Chip Processing:
Motivating Productivity, Protecting the Environment

State-of-the-art equipment, utilized in a new facility, always increases productivity. But – beyond the calculable return-on-investment – a new facility also provides an intangible gain in productivity. There's pride and increased performance when order replaces disarray, and machinings typical drabness is displaced by gleam and color.

An Ohio fittings manufacturer recognizes that clean equipment and a clean plant environment motivate employees to be more productive and quality-conscious. Thus, when planning the new facility for their operations, they specified state-of-the-art machining centers – easily accessed and maintained. Because machining generates sloppy, oil-drenched chips and swarf, state-of-the-art chip processing equipment was also specified – to keep the facility clean and oil-free. The equipment had a second objective: to generate the revenue-producing product of processed chips.

Chips, a product? Yes. This leading manufacturer has long realized that, with proper processing, machinings waste stream is transformed into a revenue stream. Their original, decades-old operations utilized a spinner and mechanical conveyances to capture fluids for reuse and to dry chips for environmentally-responsible handling. Like all technologies, chip processing has evolved. Thus, this company began the search for a vendor who could deliver the full benefit of these advancements.

Demanding Requirements:

Vendor qualifications began with discussions about the project's rigorous requirements. Probably most formidable was meeting the project's aggressive schedule, demanded by soaring sales projections. Within six months, the current operations needed to be relocated to a building which would first undergo complete renovation. The chip processing system would need to be designed and installed concurrent to the facility's design and renovation. This just-in-time delivery schedule demanded the chip processing vendor be flexible and able to communicate and adjust specifications ... in light of the on-going and inevitable design changes that renovation would undoubtedly yield.

Engineering innovation would also be required of the chip processing vendor. The new machining operations would be designated "oil dry free" as part of an enhanced cleanliness and safety initiative. No more carts dribbling coolant in the aisles; no more curly chips dropping in crevices. The chip processing system had to promote productivity-enhancing cleanliness. It must also perform efficiently and automatically, freeing highly-skilled labor from the drudgery of moving heavy machining waste.

While all chip processing applications have unique attributes, few requirements about the installation would be "standard." A vendor with the ability to innovate, and a proven track record of getting systems into production – on-time and within budget – was required.

Inter-Source Recovery Systems, Inc., of Kalamazoo, Michigan, fit the bill. "Our 'systems approach' allows us to optimize every application without the cost typically associated with customization," explained William Nemedi, Inter-Source President. "While no two applications are alike, the differences in this application were particularly exciting. Being involved at the true ground floor allowed us to design the most efficient means of chip conveyance, instead of having to work around existing machines or structural barriers. And, the customer already understood the benefits of chip processing. They were very willing to employ what they could to maximize it."

The Solution

Hourly, approximately 2,000 pounds of oil-laden chips are generated by the facility's nearly 50 machining centers. Chips drop directly from each machining center into one of four troughs, where they are pushed toward the processing location by in-floor push bar conveyors. Two of these troughs, each over a football field in length, collect scrap from the majority of machining centers. They empty into a third trough which also accumulates scrap from machining centers. Invisible to plant personnel, nearly a quarter-mile of troughs and conveyors safely collect, contain and move approximately twenty tons of oil-laden scrap each day. At the far end of the facility, a final in-floor push bar conveyor feeds scrap into a sub-floor shredder. The shredder, another component of the automated chip processing system, reduces bales and other large metal shavings into chips of a consistent size. Chips are then elevated to a pair of parts separators, which segregate parts, bar ends and tooling from the waste stream. Two 30-inch continuous chip wringers, the heart of the chip processing system, extract 98-99% of the oil from the chips.

The Results

Three products exit the chip processing system. The first is the collection of parts, bar ends and tooling. These solids gain top dollar when recycled. The second product is the oil, which is further filtered before being returned, network-style, to each machining center for re-use. The savings from reclaimed oil are substantial. The company has found that the system pays for itself through oil reclamation alone. The third product is revenue-creating, easily-handled chips. As the dry chips exit the wringer, pneumatic force conveys them through piping to a cyclone. The chips are discharged to a distribution conveyor, which feeds mechanical chutes servicing four roll-off hoppers. Sensors monitor the fill level and signal the discharge chutes to automatically reposition as needed. Throughout the week, several forty-yard containers of dry, clean, consistently-sized chips are transported to a smelter.

The midwest manufacturer knew there was money to be saved – as well as money to be made – from chip processing. But, beyond turning machinings waste stream into a revenue stream, the chip processing system helps fulfill an important objective – a clean and safe facility. The Inter-Source system automatically handled the scrap -- from machining center to removal from the facility – below the floor and out of sight. Safety and house-keeping are never compromised.

Chip processing enhances the manufacturing environment and operations. It also enhances the environment beyond the factory floor. The resultant massive oil recycling helps conserve that natural resource. And, the processed chips – now clean and dry – are safe to transport to the smelter for recycling.