Plastics refer to a family of synthetic or semi-synthetic materials made of polymers, composed of multiple long, repeating molecule chains joined together. The use of polymers and their variants dates as far back as 1600 BC, when humans processed natural polymers such as rubber and animal horns to create balls, combs, and other accessories.
Around the mid-19th century, natural polymer sources began to decline, which pushed inventors to synthesise alternatives. The efforts of these inventors led to the creation of plastics. Durable and highly versatile, plastics have experienced a rapid increase in popularity thanks to their numerous uses in our daily lives. Its use became so prevalent that some dub the current century the Plastics Age.
However, the plastics industry faces a significant challenge today: shifting to environment-friendly technologies to make their processes more sustainable. In this article, learn more about green strategies that can contribute to the success of any plastics manufacturing business.
The Importance of Sustainable Manufacturing
Sustainable manufacturing refers to the manufacture of products that conserve natural resources and energy without polluting the environment. It helps businesses combat resource scarcity and ensures that a company can continue its operations further into the future.
Implementing sustainable manufacturing practices also gives businesses a competitive edge as consumers become increasingly aware of environmental concerns and prefer environment-friendly and sustainably manufactured products.
Green Strategies to Succeed
Below are strategies that plastics businesses can implement for better sustainability:
Evaluate the Product’s Life Cycle
Evaluating a product’s life cycle offers many benefits, financially and environmentally. A life cycle assessment (LCA) is a valuable tool to identify the environmental impacts caused by the production of plastics at every stage of the manufacturing process, from raw material sourcing to manufacturing to product disposal.
Performing a life cycle analysis helps identify resource-inefficient areas or stages that negatively impact the environment, which you can target in future upgrade initiatives. The results of the life cycle analysis can inform decision-making and serve as a guide in implementing more resource-efficient and more sustainable operations.
Upgrade Production Processes
Plastic production technologies develop as the body of knowledge surrounding plastics grows. Upgrading production processes to keep up with the newer technologies can contribute considerably to achieving sustainability. There are several ways to upgrade a plastics manufacturing plant.
One way is to install better and more efficient equipment. For example, consider investing in energy-efficient hot runner systems and injection moulding machines. This advanced equipment lets manufacturers create plastic products with the same high level of quality while reducing energy consumption and minimising heat loss.
High-level automation is another way to upgrade the system. Combining process control software with data monitoring and analytics helps manufacturers track and implement raw material usage accurately, which prevents material waste.
Aside from upgrading existing equipment and software, consider introducing additional processes to the system. For example, a plastic-to-fuel operation can be a helpful addition. Plastic-to-fuel conversion processes convert waste plastics to fuel through an advanced pyrolysis technology. This technology augments the power supply to the plant while reducing plastic waste.
Use Eco-Friendly Materials
Plastics traditionally contain a resin derived from petroleum-based raw materials such as natural gas and oil. Due to the finite nature of these materials, their indiscriminate use can lead to permanent depletion, resulting in problems in production. Thus, sourcing and using eco-friendly raw materials is essential to maintain the health and sustainability of the supply chain process.
Recycled plastics are a considerably underutilised raw material source. In the US, less than 10 per cent of plastics get recycled annually. Tapping into this raw material source can increase the lifespan of each plastic product, reduce costs on raw material purchases, and conserve nonrenewable ingredients.
Aside from recycled products, consider using organic raw materials such as starch, algae, or cellulose. The plastics created from these raw materials can be biodegradable or nonbiodegradable, depending on the product’s purpose. Compared to fossil fuel-based raw materials, manufacturers can obtain organic raw materials more sustainably.
Conserve Resources
Resource conservation plays a crucial role in the success and sustainability of a plastics manufacturing business. It ensures the availability of input materials and energy while reducing costs associated with waste. There are several areas to consider when implementing a resource conservation plan.
First, consider the efficiency of raw materials. In addition to sourcing alternative raw material sources, as stated previously, it is essential to regulate the amount used. Ensure that the manufacturing process produces the least amount of waste possible. Implementing lean manufacturing principles can help in achieving this goal.
Next, look into energy conservation initiatives for the manufacturing plant. The plastics manufacturing industry is one of the most energy-intensive industries. Conserving energy can go a long way in reducing the utility bills associated with the process. One energy conservation technique is to install energy-efficient equipment, as mentioned in a previous section. Another way is to upgrade lighting and HVAC systems to more energy-efficient models.
Invest in Solar Energy
Solar energy and solar power technologies harness the sun’s radiation to generate electricity. Since the sun shines daily, especially when unobscured by clouds, the potential energy generation of a solar power system exceeds that of a fossil fuel-powered plant, which depends on finite resources. Additionally, using renewable energy reduces carbon emissions and prevents further global climate impact.
Incorporating solar energy into the plant’s power system presents several benefits. The most economical use is the reduction of electricity bills. The government also offers tax credits and incentives for entities that purchase, install, and generate power from solar energy systems. Generating power via solar energy also reduces reliance on the grid, which makes the plant less susceptible to power interruptions.
Solar power systems vary depending on the needed output. Manufacturing plants typically require a more extensive set-up compared to residential solar panel systems. Reach out to a qualified solar power expert who can recommend the perfect setup for your needs. Alternatively, businesses can find a reputable solar company by reaching out to businesses that specialize in generating quality solar leads, who’ll help connect with trustworthy and experienced solar installation providers.
Conclusion
Thanks to their countless uses, plastics and the plastics manufacturing industry occupy a prominent role in people’s day-to-day lives. However, there is a risk of raw material shortage and negative environmental impact if manufacturers continue to use outdated technologies and practices.
Fortunately, several techniques are available to help manufacturing businesses adopt a more environment-friendly and sustainable process. Follow the recommended strategies to build a more environmentally responsible and competitive future for the plastics manufacturing business.