Unitherm Insulation Systems

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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…]

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Safety Checklists for Manufacturers

safety, checklists, manufacturing safety, industrial safetyEven 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:

[Read more…]

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A Quick Guide to Energy Management Software

keyboard, energy management software, software, computer controlled systemsIf 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?

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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!

energy-efficient, lighting, energy saving, energy projects, energy management

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.

[Read more…]

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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.

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What’s New at UniTherm International?

2011 has been an exciting year at UniTherm International! Over the last year, we’ve taken major strides in improving our facility and R&D capabilities, strengthening marketing efforts, and broadening our representative base. We’re pleased share a sneak peak inside UniTherm HQ to show you changes we’re making to improve our products and services.

Research and Development Updates

Using state-of-the art technology and equipment, UniTherm engineers are more focused on research and development than ever before. This year we’ve rigorously tested our products’ performance which has led to the release of new and improved models of FirePro, discovered new applications for UniVest and FlexWatt and even launched a new product, SolarShell.

SolarShell is a glass-reinforced, plastic laminate that cures and hardens when exposed to UV rays. Be sure to stay tuned for future SolarShell updates, as we’ll release a series of test videos for this multipurpose product later this summer. [Read more…]

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Energy Efficiency in Plastics Manufacturing


The US Department of Labor reports that the energy management sector has more than doubled in the last two years, with 75% of all jobs in an industrial setting. While energy managers prove a valuable asset to large corporations, many plastics manufacturers with a slimmer budget are tasking current employees with energy related projects.

So how does a non-energy-expert implement energy saving projects? As with any project, the first task lies in evaluating the current situation, researching potential options for improvements, and calculating the potential results of each option.

What are your true energy costs?

With home energy costs, lighting and temperature control usually come to mind as the biggest portion of energy costs. This isn’t the case in plastics manufacturing, according to a recent study focusing on the balance of energy usage in an average plastic plant. Energy consumption for lighting, temperature control and ventilation equate to just over a third of the energy that machines use in most plastics facilities.

While specific energy consumption of machinery varies slightly from plant to plant, there is virtually no difference between the amount of energy consumed in injection and extrusion molding.

A critical first step in any successful energy management plan for a plastics facility is ensuring that machines, which account for 60% of all energy consumption, operate as efficiently as possible.

 

Energy-saving Measures for Extrusion and Injection Molding 

To reduce energy use in extrusion processes, consult with production managers and plant engineers to optimize equipment performance. In many cases optimization of the extruder speed can significantly lower energy usage without impacting end results.

[Read more…]

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The Down and Dirty on Reusable Shopping Bags

Whether you use them to do your part to be a little greener, or your city/state has enforced a bag ban – you probably own at least a few reusable shopping bags. (I personally own a few dozen since I never remember to put them in the car and end up buying more each time I shop.)

My usual routine is to come home, unload the groceries, and then cram all the bags inside one giant Central Market bag, shove them in the bottom of the pantry and forget all about them. But that routine is changing starting this weekend. Something I never thought about before is the stuff that gets left inside those bags – namely bacteria and mold.

The Canada Times found that “64 per cent were contaminated with ‘some level of bacteria,’ about 30 per cent had ‘elevated bacterial counts’ higher than what is considered safe for drinking water, 40 per cent of the bags had yeast or mould, and some of the bags had ‘an unacceptable presence of coliforms.'” (Yep, coliforms, as in “found in feces of warm blooded animals” via wikipedia)

It should probably be obvious that the fruit, vegetables, leaky milk jugs, and packaging that’s gone through who knows how many hands would be covered in some pretty nasty stuff, but how many people really wash their shopping bags between each use?

How To Clean Reusable Shopping Bags

Fortunately its pretty easy to get rid of the mold, bacteria, and yeast with a quick warm water and mild soap rinse. Hang those bags to try on a clothes line (or hang them on your kids’ swingset like I do for all of my line-drying needs) and fold and store them when they are totally dry. Its also a good plan to bag meats and fish separately, as well as put your produce together. And if you like to purchase in bulk from warehouses like Sams and Costco, try taking your own plastic bins to carry items home in, a quick rinse with the hose and some dish soap will leave them clean and ready for the next trip to the store.

How many of you still use plastic bags for shopping? If your area has banned them, how has it affected the shopping experience for you?

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[Review] Total Quality Process Control for Injection Molding

Peter Van Puyvelde of Materials Views provides the following book review of M. Joseph Gordon’s Total Quality Process Control for Injection Molding, 2nd Edition.

Total Quality Process Control for Injection Molding Total Quality Process Control for Injection Molding, 2nd Edition
M. Joseph Gordon, Jr.
Hardcover
746 pages
US $175.00

In this lengthy book, a total quality approach for injection moulding applications is presented. The aim of the work is to provide a detailed planning for the implementation of total quality management (TQM) control procedures for the production of plastic parts. Moreover, limits for quality control assessments are established.

In the first chapters, an overview is given of the different aspects of TQM. Next, the complete chain of a plastic product processing operation is discussed, going from the material, over the machine and mould design towards the final processing operation. When discussing the received material to be processed, one should for instance be aware of the inherent variability of the feedstock that is used. This discussion leads to procedures to properly characterize for instance the thermal properties of the material. In the part that describes TQM principles for the machine, attention is given to the machine itself and the auxiliary equipment that is needed for a successful operation.

Continue reading at Materials Reviews >>

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Husky Completes Acquisition of KTW – Leading Closure Mold Maker

Congratulations to our NPE 2012 neighbor, Husky Injection Molding Systems (find us directly behind the Husky booth at NPE)

Husky Injection Molding Systems today announced it has completed the acquisition of KTW of Waidhofen, Austria, recognized as a global leader in closure mold making.

With the addition of KTW, Husky becomes the closure industry’s only provider of complete injection molding systems, including mold, machine, hot runner, temperature controller, as well as a range of consulting and after-sales services. Husky will now offer KTW-branded closure molds as part of its fully integrated turnkey systems. [Read more…]

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UniTherm Insulation Systems

711 Jones St.
Lewisville, TX 75057
Toll Free: 800.657.9542
Phone: 972.436.1401
Fax: 972.436.0112
info@unitherm.com