Crown Beverage Packaging Olympia, Wa.

Crown Beverage Packaging
Olympia, Wa.
Can Manufacturing Process
• Plant History
• Contacts List
• Process Orientation
• Plant Safety Program
• Pollution Prevention
Olympia Plant #76
The Plant originally opened for Business in 1959 with 35 employees manufacturing 11oz. Beer Cans for the
Olympia Brewing Company.
In 1966 the original size of the Manufacturing area was more than doubled. By 1968 the number of
employees surpassed 200.
Olympia had grown to incorporate a Lithography department, a complete Beverage End operation, and a (3)
Line 2pc manufacturing department.
In 1994 the Plant was upgraded. A new building addition was put on the Plant to house our new High Speed
Decorators and state of the art Necking operations, a rebuilt Washer was added to increase the needed
output. New palletizing equipment was installed. The Plant was now a 2 line high speed operation producing
more each day than with the older 3 line operation.
In 1998 the End operations were consolidated into another plant, as End Production ceased at Olympia. The
workforce was cut in half.
Today the Plant employs 115 people including hourly and salary.
The plant typically runs on a continuous shift 7 day operation
Customers:
DPSG/7up– Sacramento, Pepsi Northwest – Olympia, Pepsi Mt Angel, Pepsi Yakama, Pepsi
Delta BC, Shasta – Tukwila, COTT – Surrey Canada, Molson/Coors – Vancouver Canada ,
Craft Brewers
Olympia Plant Contacts
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Plant Manager – Dan Joanis
Plant Superintendent‐ Cam McClary
Plant Engineer/ EH&S Coordinator‐ Mark Kirschenheiter
Plant H.R. Manager / Safety Coordinator‐ Lena Beach Plant Accountant‐ Cathy Allen
A look inside the Olympia plant…
40: Uncoil Mandrel
60: Cupping
Press
40: Uncoil Mandrel
60: Cupping Press
70: Body Makers & 80: Trimmers
90: Washer
100: Dryer
110:UV/BRC
40: Uncoil Mandrel
60: Cupping Press
70: Body Makers & 80: Trimmers
120:Turnover
170: Oven
150: Decorators & 160: Varnish
90: Washer
100: Dryer
110:UV/BRC
40: Uncoil Mandrel
60: Cupping Press
70: Body Makers & 80: Trimmers
120:Turnover
170: Oven
150: Decorators & 160: Varnish
90: Washer
100: Dryer
110:UV/BRC
70: Body Makers & 80: Trimmers
40: Uncoil Mandrel
60: Cupping Press
120:Turnover
170: Oven
150: Decorators & 160: Varnish
180: LSM
100: Dryer
90: Washer
110:UV/BRC
70: Body Makers & 80: Trimmers
40: Uncoil Mandrel
60: Cupping Press
120:Turnover
170: Oven
190: IBO
150: Decorators & 160: Varnish
180: LSM
230: Light
Tester
220: Flanger & 210: Necker
200: Waxer
Neck Forming and Inspection
Camera Inspection
14 Stage Necking
100: Dryer
90: Washer
110:UV/BRC
70: Body Makers & 80: Trimmers
40: Uncoil Mandrel
60: Cupping Press
120:Turnover
170: Oven
190: IBO
150: Decorators & 160: Varnish
180: LSM
240: Vision Systems
External
Internal
230: Light
Tester
220: Flanger & 210: Necker
200: Waxer
290: Warehouse Shipping
250: Palletizer
PlantSafetyProgram
AnnualTraining
MonthlyCrewMeetings
S.A.F.E.CardProgram
JobHazardAnalysis
S.O.P. ’s
BestPractices
Daily,Weekly&MonthlySafetyInspections
Measurement
EH&SDashboard
TracksMonthlySafetyPerformances
PollutionPrevention:
Acommitmenttocontinuousimprovement
Since1995,Crown
hasreducedits
generationof
dangerouswasteby
99.9percent!
Annualdangerouswaste
generationhasfallenfrom
382,760poundsin1995to
412poundsin2013
Howwedidit:
PlantPollutionPreventionProgram
‐ PlantPollutionTeam
‐ EstablishAnnualGoals
‐ MeetQuarterlyMeetings
‐ ReviewGoals
PollutionPreventionProjects
Past&Present
1.OnsiteI.P.A. Distiller(2012ReclaimIsopropylAlcohol)‐ reducedIPA
useby7,585lbs/yearfrom2011
2.InstalledPortableRentalD.I.Tanks (2013ChemicalElimination,
WaterReduction&Safety)
3.FishBio‐Assay(#1788303/27/2013 ProfileG05402S)
4.InstalledI‐TraxIBOOvenMats(2013NaturalGas&Electrical
savings)
5.InstallupgradeIBOOvenBurner(T.B.I.9/2014)
6.Water‐basedPartsWasher(Ultra‐SonicCleanerinstalled2014)
7.Switchedtolow‐VOCinks
CrownP2casestudy:
RentedD.I.Tanks
Benefits
Solution
Production / Quality / Cost
• Lease Portable Deionized Water Regeneration Tanks (Siemens)
• Mfg. and install, user friendly tank storage rack with cam lock hose connections, to house portable D.I. tanks while in operation. • Maintenance‐ Reduced maintenance , reduced downtime , no maintenance cost • Exposure‐ Removes potential hazardous contact with acids by elimination of acids from the plant • Water Quality‐ Consistent & Reliable • Water Usage‐ Eliminating the regeneration procedure of old columns, Annual water savings: 260,000 gallons per year
Returnoninvestment:
CostSavingsRentedD.I.Tanks
Old Plant‐Owned D.I. Columns
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Acid $3,900
D.I. Resin $1,072
Water Usage $550
Labor $600
Rental Fee N/A
Service Fee N/A MONTHLY TOTAL $6,122
Rented Portable D.I. Tanks ACID N/A
D.I. Resin N/A
Water Usage N/A
Labor N/A
Rental Fee $700
Service Fee $2,700
MONTHLY TOTAL $3,400
Monthly Savings $2,722
ANNUAL SAVINGS $32,664
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WemusttakecareofourCustomers
.