Clean ProductionManufactured without oil and water
Defined as a key topic for EVVAGRI 301: MaterialsUN Sustainable Development Goals (SDGs), No. 9: Industry, innovation and infrastructure; No. 12: Sustainable consumption and production
Producing without oil and emulsions …
The increasing energy consumption worldwide influences climate change. A considerable part of the additional energy needed is supplied by expensive oil. If oil is used as a lubricant in production, this means raw material consumption, environmental pollution and disposal costs. However, EVVA’s Clean Production (CP) protects the environment and resources because it works dry, i.e. it produces without oil or emulsions. The emulsions used in production do not contain oil. They consist of approx. 97% water, the rest is a non-hazardous chemical on which fungi can also grow.
… and without water
EVVA Clean Production is not only oil-free, but also 100% water-free. The cleaning of the parts with chlorinated hydrocarbons (CHCs) can thus be completely eliminated, i.e. a complete work step.
Proportion of Clean Production machines (EVVA headquarters) in relation to the entire machinery
Clean Production impressively demonstrates how well ecological, economic and social sustainability can complement each other.
The sustainable use of materials and resources has been defined by our stakeholders as a key topic – Clean Production by EVVA is one of the strongest levers for this. The company introduced Clean Production machines many years ago to limit material consumption. In the reporting period, we were able to increase our CP share to 65% of the total machinery, i.e. approx. 300 machines already produce using this technology. Between 2015 and 2019, EVVA invested around 5 million euros in new CP systems. This saves us considerable resources and emissions:
One downside is that a CP machine requires about 50% more electricity than a conventional oil-based system (because of the cooling units and the higher compressed air requirement). But it can often replace not only one, but even several conventional machines. On average at EVVA, a single new CP machine replaces 3 to 5 systems previously used for the same purpose. A CP machine produces completely dry and does not require any of the usual downstream washing processes of the production parts to clean them of oil. Metal chips can also be recycled immediately without any cleaning. The higher power requirement is offset by very high raw material savings, by avoiding cleaning and waste as well as the much higher production output.
He who consumes less, also must buy less. In addition to the ecological effect mentioned above, at the current 65% proportion, our Clean Production savesaround 200,000 euros per year in purchasing and disposal. Our demand for oil has halved in just a few years: from approx. 15 tonnes of oil in 2010 to 6.8 tonnes of oil in 2019.
CP production enables a much faster production run of the components than with conventional machines (e.g. because the workpieces do not need to be de-oiled). After approx. 8 years, our CP machines have paid for themselves.
Working with oil can cause skin irritation. So the less needed, the better for the production staff.
In recent years, EVVA has been awarded the City of Vienna's Environmental Award and the TRIGOS Sustainability Award for its sustainable, Clean Production innovation. If new machines are purchased, whether they are Clean Production-capable is a decision criterion. That’s why 100% of our new machines have been equipped with this technology since 2015. Around 60% of them were designed, manufactured and assembled by our in-house mechanical engineering department. This know-how is something EVVA is particularly proud of. After all, it is even better than recycling to be able to reduce the need for resources in the best possible way.
How: Currently, the CP share in the headquarters’ machinery is 65%. We want to increase this to 75% with the purchase and in-house development of further CP machines.
Positive effects: The increase will result in these additional resource savings: 2 tonnes less oil required per year, 1.5 tonnes less emulsions per year and 30,000 litres less water required per year. EVVA also expects to make further purchasing savings on oil/water of around €50,000 per year.
How: This new machine for the oil-free and water-free production of high-quality locking cylinder plugs will be one of the most important CP machines in EVVA’s history. This alone will increase EVVA’s Clean Production share by approx. 5%.
Positive effects: The aim is to save 5.8 tonnes of oil/water, amounting to 28% of the total demand for these two resources at EVVA headquarters. Our oil purchasing costs are estimated to decrease by approximately €19,000 per year.