Scrap is often a significant, variable overhead cost for manufacturers. It represents the materials wasted during the production process and can impact overall production efficiency and profitability. Managing and reducing scrap is crucial for cost control and improving the bottom line. Techniques such as lean manufacturing, better quality control, and process optimization are often employed to minimize scrap.
PEAK Performance Compounding (PEAK) proudly assists our customers in cost-reduction efforts by utilizing closed-loop recycling to repurpose scrap into reusable resin. Closed-loop recycling not only helps in reducing costs but also supports sustainability efforts by minimizing waste and promoting the reuse of materials. It’s an effective way to improve efficiency and reduce the environmental impact of manufacturing processes.
The following case study will examine how PEAK utilized closed-loop recycling to minimize waste in Polyphenylene Sulfide (PPS) profile extrusion.
Customer Profile:The customer in this case study is a leading extrusion processor, specializing in profile extrusion for the chemical processing industry.
Customer Needs & Challenges: The customer was yielding high levels of PPS scrap in their profile extrusion process. They were therefore looking for a compounding partner to turn the scrap into reusable pellets to be recycled back into their manufacturing process. The recycled resin would be blended in part into the virgin resin for non-critical products.
The PEAK Solution: PEAK worked diligently with the customer to grind the molded scrap into extrudable feedstock for PEAK to pelletize. Various trials were conducted in the conversion process and together we developed a specification on both customer incoming scrap and the final compounded pellets.
Utilizing proper equipment, blending, extrusion and multiple down-stream operations we were able to meet customer goals and specification requirements.
The Outcome & Benefit: PEAK proudly developed a low-cost and reliable PPS recycle stream for our customer. This operation eliminated $100,000 in PPS scrap inventory and provided means for future recycling of rejected materials. This recycling process reduced overall production costs for the PPS part by nearly 20% and supported the customer’s highly-valued sustainability goals.
For more information on this case study or to discuss how PEAK Performance Compounding LLC. can assist with your unique material needs, please email info@peak-pci.com
