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DONALDSON Australasia says a 2006 Manufacturers' Monthly Endeavour Award for Environmental Solution of the Year for one of its clients, is first-hand proof that recycling can be more than just a benefit for the planet - it can also be a profitable entity.
Dedicated sheet-fed print communications business Penfold-Buscombe was highly commended in this competitive category of the Manufacturers' Monthly awards as part of a triumvirate including Donaldson and Visy Recycling that engineered what is arguably the Australian printing industry's first large scale recycling loop.
Donaldson Australasia industrial air filter national manager Bill Halbert said the Highly Commended Award, judged by industry experts, recognised the length to which the three companies went to ensure Penfold's upgrade didn't just collect waste, it actually made a profitable concern out of the recycling.
"Our consulting engineer, Dominique Ollitrault, had to consider that Penfold was not just making a periodic upgrade to its waste handling systems when we began the project," said Mr Halbert.
"He was mindful that it had to be efficient in its energy consumption, needed to align with the company's excellent OH&S standards, and was able to handle all matter of paper-based waste from a large-scale print and bind operation.
"The collaboration between our organisation, Penfold-Buscombe and Visy Recycling has proven to be a telling move all the way along the waste stream.
"Donaldson engineered the collection and handling system, Penfold goes about its normal processes in the knowledge its plant is clean and recycling-conscious, and Visy receives economically viable quantities of waste paper and cardboard which it recycles into various grades - some of this as export stock.
"As a dust and materials handling specialist across many industries, Donaldson Australasia is proud to be associated with two progressive organisations that culminated in Penfold-Buscombe's prestigious award for environmental excellence," said Mr Halbert.
Donaldson Australasia provided the vital waste handling system and engineering to facilitate this win/win recycling.
Dominique Ollitrault designed and fitted the system as part of the printer's routine upgrade to meet rapid expansion in business and maintain environmental standards.
Visy Recycling subsidised the project to ensure an uninterrupted supply line of raw material it can purchase for its dedicated recycling plants.
Donaldson Australasia's Mr Ollitrault says Penfold Buscombe originally committed to upgrade this facility at about this time not just to preserve valuable resources but to maintain a very clean working environment for its employees.
"The new waste paper handling system was installed to replace an existing system which was about to encounter an increasing workload," said Mr Ollitrault.
"What is now a 24/7 operation creating offcuts from books and magazines that run off stitching lines and folding processes creates waste from general printing, cutting and binding.
"The idea was to stay one step ahead of any blockages and machine downtime so as to avoid potential labour allocation to pick up mess or empty full bins, plus it ensures workers don't face a dusty environment near the compactor.
"Our solution was to install a system comprising a separator AMSP35, rotary valve RV750, two paper trim fans (1 x 75kW, 1 x 30kW), Dalamatic DLM 3/5/15 dust collector and a 55kW clean air fan.
"The system has been designed to allow an extra capacity of volume (30%) for growth and future additions to the shop floor.
"It easily copes with output from one of the fastest growers in the printing industry, yet currently it only needs about 2/3 capacity to handle all the tasks."
The system is facilitating waste handling of product from seven presses, seven folders, three stitching lines, one mailer and four guillotines.
With the way business has been expanding, it was clear the old system wasn't adequately designed to cope with volume, or to perform satisfactorily at the discharge point.
Now everything has been replaced, including the ducting, and the new collector contains a sensor to eliminate any potential overflow that could halt work.
Paper-trim handling is very different to dust control; hence specific solutions were implemented by Donaldson.
Matters such as installing the right size and configuration of ducting become increasingly important, such as on discharge points where high volume is being handled.
The solution also required a separator - an air stream - for trim that could be as much as one metre long. This replaced a cyclone, shows better energy efficiency and is far more compact.
Overall system performance is highly vital in the middle of the night when labour resources are at their lowest and any problem would have meant a slowdown in production.
This new solution has improved productivity by about 20% and potential downtime is much less of a concern compared to what it was before.
Visy Recycling collects the waste from Penfold Buscombe and moves it to its bulk centre in western Sydney for sorting and compressing into one tonne blocks, before shipping to various sites for re-use.
For example, 'white liner' is manufactured to be used for the exterior of cardboard boxes for printing purposes. Lower grade mills are recycled to make for cardboard.
Plastic film is also collected from the site which is exported and passed onto companies specialising in plastic product manufacture overseas.
Richard Adams, NSW commercial manager at Visy Recycling, says the example set at Penfold Buscombe shows there is a very real commercial advantage for any site to put leftover resources through a recycling process rather than into general waste.
"It actually costs less than putting it out with general waste and most products can be sorted into various grades for recycling," said Mr Adams.
"From Penfold Buscombe, we retrieve about 200 tonnes per month, so to emphasise the importance of recycling industrial leftovers we always consider subsidising a scenario that can provide volume and quality.
"Although predominantly recognised as a paper recycling company, we have expanded into other areas such as glass and plastic which undergo value added processes before being moved to specialist users of these materials.”
26-Sep-2006
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