Improving BSO Services and SME Performance Through Cleaner Production

Improving BSO Services and
SME Performance Through

Cleaner Production
[SPEAKERS NAMES]
[DATE]
Module 3:
A closer look at the
Cleaner Production process
CASE
STUDY
Midland Metals
Enterprise Profile:
country
sector
Zimbabwe
Foundry
ownership Family-owned
established 1998
employees 16
revenue
US $65,000
Based on case study created by the United National Environment

Program, Division of Technology, Industry and Economics
Improving MSME Performance through Cleaner Production. Module
3: A Closer Look at CP. Visit www.encapafrica.org.
Background: What is a Foundry?
Midland Metals
CASE STUDY
A foundry is:
a factory that pours molten metal into
molds, producing cast metal objects.
Casting is one of the oldest industrial processes
There are different casting processes.
The focus here is: GREEN SAND CASTING
Some
typical
cast metal
objects:
Aluminum
pots
Engine blocks,
axles
low tech

Turbine blades
in jet engines
high tech
5
Background: SAND-CASTING
Midland Metals
CASE STUDY
Basic materials & equipment for green sand-casting

Pattern
(a copy of the shape
you want to produce,
made of wood, plastic
or metal)
Sand,
mixed with clay binder &
water (so it will hold its
shape) plus coal dust to
improve surface finish
Container of molten
(filled from furnace)
metal
Top and bottom mold forms

(made of metal, open at top and bottom)
Rammer (tool to compact the sand;

often a pressing machine is used)
Midland Metals
CASE STUDY
A very basic summary of the sand casting process. . .

First of all,
mix the sand.
THEN
MOLDING:
Sand placed
into bottom
mold form &
compacted

2 MOLDING:
Pattern placed into mold
3
MOLDING:
Add the top
mold form
Midland Metals
CASE STUDY
A tube or pipe
provides a path to
pour the metal in
Pattern is still inside!
4
MOLDING: Fill top form

with compacted sand.
8
5
In the middle of the

sand is a cavity
shaped like the
pattern!
MOLDING:
Take the top
mold off and
remove pattern
& pipe or post
Pouring
hole
6
Midland Metals
CASE STUDY
MOLDING: Replace the

top mold and fasten
securely!
8
7
CASTING:
Pour the metal (container is
filled from furnace immediately
before you are ready to pour)

Midland Metals
CASE STUDY
Wait for the metal to cool

(minutes to days,
depending on the size of
the casting)
10
Midland Metals
CASE STUDY
A copy of the
pattern has now
been made in metal
9
CLEANING. Sand is
cleaned off the part, the
tab where metal flowed
in must be removed.
SHAKE OUT: Break apart the two

halves of the mold & take out the
partusually requires vibrating or
striking the mold to break apart
the sand

10 Mold forms are reused

Sand is broken up,
11 screened to remove
debris and clumps, and
sent for remixing
11
Midland Metals
CASE STUDY
Sand-casting is
simple in concept, but
demanding in
execution. It is a
process essential to
making basic and
advanced products. . .
it is also hazardous
and energy-intensive!

12
Midland Metals
Enterprise Profile, contd:
products
Production
volume
Markets
Midland Metals
CASE STUDY
Iron mill balls &

crushing hammers
(used for crushing ore)
25 tons/month
(planning 10-fold expansion)
Mining sector
3-15cm
(mill balls)
13
Midland Metals
CASE STUDY
Foundry process map

Sand (new/old),
bentonite*, coal dust,
water, energy
Sand mixing
area
Dust, gases, noise,

reject mixed sand,
surplus sand
Patterns, mold forms,

sand filling, coatings,
energy
Molding
Molding Section
section
Dust, gases, surplus

sand, noise, rejected
molds
Casting area
Gases, organic
fumes
liquid metal
Energy
INPUTS
Shake-out &
Cleaning area
Finished
products

Dust, gases, mold

forms, used sand
Non-Product
OUTPUTS
*Bentonite is a mineral clay.
It forms a binding agent
when mixed with water.
14
Initial CP assessment findings
Midland Metals
CASE STUDY
1. Sand contains significant amount of dust

2. Wind blows sand and dust from stock piles
3. Workers estimate quantities for sand binder and
hardener
4. Energy consumption of furnaces higher than normal
for similar operations
5. Furnace tap-hole not well sealed after use
6. Liquid metal spills during filling of molds
7. Large number of rejects
8. Sand is lost in each cycle
9. Sand mixing and reclamation very labor intensive
15
Material balance for sand mixing

INPUTS
OUTPUTS
Energy
- Electricity = 6 MWh
Raw materials
- New sand = 135 t
- Old sand = 540 t
- Coal dust = 55 t
- Bentonite = 55 t
- Water = 40,320
litres
only 75% reclamation

efficiency (25% of
sand in each batch is
lost.)
Midland Metals
CASE STUDY
Emissions to the
atmosphere
- Dust = 30 t
SAND
MIXING
PROCESS
(mostly
manual)

Waste
- Used sand = 105
t
Products
- Moulds and
cores = 672
tonnes
Annual
figures
16
Sand Mixing: Raw materials costs

Input
Midland Metals
CASE STUDY
Quantity
per 50 kg
batch (kg)
Annual quantity*
(kg)
New Sand
10
134,400
0.02
2,677
Old Sand
40
537,600
Bentonite
53,760
0.17
9,027
Coal Dust
53,760
0.07
3,673
3 litres
40,320 litres
0.02
840
Total
16,217
Water
Unit cost
(US$/kg)
Annual
Total cost
(US$)
(*56 batches/day x 240 days/yr)
New sand = 17% of

raw material costs

17
Biggest CP opportunities
Waste of raw material (sand)
During mixing stage
Spillage
Dust
Midland Metals
CASE STUDY
loss = 2000 kg
! 25%
sand per ton product
Inefficient use of labor

Manual sand mixing
Manual screening for sand reclamation
RESULT:
4 man-hours required
to mix 1 batch

18
Rapid payback CP opportunities
Midland Metals
CASE STUDY
Annual savings (US$)
Good housekeeping
Input
substitution
Cover the new sand

Implement more thorough
inspection, segregation of incoming scrap
278
116
Use sand with low dust content
Better process control
Optimize furnace-melting conditions

Train workers to properly handle
and measure sand binder & hardner
Equipment modification
Improvise proper closing mechanism

for furnace taphole
Install goods spouts on melting pots
139
185
28
28
Total annual savings:

232
$1005
19
Capital investment CP opportunity:

Mechanical sand reclamation/mixing
Midland Metals
CASE STUDY
Old system:
Manual sand
reclamation & mixing
Roller sand mixer +
accessories + shipment
$8,106
Sand shaker
$3,706
Sand screen below the shaker
$347
2 x 5 kW motor
$926
10 m conveyor belt
$694
Other construction material
$463
Sand storage hopper
$1,158
Installation costs
$810
Contingencies
$1,621
TOTAL INVESTMENT COST
$17,833
Molds
shaken out
Shaker table
with Screen
Conveyo
r
Belt
(Removes
lumps)
(Transports
sand)
New system:
Mechanical
sand reclamation plant
Hopper
(Feeds sand
to mixer)
Mechanical
Sand Mixer

20
NEW sand mixing

material balance
Midland Metals
CASE STUDY
INPUTS
Energy
Electricity=24MW
Increase
h
from 6 MWh
Raw materials
- New sand = 65 t
was - Old sand = 610 t
135 - Coal dust = 55 t
t - Bentonite = 55 t
- Water = 40,320
litres
OUTPUTS
Emissions to
the atmosphere
was 30 t
- Dust = 15 t
SAND
MIXING
process
Waste
- Used sand = 50
t
was
105
t
(mechanized)

Products
- Moulds and
cores = 672
tonnes
21
Profitability analysis:
Mechanical sand reclamation/mixing
INVESTMENT COST
Vs.
$17,833
Midland Metals
CASE STUDY
SAVINGS (annual)
31.25% saving on labor
$3,543
24% saving on raw

materials
$8,351
Lower overall
operating costs*
$2,630
*even with increase in electricity costs
Total net savings (per year)
ANALYSIS
Payback Period
Net Present Value (@20%, 5 years)
Internal Rate of Return

$14,525
<2 years
$25,606
77%
22
Benefits of Cleaner Production
Midland Metals
CASE STUDY
1. Improved Profitability
Raw material saving of 25%
Labour costs cut by 30%
Reduced plant and equipment maintenance costs
2. Improved product quality

3. 5 to 7 fold increase in production levels (pieces/per
day), so total profits increase 5 to 7 fold as well
4. Reduced environmental impact

23

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Improving BSO Services and

SME Performance Through

Based on case study created by the United National Environment

Background: What is a Foundry?

Improving MSME Performance through Cleaner Production. Module

Basic materials & equipment for green sand-casting

Top and bottom mold forms

Rammer (tool to compact the sand;

A very basic summary of the sand casting process. . .

Improving MSME Performance through Cleaner Production. Module

Pattern placed into mold

Pattern is still inside!

MOLDING: Fill top form

In the middle of the

MOLDING: Replace the

Improving MSME Performance through Cleaner Production. Module

Wait for the metal to cool

SHAKE OUT: Break apart the two

Improving MSME Performance through Cleaner Production. Module

10 Mold forms are reused

Improving MSME Performance through Cleaner Production. Module

Iron mill balls &

Foundry process map

Dust, gases, noise,

Patterns, mold forms,

Dust, gases, surplus

Improving MSME Performance through Cleaner Production. Module

Dust, gases, mold

Initial CP assessment findings

1. Sand contains significant amount of dust

Material balance for sand mixing

only 75% reclamation

Improving MSME Performance through Cleaner Production. Module

Sand Mixing: Raw materials costs

(*56 batches/day x 240 days/yr)

New sand = 17% of

Improving MSME Performance through Cleaner Production. Module

Inefficient use of labor

Improving MSME Performance through Cleaner Production. Module

Rapid payback CP opportunities

Cover the new sand

Use sand with low dust content

Better process control

Optimize furnace-melting conditions

Improvise proper closing mechanism

Total annual savings:

Capital investment CP opportunity:

Sand screen below the shaker

Other construction material

Sand storage hopper

TOTAL INVESTMENT COST

Improving MSME Performance through Cleaner Production. Module

NEW sand mixing

Improving MSME Performance through Cleaner Production. Module

24% saving on raw

*even with increase in electricity costs

Total net savings (per year)

Improving MSME Performance through Cleaner Production. Module

Benefits of Cleaner Production

Raw material saving of 25%

Labour costs cut by 30%

Reduced plant and equipment maintenance costs

2. Improved product quality