Fortune 100 Imaging Equipment Manufacturer Turns to Specialty Design for Greener, More Efficient Toner Recycling Program

Release date: August 5, 2009

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Fortune 100 Imaging Equipment Manufacturer Turns to Specialty Design for Greener, More Efficient Toner Recycling Program

READING, PA - For one Fortune 100 imaging and printing equipment manufacturer, an O.S.H.A. and D.E.P. mandated toner recycling program was creating a massive production bottleneck and racking up millions of dollars in unnecessary costs. The customer recently sought an automation solution from Specialty Design & Manufacturing Co., Inc. to address the problem. 

The Fortune 100 manufacturer contracted Specialty Design engineers to design, build, and ship seven custom-built generic toner removal stations to their American manufacturing facility. Having achieved payback on their investment just six months after project implementation, the automation solution proved to be appropriate and cost-effective.

"These special machines revolutionize the method by which the customer manages their toner recycling program," said Lee Ahrens, Engineering Director at Specialty Design. "Where they once ran a costly, labor-intensive toner disposal operation, our equipment now allows them to run a cleaner, greener and more efficient recycling operation."

Prior to meeting with Ahrens and other Specialty Design engineers, the Fortune 100 manufacturer had no automation process in-place to manage their toner recycling operation. To adhere to newly passed O.S.H.A. and D.E.P. regulations, the customer employed 30-40 people per shift to process the demand of used toners being returned for re-use. Problems inherent to their existing system included spillage, high processing costs, and carpel tunnel exposure.

Specialty Design's automation engineers designed a four-station, indexing turntable machine that allowed the customer to reduce the shift headcount from 30-40 employees to just one employee per machine. The machines all worked within a mandated 20 second cycle time, compared to a variable cycle time from the previous operation based on individuals' performance. Each machine completed all hole piercing, drilling, vacuum, and toner evacuation automatically.

For additional information about this project or to learn more about Specialty Design, visit www.specialtydesign.com or contact Justin Knabb at 610.779.1357. Specialty Design is a leader in the design, manufacturing, and integration of automated special machines. In addition, Specialty Design offers value engineering services, ranging from contract manufacturing opportunities, to CNC and Wire EDM machining for creating tooling, fixtures, and dies.

Celebrating a 20 year Specialty anniversary

Last month we recognized and congratulated an employee for his long tenure of loyal and outstanding contributions to our team:

• We thank Teri K. for her 10 years working in our Building Products division and 10 years working in our Machine Shop.

The administration and staff at Specialty Design congratulate Teri and her family on reaching this milestone of 20 years at Specialty!!

Last month we recognized and congratulated an employee for his long tenure of loyal and outstanding contributions to our team:

• We thank Teri K. for her 10 years working in our Building Products division and 10 years working in our Machine Shop.

The administration and staff at Specialty Design congratulate Teri and her family on reaching this milestone of 20 years at Specialty!!

Recognizing another Specialty anniversary

Last month we recognized and congratulated an employee for his long tenure of loyal and outstanding contributions to our team:

• We thank Mark Y. for his 15 years working in our Building Products division.

The administration and staff at Specialty Design congratulate Mark and his family on reaching this milestone!!

Last month we recognized and congratulated an employee for his long tenure of loyal and outstanding contributions to our team:

• We thank Mark Y. for his 15 years working in our Building Products division.

The administration and staff at Specialty Design congratulate Mark and his family on reaching this milestone!!

Case Study: Semi-Automatic Weld Fixture

Background:  A worldwide crane manufacturer recently called upon Specialty Design to design and build a weld fixture for a crane boom that would both decrease manufacturing time and create a safer environment for their workers.  We were up to the task, and we were fortunate to draw upon 40+ years in the business of building custom fixtures.

                

Solution:  Specialty Design worked with the customer to design and build a series of expanding mandrel-type fixtures that incorporated the following features:

• Lengths up to 45 feet
• Reinforced structural construction
• Grounding rail on both sides
• Exact expanded dimension
• Hydraulic cylinders with valves
• Guide rods / adjustable feet
• Lifting lugs

These new mandrels greatly reduced what was once a very time-intensive and dangerous labor process in the production of a crane boom.

                   

         

Case Study: Dual Filling Machine for Dentistry Supplier

Background:  A dental supply manufacturer needed a complete system that would feed, orient, and spray print a compule, at approximately 1" long and a 1/4" diameter.  To fulfill their objectives and satisfy their budget requirements, the customer desired a fully automated system, which would work at a rate of 120 pieces per minute.

              

Solution:  We designed and built a system to perform the customer-requested functions with the following features:

• Tooled vibratory feed bowl
• Vibratory feed track
• Eight-station Cam-type index unit with eight pocket-type Cam-driven fixtures
• Commercial printer
• Dual-track escapement chute with flip-arm for batching
• Heat-seal bagger with Interloc

The customer can now batch feed a machine that will print at 120 pieces per minute, count, and bag parts to programmed batch sizes.  Printing includes product, date of manufacture, and the manufacturer's name.