Manufacturers’ Monthly Endeavour Awards Finalists – Environmental Solution

As nominations close for the 10th Endeavour Awards, we highlight the finalists for each category, giving you an insight into innovation and excellence in the manufacturing industry.

PTRONIK

pMC Master Control

PTronik has been recognised for its unique factory dust management system with anomination for the Environmental Solution of the Year award.

PTronik has been actively involved in the supply of electronic timer control systems for industrial dust collector systems for over 30 years. Under new ownership in 2004, the PTronik research & development team soon realised the market need for a process control solution to intelligently automate industrial dust collection management.

By 2009, the company had engineered a number of sophisticated control solutions including its flagship product, the pMC Master Controller.

In 2012, the pMC now included automated tracking of the state of filter bags and has a worldwide patent pending.

Ptronik’s pMC Master Control was the answer for Impact Fertilisers’ manufacturing plant to retrofit upgrade its dust collector to achieve a high level of "environmental performance standards and safety” and to “employ innovation for the pursuit of excellence”.

Impact Fertilisers’ 20-years-old dust collector, although mechanically functioning well, had a control system well below par to meet today’s environmental expectations.

Ptronik’s pMC Master Control employs breakthrough innovative engineering principles to automate the cleaning process by continuously monitoring plant performance, collecting and diagnosing the performance data, and automatically triggering ‘pulse’ cleaning to suit pre-defined criteria.

The PTronik pMC is a self-contained process controller for industrial dust collectors that continuously monitors the condition of a dust collector filters and automatically controls and manages the filter cleaning process.

The installation of the pMC had significant affect on Impact Fertilisers operations via reductions in energy use, improvement in OH&S outcomes with air quality with trend data logging and diagnosis, savings in operational filter bag consumerable costs, optimised plant operating efficiencies by reducing plant downtime.

The pMC has been recognised by industry as a significant contributor to best practice and has been awarded for its energy management, electronic and software design, and engineering principles. 

BALTIMORE AIRCOIL

Baltimore Aircoil is a worldwide manufacturer of evaporative heat transfer and ice thermal storage products that conserve resources and respect the environment, and is a now a nominee of the Environmental Solution of the Year award.

BAC manufactures at Somersby, NSW, creating products to boost end user efficiency while taking responsibility for its impact on the environment. Within its own Somersby facility it has made a number of changes to become more sustainable.

Electricity – Scope 2  carbon emissions. Annual usage was reduced, with a saving of 66,320 kwh which equates to 11 per cent. Key changes included changing lights within factory and office, new compressor, and reducing two brake presses to one brake press. Further reductions in electricity are expected in the next financial year.

Gas – Scope 1  carbon emissions. Air conditioning adjustments saw a 30.5 per cent reduction in Gigajoule usage when comparing a five month period Aug-Dec 2011 Waste Management Program. Employees are encouraged to improve all methods of waste disposal at BAC. Major changes have occurred in the way waste was treated.

Recycling for the past 12 months: waste steel: 144.09 tonnes (up 0.41 tonne). Wood  59.91 tonnes: increased 4.86 tonne. PVC Sheeting : started Jan 2013, with an estimated ten tonnes being sent to China. Paper: 1.825 tonnes of A4 ream paper (up 0.31 tonne).

Canteen waste – Recycling bin introduced August 2011 to collect all recyclables. This equates to a 240 litre bin full each week.

BAC products are designed and manufactured to ensure extended operating life as well as provision for recycling  materials once decommissioned. A large majority of sheet metal material used is purchased locally, reducing the “carbon miles” spent.

BAC has gone as far as designing a whole new line of heat rejection equipment that doesn’t require chemical water treatment.

This equipment, known as the 3C Cooler, can reject heat from a process (similar to a closed circuit cooling tower) while using up to 80 per cent less water and without requiring chemical dosing which would inevitably end up in sewerage.

WRIGHTWAY PRODUCTS

Wrightway Bin

Wrightway is a Lismore, NSW-based family business established in 1996, involved in  manufacture of a range of Lid Lifta foot pedals for waste bins, the wrightway2MT bin tipper, and new related products such as the Wrightway Bin.

There are millions of wheelie-bins in use on a daily basis worldwide, and a common problem to every one of them is their unyielding nature when they need to be relocated, even when empty.

The bin maintains the integrity of the bin (no holes), eliminates the health risks and damage from dragging, and lessens the likelihood of strain or back injuries caused by the use of standard wheelie-bins within industrial situations.

The Wrightway Bin facilitates the operator being able to slide the bin forward when it is located with its rear wheels against a wall rather than dragging the bin and its contents forward by fingertips.

The underside of the bin lip is host to insects and bacteria and dragging damages the base of the bin, especially on non-slip flooring, resulting in the recurring expense of replacement bins.

The Wrightway Bin allows the bin to be manoeuvred without effort (even in tight spaces), allows smaller stature operators to complete tasks without risking their wellbeing, and eliminates damage (and replacement expense) caused by dragging bins over non-slip flooring, without compromising the integrity of the bin itself.

The bin is raised above ground level and as it never has to be dragged at any stage of relocation, worn-through bases are prevented.

The Wrightway Bin has been highly successful and enthusiastically received by staff, for instance, Norco now have over 60 Wrightway Bins in the South Lismore factory, whilst Lion-Nathan has installed over 150 Wrightway Bins® throughout their facilities. Trials are being carried out in Coles, Woolworths, KFC, and others.

CST WASTEWATER SOLUTIONS

Bathurst Regional Council water recycling system

CST Wastewater Solutions formed more than 20 years ago to supply the industrial and municipal wastewater markets.

Bathurst Regional Council has introduced a supernatant recycling system into the filtration plant in the town water supply, helping to conserve potable water and providing substantial water savings over the long term.

A Berson UV disinfection system, supplied by CST Wastewater Solutions, was fitted between the pumping station and the rapid mix tank to disinfect the recycled water from the sludge lagoons before returning it to the rapid mix tank.

The system fully disinfects up to a flow rate of 60 L/s and has a variable power control to enable the UV dosage to be adjustable to suit operating conditions.

Bathurst council’s recycling system, installed by Ted Wilson & Sons using equipment supplied by CST Wastewater Solutions, recovers and disinfects the filter backwash water at the plant.

Disinfection of backwash supernatant – clear liquid that collects above sediment – is not widely used in Australia, but can recover up to 10 per cent of raw water supply while avoiding the need for discharge flows into river systems. CST’s technology has a huge environmental benefit and the technology is available nationally.

Serving a population of about 37,000, Bathurst’s water filtration plant was originally constructed in 1972.

Significant upgrades from 1987 to 1994 increased the water treatment capacity from 27 to 60 million litres per day.
The filter backwash water is discharged into the system’s three sludge lagoons, along with sludge from the sedimentation tank.

The new system involved the construction of a supernatant pumping station and associated pipework to enable the automatic recycling of supernatant from the sludge lagoons into an in-ground well, and then into the first chamber of the rapid mix tank.

The overall water to be saved is estimated to be 13,000 ML over 50 years.