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CGPP Report 2004/26

AT A GLANCE
The purpose of this project was to
demonstrate practical solutions and
methodologies for reducing energy usage
and minimising waste production. Tech
Group Europe effected a minimisation of
energy usage by the installation of
intelligent motor controllers (optimisers)
and barrel lagging jackets on various sizes
of injection moulding machines. The
company reduced scrap production by
undertaking scrap evaluation and by
introducing a number of process changes.
In addition, scrap plastic from the
manufacture of medical device
components was diverted from landfill
to a recycling facility off site.
As a result of its participation in this
programme, the company achieved a
significant reduction in costs as well as
energy usage, waste production and
carbon dioxide emissions. In addition,
equipment lifetime has been extended,
and reliability improved. The company has
also managed to create increased
awareness of 'Cleaner Greener Production'
issues among employees, suppliers and
customers. The initiatives undertaken by
Tech Group Europe could be replicated
across a number of other industry sectors.

MINIMISATION OF ENERGY USAGE AND

WASTE PRODUCTION IN A CONTRACT
MANUFACTURING COMPANY
AIMS OF THIS PROJECT

PROJECT DESCRIPTION

The purpose of the project was to

demonstrate practical solutions and
methodologies for reducing energy usage
and minimising waste production. Tech
Group Europe opted to minimise energy
usage by the installation of intelligent
motor controllers (optimisers) and barrel
lagging jackets on different types of
injection moulding machines. The
company reduced scrap production by
undertaking a scrap evaluation and
introducing process changes. In addition,
scrap plastic from the manufacture of
medical device components was diverted
from landfill to a recycling facility off site.

The key project activities were as

follows:

TECH GROUP EUROPE

1. Fit barrel lagging jackets on the

barrels of injection moulding
machines
Barrel lagging jackets insulate the
injection moulding machine barrel and
prevent heat loss. They are similar in
design to the hot water tank lagging
jackets that are found in most homes.
Barrel lagging jackets do not come as
standard on injection moulding
machines. Their suitability depends on
the type of raw material (i.e. plastic)
being processed.

Tech Group Europe is one of the leading

technical moulders in Europe. The
companys manufacturing activities are
predominantly focused on the medical
device, pharmaceutical and consumer
electronic sectors.

Printed on recycled paper using water based inks

Tech Group Europe is a subsidiary of Tech

Group Inc, a privately owned corporation,
which was founded in 1998 and which
now has facilities in the USA, Mexico,
Puerto Rico, Ireland, Singapore, the
Philippines, Malaysia and China. The
corporation employs more than 1,500
people worldwide.

Fig 1. Tech Group Europe Dublin.

Tech Group Europe employs

approximately 110 people at its plant in
Mulhuddart, Dublin. The plant has been
in operation for approximately six years.

Fig 3. Example of permanent barrel

lagging jacket fitted to barrel of injection
moulding machine.
Fig 2. Clean room manufacturing area.

BETTER BUSINESS IN A BETTER IRELAND

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2) Fit optimisers on motors of injection moulding

machines.
As their name suggests, optimisers search for the optimum
efficiency of a motor and then adjust input power
accordingly as the load varies. Optimisers can be applied to
AC motors. They do not affect the speed of the motor:
rather, they alter the voltage characteristics to bring about
savings by capturing redundancy when the motor is off
load.

Fig 5. Material for recycling.

2. Optimisers
The following annual savings may accrue as a result of
installing optimisers.
Energy

CO2 Emission

Savings

Reduction

Payback

(kW/hr)
241,744kWhr

Fig 4. Optimiser unit fitted to injection moulding machine.

3) Reduce process scrap and recycle plastic scrap

Having reviewed the injection moulding processes, plastic
scrap was identified as the single largest contributor to on-

175,264kg

The installation of an optimiser led to the following

improvements:

site waste. Due to the nature of the products

being manufactured, i.e. medical devices, in-process

greater motor efficiency

recycling was not an option. Other potential outlets for

increased lifespan of the motor

disposal of this waste were sought and found.

improved air circulation system

enhanced power factor correction

In tandem with carrying out the above initiatives, the

project team identified what production activities were
generating scrap within the facility. Process scrap reduction
was achieved through process improvements and
revalidations, problem solving, and retraining.

ACHIEVEMENTS
1. Barrel Lagging
Various sizes of injection moulding machines were fitted
with barrel lagging jackets. The total savings accruing as a
result of that initiative are 34,000 per year, which are
mainly accounted for by reduced energy costs.

1.38 yrs

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3. Plastic Scrap Reduction

Significant scrap reductions have been achieved as a result
of setting up cross-functional teams and of introducing new
problem-based training methods. This has resulted in a
reduction in scrap parts per million produced (i.e. from
2,800 parts in January 2003 to 1,300 parts in July 2003). As
a result of this initiative, part of Tech Group Europes scrap
reduction programme costs reduced by 14% during the
period January 2003 to August 2003.

OBSERVATIONS
Scrap reductions were made possible by introducing simple
modifications to process systems.
Optimisers are suitable for certain types of motors only, and
each motor is different. Monitoring must be undertaken
prior to installation even if motors appear to be identical.
Barrel lagging jackets cannot be installed on all injection
moulding machines: suitability is dictated by the materials
being processed.

LESSONS
Substantial savings may be gained from the type of energy
and waste-reduction initiatives that were introduced by Tech
Group Europe: these methods could also be applied by
other injection moulding companies and across several other
industry sectors.

Approximately 50% of the plastic waste is now diverted

from landfill and is recycled off site.

Participation in this project proved to be a catalyst for the

introduction of additional CGPP improvements within Tech
Group Europe.

4. Overall
Other companies and divisions within the Tech Group
Corporation will be able to implement these CGPP measures,
and this has been acknowledged at parent company level.

MORE INFORMATION

The suppliers of Tech Groups injection moulding machines

are investigating the benefits of installing optimisers on their
machines.

Ms. Helen McDonnell.

EHS Officer
Tech Group Europe
Damastown Close
Damastown Industrial Park
Mulhuddart
Dublin 15

Tech Group Europe operates a profit-sharing scheme for its

employees. The savings (and therefore the profits) that have
been achieved as a result of the companys participation in
the Cleaner Greener Production Programme have increased
staff motivation and have stimulated interest in becoming
involved in other CGPP projects.
Table 1 - Direct economic savings from each element of the project
Initiative

Total Annual Savings(Euro)

Barrel Lagging Jackets

Optimisers
Plastic Recycling

34,000
9,712
10,150

Total

53,862

For more information on this project contact:

Email:

helen.mcdonnell@techgroup.com

Tel:

01-885 9700

Fax:

01-885 9701

Website: www.techgroup.com

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CLEANER GREENER
PRODUCTION IS
the application of integrated preventive environmental
strategies to processes, products, and services to increase
overall efficiency and reduce risks to humans and the
environment.
Production processes: conserving raw materials and
energy, eliminating toxic raw materials, and reducing the
quantity and toxicity of all emissions and wastes
Products: reducing negative impacts along the life cycle
of a product, from raw materials extraction to its
ultimate disposal.
Services: incorporating environmental concerns into
designing and delivering services.

CLEANER GREENER
PRODUCTION REQUIRES
new attitudes, better environmental management, and
evaluating available technology options. We need to take
good environmental practice to the stage where it is an
inherent part of any business operation.

HOW IS CLEANER GREENER

PRODUCTION DIFFERENT?
Much of the current thinking on environmental protection
focuses on what to do with wastes and emissions after they
have been created. The goal of cleaner, greener production
is to avoid generating pollution in the first place.
This means:

Better efficiency
Better business
Better environmental protection
Lower costs
Less waste
Less emissions
Less resource consumption

WHY IS THE CLEANER

GREENER PRODUCTION
PROGRAMME BEING RUN?

The long-term goal is to ensure that cleaner, greener production

becomes the established norm in Ireland. The programme seeks to
promote environmentally friendly business through increased
resource productivity, waste reduction, recovery of materials,
improved efficiency in a product value chain, energy management,
and a change of culture within organisations.
The programme aims are focussed on avoiding and preventing
adverse environmental impact rather than treating or cleaning up
afterwards. This approach brings better economic and
environmental efficiency.

PROGRAMME MANAGERS:
The Clean Technology Centre (CTC) at Cork Institute of
Technology was appointed to manage the programme in
association with OSullivan Public Relations Ltd, and Energy
Transport Actions Ltd, (ENTRAC).
The CTC was established in 1991 and is now nationally and
internationally regarded as a centre of excellence in cleaner
production, environmental management and eco-innovation across
a range of industrial sectors.

WHERE CAN I GET

FURTHER INFORMATION?
This case study report is one of 29 reports
available from the organisations that
participated in the first phase of the Cleaner
Greener Production Programme. A summary
of all the projects and CD containing all the reports
are also available. More information on the Programme
is available from the Environmental Protection Agency
Ms. Helen Walsh,
CGPP,
Environmental Protection Agency,
Richview, Clonskeagh Road, Dublin 14, Ireland.
Tel. 01 2680100
Website

Fax. 01 2680199

www.epa.ie

select link to cleaner production.

Email. ertdi@epa.ie
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The Irish Government, through the National Development

Plan 2000 - 2006, has allocated funds to a programme for
Environmental Research, Technological Development and
Innovation (ERTDI).

The Department of the Environment and Local Government asked

the Environmental Protection Agency (EPA) to run the CGPP as
part of the ERTDI programme. With the programme continuing to
2006 about 60 businesses will be supported to implement cleaner
greener production and to demonstrate their achievements to the
rest of Ireland.