THINKING GREEN – HELPING THE PLANET
Recycle Steel, Recycle Paper, Recycle Paint, Recycle Everything
HELPING THE ENVIRONMENT
ENERGY - Operating Efficiently
UNARCO's new state-of-the-art powder-coat paint lines have brought about several drastic improvements that realize strong energy efficiencies everyday. By utilizing lines with lower power intake and paint ovens that go into standby mode automatically, when not in use, our energy usage has decreased by over 30% even as production has increased.
Much of the plant and offices have been switched to LED lighting to save energy utilizing automatic sensors that turn lights off when areas are unoccupied. In addition, added windows have had a great impact by utilizing natural light in the high-bays within the plant.
Current investigation and trials are being completed for battery-operated forklift trucks to further lessen our impact on the environment.
TECHNOLOGY – Thinking about the Environment
UNARCO manages a “Paper Free” document system. Electronic document and file storage keeps thousands of pounds of paper out of file cabinets by maintaining accounting and plant records on servers rather than paper.
Tens of thousands of dollars have been invested in systems and software to promote preferred methods of billing, order reception and payment which require no paper or mailing. EDI transmissions, wire transfers and ACH are used to reduce mailed content and printed paper.
Highly-computerized technology on all pallet rack paint lines has helped maximize the coverage efficiency of our powder. These advances have helped drastically reduce powder usage. In-line cyclone units help separate particles for re-use at 95% efficiency.
AIR QUALITY and SOIL CONSERVATION – Protecting the Environment
UNARCO is very active in environmental protection, the safe handling of waste and the resourceful use of energy. UNARCO has won multiple environmental and community awards from state and national organizations. The State of Tennessee recognized UNARCO with the Governor’s Award for Excellence in Hazardous Waste Management.
UNARCO was the first in the state to receive an operating permit under Title V Air Quality Standards. Ongoing capital expenditures have been devoted to the continuous improvement in air quality systems.
New Truegrid pavers and gravel containment samples are being installed in lieu of concrete pads to help reduce storm water runoff.
RECYCLING – Good for the Environment
All steel component parts are made from a minimum of 50% recycled material.
Nearly 20 million pounds of scrap metal and banding materials are separated and recycled each year to help the environment. Wood and cardboard dunnage on inbound shipments are evaluated and re-purposed to package and store items along the manufacturing phase.
Chemicals and solvents are reclaimed and later sent off for fuel re-blending to keep them out of landfill.
New colors are being developed from waste powder paint with particles too small to reclaim and use. These small particles can be blended into special colors instead of ending up in the landfill thus harming the environment.
All computer equipment, electronics, cellular phones, batteries and supplies are recycled.
System Highlights:
Steel, Plastic, Wood scraps are all separated and recycled.
Cardboard boxes and totes are reused to transport recycled materials
Plastic banding used for inter-plant transfers is shredded and recycled
Computer components are separated and usable parts are sent to Reuse Facilities
Powder coat paint waste is heavily monitored as UNARCO refines its processes to drive down the amount of generated scrap powder
Mill chemicals are refined and reused during the manufacturing process
A recent multi-million dollar investment in multiple powder coat pain lines has led to cost savings and a much more energy efficient operation. Energy costs have decreased by 17% over the last year not only saving money, but also helping the environment. Powder coat waste from the new paint lines is 23% less because of process improvements and newer technology. Powder coating materials are now brought in using extra-large totes, which are reused and multi-purposed in daily plant operations. The paint line investment has led to a much more streamlined use of energy and generated waste.
For more photos of Pallet Rack view the UNARCO Pallet Rack Photo Gallery.
ONGOING ENERGY MANAGEMENT – Saving Energy
Energy consumption is carefully monitored and controlled to reduce waste during manufacturing. UNARCO is exploring alternative energy sources for controlling air temperature and quality within all plants. UNARCO teams with local municipalities to help the environment.
Recent experimentation has begun on paint curing times in ovens and the association with chemical composition of paints. Paint formulation is being adjusted to help conserve energy in ovens.