Through seven years of waste reduction efforts, SKF’s Flowery Branch, Georgia, facility has reduced waste streams by 60percent, as it chases the elusive goal of zero waste. “It’s like peeling back an onion,” says V.P. and General Manger Ed Bennett. “There’s always another layer to go after.”
   Here’s a look at materials the plant has eliminated or minimized in its waste stream.

Wastewater
Heat treat washers at the plant were producing 1.6 million gallons of wastewater annually, which had to be hauled away at a cost of $90,000 per year. One option for dealing with the excessive amounts of wastewater was to purchase an additional Ultra Filtration system at a cost of $80,000. The recycling team determined that the 25-year-old washer was using an inefficient process to bring oil to the top of the washer to be skimmed. By adding a skimmer and adjusting the controls, the team significantly reduced the amount of water needed for the machine to operate efficiently. This eliminated the need to purchase the $80,000system, as well as the $90,000 cost to haul the water away.
   The same team investigated the plant’s air conditioning systems, which were generating 300,000gallons of wastewater annually in the form of condensate. At the same time, the team realized that up to 2,000gallons of water were being added to the grind coolant system daily. By reclaiming the condensate and using it as make-up in the grind coolant system, the team cut the amount of HVAC wastewater generated in half, saving 150,000gallons per year. At the same time it reduced the need for fresh water to be added to the coolant system.

Bearing balls
Previously, bearing balls that were damaged in the manufacturing process or that were left unused in certain manufacturing lines, were dumped together and sold to a scrap metal buyer. Using point source reduction methods, employees analyzed where scrap balls were generated and developed methods to reduce the number of balls being scraped. They also found a recycler who takes the scrap balls, reworks them into scrap steel and resells the scrap to other manufacturers.

Grinding wheels and hone stones
Grinding wheels and hone stones used to machine bearing raceways were previously thrown in the trash and eventually shipped to a landfill at a cost to the plant. Now, they’re shipped back to the manufacturer for recycling.

Wooden pallets
The plant previously used non-returnable wooden pallets. With the help of the SKF Corporate Traffic Group, the Flowery Branch facility switched to GSP2 and GSP3 reusable pallets, now used by SKF worldwide. These modular units can be configured as needed and reused numerous times. “We’ve recently expanded our pallet program to include suppliers throughout the U.S. and in Japan,” notes Perdue. “Each pallet makes 10or more trips between SKF, our customers and suppliers.” By going to the reusable pallets in Flowery Branch and throughout the world, SKF has saved hundreds of thousands of dollars worldwide.

Metal Oil Drums
Although the Flowery Branch facility had a tank farm on the premises, certain oils were purchased in 55-gallon metal drums. When empty, some of the drums were sent back to the supplier, but many were sent to a landfill. A team member suggested that oils be purchased in bulk and stored in tanks. This eliminated most of the metal drums and resulted in a more efficient method of supplying oils to the plant. Now, when the plant needs oils in smaller quantities, if practical, they purchase it in 500-gallon totes, which are returned to the supplier when empty. While some 55-gallon drums are still used, the quantity has been significantly reduced.

Paper and cardboard
In plant offices, recyclable paper is separated from non-recyclable trash. Corrugated board from shipping containers and packages is baled. Both the paper and corrugated are sold back to a recycler.

Fluorescent lights
When employees learned that the material inside the plant’s fluorescent lamps was hazardous and an environmental danger should the lights break, they researched environmentally friendly alternatives. Now, as the lights burn out, they are being switched to the safer style, while the old ones are shipped to a recycler.

Energy resources
Plant personnel have also gone outside for expertise in reducing energy usage, relying on experts from Georgia Natural Gas and their electricity supplier, Georgia Power. For example, Georgia Power conducted a usage survey, and identified areas where energy use could be conserved. As a result, the plant has modified their method of generating compressed air, and is investigating the possible retrofit of a 25-year-old boiler with a more efficient burner.

Fluids management
Again relying on outside expertise, the plant has hired an outside fluid care provider to manage the purchasing, inventory and use of all oils and chemicals. The result has been more efficient usage of industrial fluids, less waste and better oversight of related environmental issues which, in total, generated over 10 percent cost savings in 2001. For example, waste fluids that were previously hauled to a disposal site are now sold to a recycler who creates blended fuels for resale to other companies.

Recyclable materials
Anything and everything that can be recycled at the Flowery Branch facility is recycled. This includes paper, pallets, plastic shipping tubes, computers and printers, wet and dry cell batteries, electronic circuit boards, scrap copper wire, printer toner cartridges and drums and more. Before the plant began its recycling efforts, facility waste streams generated three to four dumpsters of trash weekly, most of which was destined for a landfill. Now, the plant is down to one dumpster per week.