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America every month, each 1 m3 in
volume. They contained aircraft
balance weights, which used to be held
in trays made from silica-impregnated
expanded plastic. This was not
recyclable and went to landfill.
The company asked the supplier to
replace this packaging with a cardboard
tray based on a ‘McDonald’sstyle’
drinks holder. The supplier came
up with a new packaging design which
not only protects the product but has
resulted in the following savings:
• reduced waste fees — 300 m3 of
plastics not sent to landfill per year
• reduced packaging fees and
airfreight costs, and greater
potential for cardboard recycling.
Reduce power consumption
The company conducted a formal
survey of its power consumption.
As a result:
• all lights are turned off when they
are not required, resulting in lower
electricity consumption
• to achieve an agreed lower max.
demand quantity to cut expenditure,
gas heaters are turned off unless
Cleaner Production
Case Study
Cleaner production involves
reducing the consumption of raw
materials (including water and
energy) and reducing the volume and
toxicity of waste and other emissions.
Hawker de Havilland has proved
that cleaner production is not only
an investment in the triple bottom
line, but makes perfect operational
sense by yielding pragmatic,
sensible outcomes.’
Michael Jupe, Hawker de Havilland.
What did they do?
Recover aluminum swarf
Hawker de Havilland entered into
a contract with a metal merchant to
install a new briquetter to compress
aluminium swarf (shavings) into dense
bricks, which are then collected and
removed off-site for recycling. Cutting
fluid is separated from the aluminium
during compaction. This system has
replaced an older process that
produced large coolant-impregnated
blocks that had to be manually lifted
from the machine. The new process
minimises occupational health and
safety (OH&S) risks associated with
manual handling.
Recovering the swarf has yielded
substantial benefits:
• approximately 500 tonnes of swarf
are recycled per year, using a costand
OHS-effective process.
• 250,000 litres of cutting fluid
(comprising oil and water)
will be reused per year.
Improve recycling
The company has put concerted effort
into recycling materials which were
previously sent to landfill.
Cardboard
Using an improved collection system
and a compactor, more than 31 tonnes
of cardboard are recycled per year.
Import boxes have been redesigned
and used for export, thus saving the
manufacture, use and disposal of the
original box.
Plastics
Savings achieved through cardboard
recycling encouraged the company to
look at plastic recycling.
‘
Published by: Department of Environment and Conservation (NSW)
59–61 Goulburn Street Sydney; PO Box A290 Sydney South 1232
Ph: (02) 9995 5000 (switchboard); Ph: 131 555 (information/publication requests)
Fax: (02) 9995 5911; Email: info@epa.nsw.gov.au;
Website: www.environment.nsw.gov.au; ISSN 1445-2332 DEC 2004/55 July 2004
required, and a lower temperature
setting has been selected so
costly over-runs are avoided
• leaks in the compressed air
system have been addressed.
Why did they do it?
What began in 2001 as a simple
project to compact and recycle
cardboard and plastic has been
transformed into a million dollar
bonanza for Hawker de Havilland,
encompassing aluminum recycling,
the recovery of machining cutting fluid
and other resource savings.
By working with suppliers and
treating all waste as a resource,
Hawker de Havilland is well on its
way to reducing waste by 85%.
Hawker credits much of its success
to working with like-minded metals
manufacturers in a group that was
facilitated by the Advanced
Manufacturing Centre.
What are the
environmental gains?
Diverted from landfill each year:
• 12 tonnes (800 m3) of plastic
• 31 tonnes of cardboard
• 300 m3 of silicaimpregnated
plastic.
In addition:
• 500 tonnes of aluminium
are recycled per year
• 250,000 litres of cutting fluid are
available to be reused per year
• energy consumption has reduced
by about 10.4 million kWh per
year from aluminium re-smelting
alone (and greenhouse gas
emissions are reduced).
• 60 million litres of water
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