Pollution Prevention Pays Examples
New Electrode Design Reduces Inherent Waste
A 3P project team from 3M’s Valley, Nebraska facility reduced the inherent
waste (waste inherent to the product design and process) from Red Dot Resting
(RDR) Electrodes, adhesive electrodes used in electrocardiogram or EKG
applications, by redesigning the electrode. The team changed the configuration
of the electrodes on the card which reduced silver coating weight, adhesive
coating weight, and the overall size of the electrode. The project prevented
nearly 11 tons of waste and saved nearly $1,000,000 in its first year of
implementation.
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3M Brazil Reduces Solvent Emissions from Tape Production
In 2005, a 3P team from 3M Brazil's Itapetininga facility replaced the solvent-based paper treatment process the plant used to manufacture packaging, medical and masking tapes with a new, water-based process. As a result of this change, the facility reduced solvent emissions by over 45 tons per year. By preventing solvent emissions at the source, the plant also eliminated the need for pollution control equipment, reducing the plant's energy use and eliminating over 125 metric tons of CO2 emissions annually. The project is expected to save the Itapetininga facility over $850,000 in its first year of implementation.
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New Signing Product Reduces Costs, Energy, and Waste
3M's Traffic Safety Systems Division invented a new prismatic reflective signing product that uses less energy, reduces process and design waste, and emits less volatile organic compound emissions during production than 3M's existing beaded signing products. For every square yard of new signing product produced, 3M saves 10,587 Btus of energy and reduces process waste (including solvent emissions and landfill waste) by over 65%. The new product was invented and rolled out in just under three months and met or exceeded existing solvent-based product specifications. This new product has been well-received by customers and will allow 3M to grow its beaded sign business while improving the business's environmental footprint.
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3M's Valley, Nebraska Facility Reduces Packaging Waste
3M's Valley, Nebraska facility was recognized under the 3P Mobius criteria for working with its vendor to switch to reusable packaging for some of the components it purchases to make respirators. Before this project, Valley received the components on spools packaged in a box. The components vendor did not want the original boxes back so the empty spools had to be returned to the vendor in new, different boxes. The facility worked with the vendor to change the component packaging to a system where both the empty spools and their containers can be returned, reducing shipping waste by approximately 8 tons in the first year of the project and saving 3M Valley over $1,500 in packaging and disposal costs.
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Returnable Steel Crates for International Shipment Reduce Waste
3M's Cottage Grove, Minnesota, facility developed a collapsible, reusable steel crate that reduces waste and saves money. Prior to the development of this 3P project, all shipments of automotive products to Germany went in a multi-piece wooden crate. When received in Germany, the automotive products were removed from the crate and the crate thrown away. An employee team looked at many alternatives to reduce waste from these shipments and soon settled on the idea of using returnable packaging. After developing concepts, the team worked with an outside contractor to build prototypes for testing. The final design had to be robust to hold 1,800 pounds of product, double stacked in a shipping container. As a result, the new crates are made of steel and collapse to one-third of their height for the return trip to the U.S. The team's work eliminated 315 tons of solid waste and produced $101,800 savings in the first year alone.
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