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.

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.

             

                     

                

Case Study: Press Conveyance System

Background:  A pharmaceutical equipment manufacturer needed a special machine to eliminate the labor-intensive operation of removing molded plastic handles from their tree.

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Specialty Design was able to offer a cost-effective solution...

 

Solution:  We designed and built a press that cut the handles from the tree at a rate of 32 pieces per cycle at a 12 second cycle time.  The unit utilized the following features:

• Commercial base frame
• Pneumatic press
• Custom die
• Chain feed with WHMW nests
• On-demand feed cycle

 

Case Study: American Red Cross Coagulant Dispensing Machine

Background:  For numerous applications, medical practitioners such as those at the Red Cross utilize absorbent pads for applying coagulants.  For example, in order to decontaminate operating room surfaces or clean blood off of patients, these pads are impregnated with coagulants and are kept sterile, lint-free, soft, and slightly abrasive. 

Prior to approaching Specialty Design, the Red Cross dispensed coagulants onto absorbent pads by hand.  This approach proved to be too slow and the application too inconsistent.  Specialty Design was able to offer a cost-effective solution...

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Solution:  We designed and built a special machine that had the following features:

• Robotic gun movement
• Pneumatic dispensing guns
• UHMW bottle tray
• Stainless/UHMW gauze tray
• PLC control
• Alumninum/Lexan guarding

The Red Cross can now produce coagulant pads in one table load at 30 second cycle times.  Furthermore, coagulants are dispensed in a more uniform and consistent fashion.  Not only did our special machine meet the Red Cross' firm expectations for producing a critical product, but the Red Cross informed Specialty Design that the machine has most recently been provided for military use.

Project Snapshot: Rifle Barrel Chamber Machine

Task:  Design and build equipment to chamber rifle barrels.

Production rate:  1 piece every 12 seconds.

Machining tolerances: 

• Chamber diameter: +/- .0002"
• Chamber depth: +/- .002"
• Chamber finish: #32

Specialty Design's solution...

Features:

• Pneumatic clamping
• Pneumatic powered drill head with electric motor
• Thru barrel coolant system
• Electrics with PLC

Project Snapshot: Seal Blanking Machine

Task:  Design and build equipment to cut close tolerance seal blanks.

Production Rate:  60 feet per minute.

Tolerances:  Any length accurate to +/- .0005."

Specialty Design's solution...

The machine integrated the following features:

• Payoff reel
• Servo-driven roll feed
• Pneumatic cutter
• Run-out table

Case Study: Precision Filling Line

Background: 

A pharmaceutical company required a bottle fill machine for a new type of resin, as none of the commercially available machines would satisfy their needs. 

See Specialty Design's solution below...

Solution: 

Specialty Design designed and built a machine that satisfied customer's requirements to fill long-neck bottles at a rate of 300 per minute with a precision fill.  To work with the new type of resin, the machine utilized the following features:

• A stainless steel framework
• A vinyl slat conveyor
• A screw driven resin feed hopper
• A vibratory system for resin chute and bottles

Case Study: Molding Press for Submarine Batteries

Background:

Battery manufacturer required a press to make large (40 in. x 90 in.) battery grids. 

See Specialty Design's solution below...

Solution:

Specialty Design designed and built a large horizontal press that integrated the following features:

• Hydraulically powered, floating, ram-on guide rods and bushings
• Heated platens
• Overhead crane to load and unload the molds

Case Study: Moving Gantry for Automotive Gluing and Forming Application

Background: 

Fortune 500 customer wanted to automate their production of formed carpet for the automotive market. Their existing production method was inefficient, too labor intensive, quality was not consistent and volume was inadequate.

See Specialty Design's solution below...

Solution: 

Specialty Design designed and built a gantry press that automatically glued, positioned, assembled, pressed, trimmed and formed carpet into a finished product. Payback was significant due to labor savings and increased volume, quality consistently met demanding automotive standards and all safety issues were addressed.  Here is how Specialty Design’s system worked:

1. Carpet is positioned behind the Gantry Press and underlayment is positioned in front of it.  
2. The Gantry Press picks up the carpet and moves toward the underlayment. 
3. While moving, each of the individually programmable glue heads precisely spray the contours of form holding the underlayment. 
4. Once precisely positioned over the underlayment, the Gantry Press applies a specified downward force for a prescribed period of time to form the finished carpet contour. At the same time, excess carpet is trimmed and vacuumed away. 
5. The Gantry Press returns to the home position and begins the next cycle.

Specialty Design’s system required 2 operators (versus the previous 10) and reduced the customer’s cycle time by 250%.