2015 fall conference: recycling in manufacturing-vermeer

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Vermeer “In Search of a Better Way1

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Vermeer “In Search of a Better Way”

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Vermeer Corporation

• Family owned and operated since 1948

• Approximately 2600 employees

1.5 mm sq. ft. under roof on 320 acres

− 7 manufacturing plants − 1-Parts Distribution Center − Global Pavilion & Training Center − Heath Services & Pharmacy − On-site Eco-Center/Test Building − Yellow Iron Academy

Pella, Iowa Campus – “The Vermeer Mile”

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Presenter
Presentation Notes
Corporate HQ – Pella IA Global operations in China, Germany, Brazil, The Netherlands, and South Dakota Eco Center is central hub for recycling and repurposing materials that would otherwise be disposed of as waste

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Presenter
Presentation Notes
4 – Specialty Excavation – Large Excavation equipment specialized for the Mining Industry

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Presenter
Presentation Notes
Wide variety of Trenching, Excavating, & Sub-surface Drilling equipment

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Presenter
Presentation Notes
Manufacture and stock parts for every model of equipment we produce.

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The Vermeer 4P Philosophy

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Presenter
Presentation Notes
For over 65 years Vermeer has operated under a 4P Philosophy that looks like this… We manufacturing innovative Products that are built to last and serve our customers needs We place the highest value on our People, which includes employees and customers, our community, and even the environment in which we all live We Manage our efforts to ensure we are Profitable and continue to grow, And all of this is done around a set of biblically based guiding Principles. So in a nut-shell…Vermeer strives to treat the people we serve, and the environment we live in, the way we would all individually expect to be treated.

Pollution Prevention

Projects

Community Outreach & Education

Habitat Conservation

Projects

Resource Conservation

Projects

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Presenter
Presentation Notes
Because Environmental Stewardship is Core to our 4P Philosophy, we’ve developed an EMS that emphasizes Environmental Sustainability rather than Environmental Compliance. But the unfortunate reality is that todays regulations force us to spend the majority of our time, effort and resources doing things to merely prove we’re in compliance, instead of doing things that actually benefit the environment. But today we’ll look at a few examples of how Vermeer has leveraged our core principles and values to go Beyond Compliance and drive towards Environmental Sustainability through projects on… Resource Conservation, Pollution Prevention, Community Outreach, and Habitat Conservation

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MULTI-STAGE PARTS WASHERS

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BEFORE CONVERSION

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Presenter
Presentation Notes
Several baths continuously overflowed to the drain Reject RO water direct discharge to drain Frequently discharged the entire Acid Stage to maintain quality performance

AFTER CONVERSION

3

(+ Ion Exch.)

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Presenter
Presentation Notes
Instead of discharging rinse water, we re-routed it into the upstream stages Also discovered that using the Reject RO water actually improved cleaning performance in the washer. Later, we also installed an Ion Exchange unit to recycle the Acid in Stage 3

0

10,000,000

20,000,000

30,000,000

40,000,000

Gal

lons

Rolling Annual Water Conservation

Total Water Usage Total Water Processed Series3

Water Conservation

Washer Conversion

Reduced Water 35-45% Saved 13% a year

RESOURCE MANAGEMENT

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Dumpster Diving Events

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• Implemented site-wide recycling

• Eliminated countless trash cans and dumpsters

• Reduced waste by 1100 tons/yr.

Lean & GREEN

Presenter
Presentation Notes
What’s in your trash can? How can the 3-Rs be applied?

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Red-Tag Reuse Program

Solvent Distillation / Reuse

Achieved Results:

Process and reuse 70,000 gallons of Flush Solvent per year at a savings of $641,000 per year. This material would otherwise be hazardous waste.

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• ITEM Quantity Recycle Credits• Steel 39,211 ton $3,451,077• Paint Solvent (Flush Solvent) 60,720 gal $230,945• Paper & Cardboard 476.5 ton $31,401 • Brass / Copper / Aluminum / Bronze 7.8 ton $16,881• Used Oil 16,716 gal. $13,508• Pallets 756.8 tons of mulch $8058• Plastic 121 ton• Appliances & Electronics 5.3 ton• Rubber 24.34 ton• Other (anti-freeze, batteries, ballasts, lamps, capacitors, oil filters, • Disposal Fees Avoided (1,384 tons recycled) $778,632

What did Vermeer Recycle in 2014?

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Achieved Results:

•Currently 76% beneficial use for all waste generated on campus (96% including steel recycling)

•Saved $737,937 from waste disposal fees and recycling credits (2014)

Recycling & Waste Minimization

(Steel Recycling Excluded)

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0

1,000,000

2,000,000

3,000,000

4,000,000

5,000,000

6,000,000

7,000,000

8,000,000

9,000,000

Total Lbs

Rolling 12-Month Waste Totals

Total Beneficial Use Total Non-Beneficial (Landfill) Steel Purchased (Activity Index)

Through July 2015: Non BenUse 1343515 Lbs Ben Use 3551021 Lbs

Presenter
Presentation Notes
See if Fred has an updated chart

Provides an easy way to keep the food scraps & other organics out of the landfill and turns them into a rich

compost for land applications

From the dirt it came To the Dirt it shall Return

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WHAT CAN BE COMPOSTED? Paper napkins Paper Plates Paper Towels Kleenex Vegetables and veggie peels Coffee Bags, Filters Coffee Grounds & Filters Tea Bags Scrap Foods Fruit & fruit peels Wood chips Lint from behind refrigerator Popcorn (un popped, “Old Maids” also) Greasy Pizza Boxes Food Soiled Paper Old spices Pine needles

Wooden stir sticks Wooden toothpicks Soiled cardboard Compostable dinnerware Elmer’s glue Pencil shavings Paper bags Receipt paper Beverages Egg Shells Vacuum Cleaner Bag Contents Matches (paper or wood) Flowers & house plants Grass clippings Gum Leaves Hair

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Current Locations

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Presenter
Presentation Notes
At Vermeer, we’ve discovered that applying technology to go beyond compliance not only reduce air emissions, but also improves product quality and employee satisfaction.

Pulse Welding -vs-

Conventional Welding

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36% reduction in particulate Less weld fumes in the work environment Lower energy costs

Presenter
Presentation Notes
At Vermeer, we’ve discovered that applying technology to go beyond compliance not only reduce air emissions, but also improves product quality and employee satisfaction.

Particulate Emissions Capturing

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99% reduction in particulate emissions

Electrostatic Paint Guns

Improved paint transfer efficiency by 30% Reduces paint usage and air emissions Improves ergonomics

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Zero HAP / Low VOC Paint

Vermeer has worked closely with our paint supplier to develop special paint formulations that contain zero HAPs and ultra low VOCs

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AIR QUALITY SUSTAINABILITY- vs - COMPLIANCE

46%

5%

57%

41%

4%

16% 10%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

249 tpy 249 tpy <10 tpy <25 tpy < 31,000 gpy <200,000 gpy <10 MM lbs

VOC NOx Xylene Total HAP Gasoline Diesel Weld Wire

Percent of Permit Limit Rolling 12-month Totals

Presenter
Presentation Notes
This chart truly illustrates why a regulatory goals that measures compliance don’t drive sustainability… Wouldn’t you all agree that a better measurement for environmental sustainability is measuring improvement towards a goal that goes beyond compliance…

Community Outreach:

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• School and Visitor Educational Tours

• Community Waste Collection Events

• Environmental Intern Program

• Environmental Enrichment Grants

• Community “Green Team” Committees

Presenter
Presentation Notes
One of the most personally rewarding aspects of my job at Vermeer is driving community engagement projects that promote social responsibility and environmental sustainability.

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Volunteer Disaster Clean-up Minimizes Environmental Impact

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Future State and Opportunities

• Iron Oxide Dust • Fiber Glass • Enhancing Food Waste • Water • Energy-Solar/Wind

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Vermeer Corporation reserves the right to make changes in engineering, design and specifications; add improvements; or discontinue manufacturing at any time without notice or obligation.

VERMEER and the VERMEER LOGO are trademarks of Vermeer Manufacturing Company in the U.S. and other countries.

© 2013 Vermeer Corporation

All Rights Reserved.

THOUGHTS &

QUESTIONS ?

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