROCESS OPTIMIZATION

Beverage Manufacturer (800,000 sq.ft.) Middleboro, MA
  • Designed process modifications for 20% reduction in sodium hypochlorite in vessel cleaning operations and reduce wash-water volume.
  • Follow-on downstream reductions in wastewater treatment chemicals for 2.1million gallons-per-day flow.
Photographic Film Coating Plant (150,000 sq.ft.) Waltham, MA
  • Process optimization for film coating and drying production lines.
  • 25% reduction in coating waste, and energy input & a case study for State and corporate officials.
Leather Tannery (180,000 sq.ft.) Lynn, MA
  • Process modification for tanning, curing and shaping of cow hides for leather coats.
  • 40% reduction in wastewater, 25% reduction in hazardous waste and 10% energy use savings.
Injection molder, (110,000 sq.ft.) Stratford, CT
  • REACH and RoHs impact analysis for their European Union product lines.
  • Implemented data collection and metric system for materials through-put and waste flows.

SUPPLY CHAIN

Global Manufacturer of Pharmaceutical Delivery Systems, Crystal Lake, IL
  • Developed framework and program base for sustainability efforts of this $2 billion company to meet green demands of manufacturing customers.
  • Advised and formed cGMP procedures for compressed air, ventilation and other energy consuming devices that pose contamination threat to product.
  • Selection of green cleaning products and lubricants, and verification of product claims prior to use.

EMPLOYEE ENGAGEMENT / GREEN TEAMS

State University Hospital, Farmington, CT
  • Conducted trainings and awareness building programs for staff, administrators and medical students on benefits of being "green."
  • Led team in forming plan for reviewing purchasing and cleaning policies. Trained facilities staff and managers on plant energy savings and auditing for energy savings.

LEAN & GREEN

13 companies, various locations in CT
  • Delivery of trainings to aerospace, medical equipment and electronics manufacturers focused upon integration of Lean and green principles.
  • All facilities found process and flow optimization projects which yielded significant energy and/or environmental benefits.

WATER USE / WATER FOOTPRINTS

14 Electroplating Companies (Massachusetts, Connecticut & Rhode Island)
  • Audits for 14 separate electroplating companies (6,000 sq.ft. – 80,000 sq.ft.)
  • 10 - 80% reduction in rinsewaters / wastewater generation.
  • Designed closed-loop processes for recycling plating, acid etch and other chemical baths.
  • Process lines included: Hexavalent Chromium, Zinc, Yellow, Blue and Clear Chromate, Zinc
  • Phosphatizing, Electroless Nickel, Nickel, Cadmium, Silver, Rhodium, Gold and Platinum.
Dollar Bill Paper Manufacturing (300,000 sq.ft.) Dalton, MA
  • Identified 5% reduction potential in process water use on 135 million gallon-per-day process flow.
  • Screen cleaning process modifications resulted in $40,000/year labor savings.

ZERO WASTE / RECYCLING

Periodical and Newspaper Printer (120,000 sq.ft.) Worcester, MA
  • Developed Zero Discharge System, with financial analysis.
  • Reduced hazardous waste costs by 66%
  • Implemented water-based and soy-based inks for conversion of current solvent system.
End Destination Resort (350,000 sq.ft.) private, CT
  • Reduced solid waste stream by 60% through "dumpster dive."
  • $50,000 /year saved through composting at cafeteria.
Health & Beauty Packaging (150,000 sq.ft.) Lincolnton, NC
  • New facility designed for zero waste to landfill.
  • Sourcing recycling markets for 9 "waste" streams
  • Water, electricity and fuel oil conserving technologies beyond building code.
17 Chamber of Commerce Members, Bristol, CT
  • 17 waste audits & "dumpster dives" for local businesses.
  • 10 - 35% reduction in waste & increase in green purchasing.

CARBON FOOTPRINTS

Consumer Goods Containers (9 sites) Mukwonago, IL
  • WBCSD protocols used for enterprise-wide baseline emissions.
  • Eliminated need for new 200 hp air compressor.
  • De-lamping analysis to reduce glare and increase productivity.
  • Energy savings identified in changing injection mold heaters to induction heaters.

SUSTAINABILITY PROGRAMS

Casino, Uncasville, CT
  • Created policies, goals and methods for all environmental risks on sovereign lands.
  • Tracking program for data on waste generation, employee training and other markers developed.
  • 3,000,000 pounds of food wastes diverted the local landfill.
National Pollution Prevention Initiative, Jakarta, Indonesia
  • U.S. Agency for International Development industry-led pollution prevention programs.
  • Conducted training and site assessments, created Best Management Practices for pollution prevention.
Electric Utility (750,000 sq.ft.) Milan, Italy
  • Reviewed Italy's largest electric utility for accounting of environmental costs.
  • Trained consultants, utility engineers and management on Total Cost Assessment.
  • Identified pilot projects to for program roll-out.
Beverage Company (800,000 sq.ft.) Lakeville, MA
  • Adoption of Sustainable Manufacturing practices with corporate officers.
  • Life cycle analysis of chemical versus electrical biocide.
  • Pilot study & testing confirmed financial and aquatic benefits for process cooling waters.

PURCHASING / MAINTENANCE PROGRAM

Southwest College of Naturopathic Medicine, (12,000 sq.ft.) Tempe, AZ
  • Designed program for all operations pertaining to purchasing of all supplies and materials for out-patient clinic.
  • Developed cleaning and maintenance procedures for use with "green" cleaning supplies.
  • Educated staff, administrators, and maintenance contractors on importance, implementation and review of cleaning process.

Sustainable Manufacturing Case Studies

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