Plastics is one of the most massive manufacturing industries in the US. According to Bonnie Limbach, chief communications officer with The Society of the Plastics Industry (SPI), “The industry accounts for more than $330 billion dollars in annual shipments with another $89.5 billion generated by upstream, supplying industries, bringing the total annual shipments to nearly $421 billion. Nationally, the plastics industry employed more than 1.5 million workers in 2000. Another 843,300 persons were employed by upstream suppliers of the plastics industry, bringing the employment impact to nearly 2.4 million – about 2 percent of the U.S. workforce.” It does not seem that economic downturn or global recession will severely diminish consumer and OEM demand for plastics in all shapes, sizes and formats. [Read more…]
Research & Development Tax Credits: More Accessible Than You Thought
Research and development tax credits provide golden, yet often overlooked, opportunities for manufacturers to recoup expenses of new product development, product changes or manufacturing process improvements. Recent changes to tax regulations and legislation have expanded these credits, making it easier for businesses to take advantage of the savings.
This week, I had the pleasure of speaking with Cedar Robinson, a corporate tax consultant with more than 18 years of specialized R&D Tax credit experience. Robinson explained that businesses do not have to be a high-tech research type company to qualify for tax benefits. In fact, qualified research activities often include all phases of product upgrades, new product research and development, and product & manufacturing process upgrades to improve quality, reliability or efficiency. Most manufacturers are continuously improving production processes and efficiency as part of everyday operations and virtually all manufacturers develop new or improved products. As a result, Robinson indicated that nearly all manufacturers are eligible for the R&D Tax credit. [Read more…]
The Secrets to Keeping the Workplace Safe
Thanks to James Yount of Spill 911 for his contribution to the UniTherm blog. Spill 911 offers a complete line of industrial absorbents and spill response kits as well as spill containment, material handling, janitorial, stormwater control, facility protection and safety products. Our line is diverse, encompassing the top manufacturers and the highest quality products.
What are your workplace safety policies? How do you determine what those policies are? Do you understand where the common hazards are in the workplace? [Read more…]
Untapped Energy Savings in Process Heating
Almost all industrial facilities use some form of process heating, but most companies, even those with strong energy management programs, often overlook the huge potential for energy savings in hot industrial processes.
Industrial facilities make up nearly one-third of the nation’s total energy consumption and according to a recent Department of Energy study, plants with hot processes stand to save 5 – 20% on energy costs by implementing process heating system best practices.
Taking proper steps to reduce heat loss from process equipment, tanks hoses or pipes that reach temperatures of 250°F can significantly reduce energy costs in multiple ways. In many processes, temperatures often exceed 500°F requiring significant amounts of energy to maintain process temperatures and cool a facility’s ambient air temperature. For manufacturers that continuously operate production equipment, the potential energy savings increase exponentially.
The easiest and lowest-cost method of of eliminating energy waste in hot industrial processes lies in insulating process equipment, hoses and hot air ducting. UniVest systems by UniTherm are custom insulation jackets designed to snugly fit equipment and direct heat where it belongs – inside high temperature equipment. [Read more…]
Updated: Michigan Energy Rebates and Incentive Programs
100% of available funds for the CI Prescriptive Electric Program have been paid or reserved. All new prescriptive electric applications will be placed on a waiting list.
Both Consumers Energy and DTE Energy in Michigan are currently offering incentives to plastics manufacturers who take action to control their energy consumption. Both of these electricity providers offer an array of prescriptive incentives that are very easy to take advantage of.
September 1st Rebate Status
They also both offer custom programs for projects that are not already outlined in their custom program listings.
Take advantage now, because these programs each run on a budget and funds are allocated on a first come, first serve basis.
Below is a short list of incentives all plastics processors in Michigan should consider:
Building Blocks of Energy Efficient Production
For most of us, Legos bring back fond childhood memories (or slightly less fond memories of walking barefoot through our kids’ rooms). Whatever we think of, it usually isn’t energy efficiency. Early this spring, the building block giant received the Arburg Energy Efficiency award for outstanding commitment to energy efficiency.
The 80 year old injection molded plastic toy company introduced its energy and environmental management system in 2007. In the first three years, the company increased energy efficiency by 35% and aims to improve efficiency by an additional 5% each year according to shareholder reports.
Shooting for 100% operation from energy renewable sources by 2020, Lego made significant strides reducing energy and water consumption. The company, more profitable than ever before, recently announced a switch to FSC certified packaging to further reduce its carbon footprint.
In celebration of the toymaker’s inspiring attitude and actions towards energy efficiency – and because we think they’re just too cool not to share – we’ve gathered some of our favorite industrial Lego goodies from around the web. [Read more…]
Safety Checklists for Manufacturers
Even in the safest of facilities, failure to implement safety planning measures can lead to major injuries and in some cases, fatalities in the workplace. One of the most important planning tools is a clear safety checklist that lists the necessary conditions to ensure safety for all facility personnel.
Listing OSHA requirements and applicable safety laws that apply to your plan offers a solid starting point for creating a detailed safety checklist. Most likely, your company has already researched these requirements and taken steps to ensure compliance. Locate previous OSHA inspection reports to pinpoint any previous safety concerns.
Various industrial societies and safety research organizations offer safety knowledge and recommendations beyond minimum standard requirements. In addition to a wealth of free online information, both the American Society for Testing Materials and Underwriter’s Laboratories offer safety research, recommendations for testing safety products – think expert recommendations for building materials or fire protection products. Additionally, both organizations offer safety consultants and in depth training courses for plant managers, safety personnel or equipment operators.
When compiling a safety checklist, consider six main topics or sections to address:
- Hazardous material handling
- Fire prevention and protection
- Hot surfaces and burns
- Avoiding falls and spills
- Personal Protection
- Safe equipment operation
A Quick Guide to Energy Management Software
If you’ve picked up any industrial trade journal or browsed the business section of the news for energy related topics, you’ve probably read about energy management software of some type. Everyone seems to agree that energy management software is the next big thing, but how will such systems actually help your business?
Energy management software generally provides options for evaluating effectiveness and ROI of efficiency projects or for measuring, tracking and controlling energy consumption to eliminate waste.
Software for Energy Efficiency Projects
With so many options to choose from, determining which energy efficiency projects to implement might seem a difficult task for any industrial facility. Employees tasked with reducing energy costs often have limited budgets and must prioritize new projects and plan for future implementation.
Through the Energy Efficiency & Renewable Energy (EERE) division the U.S. Department of Energy offers free calculators and software tools that allow you to analyze opportunities to reduce energy costs and help you calculate possible energy savings gained from energy efficiency projects. These tools help calculate the potential return on investment or paybacks for projects, like high temperature insulation jackets, allowing you to purchase the most cost-effective projects first and achieve the greatest amount of energy savings.
Beyond software tools, the EERE also provides a variety of training courses, seminars and webinars for those interested in reducing energy costs with software. Segmented by industry, these resources offer significant insight into options available for you to reduce energy costs.
Energy Management Systems
Available as basic software that controls lighting systems or more complex systems that measure, analyze and control energy consumption, efficiency software offers many custom options for improving efficiency. Sophisticated software systems monitor every aspect of energy consumption and manufacturing emissions, store data that you can use to pinpoint energy waste and send web or cell phone alerts notifying you of any issues.
With such a large range of software options available, determining which services you need isn’t always easy. According to a recent report by business research leader Verdantix, the best method for choosing appropriate management software lies in implementing readily available, free software, choosing a reputable software provider, and clearly outlining your needs prior to the sales process.
What systems are you currently using to monitor your energy usage?
A Bright Idea: Energy Efficient Lighting
It’s a real pleasure to introduce Greg Canniff and Justin Ferrarello as UniTherm guest bloggers. Greg, a Specification Sales Specialist, and Justin, a Social Media and Marketing Specialist, both work for MH Companies, a leading provider of lighting and integrated controls solutions. We’re excited about the opportunity to share their insight about the latest in energy efficient lighting technology!
Greetings from the world of Lighting! We’re happy to offer you a glimpse into our industry through our friends here at UniTherm.
As we’re all aware, Leadership in Energy and Environmental Design, or LEED, has become the driving factor in developing building projects across the globe. We’re asked to consider energy efficiency, environmental friendliness and sustainable methods.
Energy Efficient Lighting Options
The latest projects turning heads are those attempting to set the bar with goals of Net-Zero energy. Net-zero energy buildings operate independently of local energy grids, and some even produce more energy than they consume. We’re approaching those ambitious goals using innovative products with solid-state lighting (SSL) technologies; LED is the most widely known SSL technology.
New Energy Rebate Program for Ohio Manufacturers
Manufacturers and other non-resident Duke Energy customers in the state of Ohio who use more than 700,000 kWh per year are now eligible to receive rebates on energy projects that were completed on or after January 1, 2008.
The new program, Mercantile Self Direct, is a supplement to the existing Smart $aver Incentive Program and creates an opportunity for Ohio Duke Energy customers to apply for funds that could be used toward new energy efficiency projects that may not have otherwise happened. (not a Duke Energy customer? The Ohio Public Utilities Commission lists programs for other energy providers as well – or contact us and we’ll find out for you).
Prescriptive rebates are broken down by the following categories:
- Process Equipment (including barrel blankets and hose insulation)
- Lighting
- Heating & Cooling
- Window, Film, Thermostats
- Chillers & Thermal Storage
- Chiller Tune Ups
- Motors/Pumps
- Variable Frequency Drives
- Food Service Equipment
Custom programs are also available for projects that do not fall into these categories.
UniTherm Customers have been taking advantage of incentive programs in states across the US and are getting back anywhere from 30 – 110% on the purchase of UniTherm systems. Not located in Ohio? Contact us to see what rebates are available in your area.