Resource Efficiency in an Engine Plant

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Resource Efficiency in an Engine Plant

• Kristin J Pelizza
• Environmental Manager
• Navistar, Inc
• Melrose Park, Illinois

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About Navistar, Inc

• Formerly known as International Truck and Engine
  Corporation
• 14.7 Billion in Sales and Revenues in 2008
• Manufactures and markets medium, severe service
  and heavy duty trucks, school buses and mid-range
  diesel engines
• Eleven Major Manufacturing Facilities (Truck
  Assembly, Stamping, Engine Machining and
  Assembly, Iron Foundries)
• 15,000 Employees
• 30 Environmental Professionals
• First diesel manufacturer in North America to be
  ISO 14001 certified

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Melrose Park Plant

• Original Construction 1941
• Manufacturing Space 1.5 million ft2
• Acreage 70
• Annual Capacity 80,000 units
• Number of Employees 1,420
• Average years of service 15
• Average age 45
• Union Affiliations United Auto Workers
  International Brotherhood of Teamsters
  International Union of Operating Engineers

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• The Melrose Park Facility manufactures in-line 6
  cylinder mid-range diesel engines
• The facility is the headquarters for Navistars
  Engine Engineering and is home of Green Diesel
  Technology
• The Melrose Park Plant has had a functioning
  Environmental Management System since 1990
• 13-time Governor's Award Winner for Pollution
  Prevention
• Zero hazardous waste generated from manufacturing
  since 1994

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Navistars goal is to be acknowledged as an
Environmentally Responsible Corporate Citizen by
regulators, neighbors, employees and all
stakeholders.

• Our operating principles
• Compliance is baseline. Non-compliance is not an
  option
• Actions taken must be protective of human health
  and the environment.
• Environmental projects must be cost effective

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Navistars Environmental Protection Policy

• Conduct operations in compliance with laws and
  regulations
• Design, construct and operate facilities to
  protect employees and neighbors health
• Implement self-monitoring, assessing and
  reporting programs
• Innovate to minimize or prevent wastes
• Provide management support and training
• Work with all levels of government
• Operating policies, procedure and programs to
  implement environmental policy

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Pollution Prevention Project

• Development of new engine (I-326) to comply with
  upcoming diesel engine regulations
• Identify engine areas that needed to be protected
• Select paint that satisfied customer
  specifications
• Cost effective
• Rust preventative
• Select paint that satisfies company
  specifications
• Process
• Quality
• Environmental, Health, and Safety

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The project was implemented by

• Waste Management and Research Center Engineers
• Manufacturing Engineers
• Test and Paint Process Engineers
• Quality Engineers
• Environmental Team
• Support of the plant leadership
• Technical and sales personnel from coating
  manufacturer

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Cylinder block

Crankshaft Camshaft Cylinder head

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I-313 Engine
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I-313 Engine

• 4 engines per gallon of paint
• Average of 69,000 engines/annually
• Using approximately 17,250 gallons of paint per
  year
• 48,300 lbs of VOM annually
• 50 cubic yards of waste paint sludge
• Average annual cost of paint and waste disposal
  300,000

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I-326 Crankcase
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I-326 Engine
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I-326 Engine

• 23 engines per gallon of paint
• Average of 69,000 engines/annually
• Using approximately 3,000 gallons of paint per
  year
• 9,870lbs of VOM annually
• 14.5 cubic yards of waste paint sludge
• Average annual cost of paint and waste disposal
  170,000

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• I-313 Blue Coat
• 4 gallons/engine
• 17,250 gallons of paint used per year
• 48,300 lbs of VOM annually
• 50 cubic yards of paint waste annually
• Cost 300,000

• I-326 Clear Coat
• 23 gallons/engine
• 3,000 gallons of paint used per year
• 9,870 lbs of VOM annually
• 14.5 cubic yards of paint waste annually
• Cost 170,000

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Environmental Performance

• Governor's Award Winner for Pollution Prevention
  for thirteen years in a row
• Annualized savings of 130,000
• 82 reduction in paint usage
• 12.5 reduction in paint sludge
• 82 reduction in VOM emissions

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• Environmental Savings
• Voluntary Programs
• Waste Wise
• 33/50
• Green Lights
• Energy Star
• National Performance Track
• National Waste Minimization Partnership
• Clean Air Counts
• 102 External Awards received since 1992
• 95 million in company savings since 1992