Pollution Prevention Case Study

APV Crepaco

Machining Fluid Waste Reduction Program
Standard Industrial Classification (SIC) Equipment for food processing, pharmaceutical, cosmetics and chemical industries/3556
Type of Waste Coolants, waste machine cleaner
Strategy Process modification
Company Background APV CREPACO is a 650-employee company manufacturing equipment for the food processing, pharmaceutical, cosmetics and chemical industries. It operates a large metal fabrication shop in Lake Mills that employs 300 machinists who use over 130 machine tools to fabricate equipment from ferrous and nonferrous stock.
Original Process APV CREPACO uses metal working fluids as coolants and lubricants for machining ferrous and non-ferrous metals. In 1993, the company began experiencing serious problems with its machining fluid management system. Although the existing method of fluid management was well within regulatory guidelines, the system used excessive amounts of fluid and generated significant disposal costs. Employee health problems (contact dermatitis) also resulted from contact with spoiled fluids.
Motivation The company wanted to reduce waste and eliminate health problems.
Pollution Prevention Process During 1993, APV CREPACO employees founded the "Missing Link" machining fluid management team and developed a program to reduce waste and eliminate health problems. The team consisted of seven members representing the employee groups that used or managed the fluids (i.e., machinists and maintenance personnel). The team began to define the nature of the machining fluid problem by meeting as a small group and then asking for input from other employees in the facility. This information was then evaluated using statistical analysis. The team identified the following problems related to the machining fluid system: the use of obsolete fluid formulations; poor mixing water quality; lack of quality control over fluid concentrations; cross contamination between fluid types; bacterial and fungal contamination of fluids; and machining fluid recycling equipment that was inoperative.

The team members made use of a number of educational opportunities, including vendor videos and UW-Extension teleconferences, to learn more about coolant management and waste reduction. They put together a list of possible solutions to the machining fluid problems and surveyed other employees for both additional suggestions and to encourage project ownership by non-team members. Based on their research, the team implemented a number of waste reduction strategies and used outside vendors and the UW-Extension Solid and Hazardous Waste Education Center to review progress and make additional recommendations. These strategies include:

  • Using best available fluid formulations to extend fluid life
  • Reducing fluid formulations to two and thus simplifying recycling
  • Improving mixing water quality to avoid fluid degradation
  • Adding external sumps and reservoirs with oil skimmers to maintain fluid quality
  • Creating a machine clean-out and a fluid recycling schedule to eliminate equipment contamination and unnecessary fluid disposal
  • Improving ease of fluid level monitoring to simplify fluid maintenance and minimize unnecessary fluid replacement
  • Training machinists to assess and maintain fluid quality
  • Tracking fluid waste generation to identify problems
  • Labeling materials to avoid cross contamination
  • Bringing the fluid recycling equipment up to operating specifications
  • Developing standard operating procedures for fluid use, recycling, and disposal.

The team conducted employee training sessions to ensure that the new fluid management program would be accepted by the machinists and integrated into normal duties. The team ensured the long-term viability of the fluid management program by: calculating financial gains and reduced waste resulting from their efforts; making a presentation to company employees and management to explain the program and underscore the importance of their accomplishments; and making recommendations for ongoing management and machinist support of the new fluid management program.
Material/Energy Balance Original Process
Feedstock
Soluble oil type grinding and cutting fluids

Waste
Spoiled coolant and waste machine cleaner. 50,000 gallons/year of machining fluid was being disposed of as hazardous waste.

Disposal
Hazardous waste was removed by a hazardous waste management company.

Pollution Prevention Process
Feedstock
Synthetic grinding and cutting fluids

Waste
24,000 gals/year of used coolant. New fluid purchases have been reduced by over 50%.

Disposal
Hazardous waste is removed by a waste management company. Waste machining fluid disposal has been reduced by 50%.
Economics The company originally spent over $75,000/year on new fluids and fluid disposal. Ongoing annual cost savings are $54,000 (a 70% reduction).

Capital Costs
$8,000 to purchase coolant equipment to upgrade existing equipment.

Operation/Maintenance Costs
No significant costs.

Payback Period
Less than one year.
Benefits As a result of the changes implemented, cases of dermatitis attributed to spoiled fluids have been eliminated. The improved fluid quality has also reduced tooling wear and has improved product quality.
Obstacles Some obstacles include: organization and education of machine operators.
Technology Transfer The team has transferred the lessons learned from their experience to others by providing tours of their facility to other companies with similar problems. Their experiences serve as a machining fluid management model for other metal fabricators in Wisconsin.
Company Address APV CREPACO
100 South CP Avenue
Lake Mills, Wisconsin 53511
Contact person Kevin Q. Johnson
414/648-8311
Pollution Prevention Resources Free, On-site Technical Assistance
University of Wisconsin Extension
Solid and Hazardous Waste Education Center
Milwaukee area: 414/475-2845
Remainder of state: 608/262-0385

Pollution Prevention Information Clearinghouse
Wisconsin Department of Natural Resources
Hazardous Waste Minimization Program
608/264-8852, 608/267-9523 or 608/267-3763
DNR Logo


Bureau of Cooperative Environmental Assistance
Wisconsin Department of Natural Resources
P.O. Box 7921
Madison, WI   53707
608/267-9700

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