Company is exploring opportunity to reduce offcuts of film edges in reforming which wre originally perceived as inherent to the laminating process and “irreducible”.Negotiation with supliers and consumers reveals opprotunity to significantly reduce the offcuts and related loss of material and production of waste by bringing size of product closer to the standards of the laminating film supplier.

Mapping the material losses in a cement bags manufacturing company revealed that losses of ink and solvents occur mainly at the end of each production batch due to ink leftovers in the machine that are removed by solvents. Reducing the feed tray size, the volume of feed tubes, and the dead volume in the ink trough significantly reduces the quantity of ink leftovers, and the required solvent quantity.

Productivity loss was noted in a cement bags manufacturing facility due to unmonitored change over of dies between different product batches. Monitoring the changeover time, and adoptin a “Single Minute Exchange Dies” method elimiates the loss of production.

Ink used in a printing company is prepared through manual mixing using a vigorous stirring system in a trough. This led to spillage of 4% of the prepared ink. Switching to an automatic stirring system, with programmed stirring speed and time eliminated that loss.

A printing facility observed high consumption of cleaning solvent that is used to clean the printing machines, due to an inefficient cleaning method practiced.

Installing an automatic washing machine for cleaning the movable parts of the printing machines together with a solvent recovery unit to distill and recover used solvent shall save over 95% of the cleaning solvent baseline.