The company's decision to invest in new CPS Ink and Stencil Cleaner
technology has increased productivity, improved the work environment, reduced
environmental impacts and benefited the company financially.
Screens are now washed in a central area by one operator, cleaned of ink, stains and stencils and fully renovated for reuse. The washing units are connected to the
plant's exhaust system offering effective ventilation.
The CPS Ink Cleaner removes ink from the screens without using rags. The recycled screen wash is pumped and circulated from the upper level of the tank ensuring prolonged and improved cleaning. Diluted chemicals are used to make the ink soluble. Recirculation through a filter mat collects larger particles and prevents pump blockages. The solvent
tank's conical shaped bottom ensures effective collection of sediments and facilitates removal of sludge.
CPS Ink Cleaner
The CPS Stencil Cleaner removes stencils. A spray dispenser unit keeps the stencil remover or degreaser in good order.
CPS Stencil Cleaner
The process has reduced considerably the number of ink soaked rags.
More importantly, solvent recycling has led to a significant reduction in the
volume of solvent used and sent off-site. The amount of solvent required has
fallen by 60 percent, from 15,000 litres per annum before the initiative to
the current level of 6,000 litres. Furthermore, the solvent now needs to be
replaced only once every 4-6 months.
The CPS system is far less hazardous than when thinners and traditional reclaiming technology were used. It has
minimized the volume of generated waste, reduced hazardous content and reduced the amount of waste needing to be disposed. The system also filters waste and controls the pH of wastewater discharged to the sewer.
Installation of the CPS system has resulted in increased productivity. Print machine down time has been reduced by 1,950 hours per annum, representing an annual earnings opportunity of $105,000. The system provides additional earning capacity at no additional cost amounting to $25,000 and an improved gross profit from capacity increase of $25,000 per annum. Printers and juniors are freed from the tedious task of cleaning screens, time which is able to be spent on more productive activities. The overall increase in productivity is reflected in faster job delivery and client satisfaction.
In occupational, health and safety terms, operators are less exposed to fumes from thinners and the danger of spillage. The CPS system protects the operator from solvent
vapors and contact with chemicals. Chemicals used by the system are very dilute, while elimination of flammable solvents has substantially reduced the risk of fire.
The cost of the initiative was $45,000, which was partly financed by an interest free loan of $22,529 from the South Australian Environment Protection Agency under its Cleaner Industries Demonstration Scheme.
With total annual savings of $164,930, the pay back period
was approximately 4 months.
| Total outlay |
45,000
|
| Savings per annum |
$
|
|
Savings in use of thinners
Savings in rag usage
Improved gross profit from capacity increase
Additional earning capacity without additional cost
Reduced print machine down time
Total Savings
|
6,190
3,740
25,000
25,000
105,000
164,930
|
| Payback period |
4 months
|
