**A Testing Laboratory Case Study**
Some companies take sustainability seriously by not only meeting compliance standards but going above and beyond. Investing in eco-friendly practices can lead to long-term financial benefits, not just by avoiding fines and legal issues, but also by improving efficiency and reducing waste. However, one automotive R&D lab found a solution that saved money immediately, cut costs over time, and solved multiple chemical handling challenges.
Intertek is a global leader in third-party testing and research services for the R&D industry. Their Automotive Research Lab in San Antonio, Texas, is one of the largest independent facilities in the U.S., offering engine, transmission, emission, and fluid testing services. As part of their rigorous testing procedures, Intertek builds engines to ASTM standards, ensuring precise control of environmental conditions during fluid testing. Before assembly, each component is measured and weighed, and after testing, the process is repeated to analyze changes and evaluate fluid performance.
To prepare parts for testing, lab staff must clean them using solvents like N-pentane, N-hexane, Toluene, Tri-solv, and Acetone. This cleaning process was both time-consuming and risky. Handling 55-gallon drums of chemicals involved tipping them on their sides to dispense the liquids through spigots, which often led to leaks, clogs, and spills. The process was not only inefficient but also posed safety and environmental risks.
The challenge of fully draining the drums was another issue. Even with careful handling, some solvent remained at the bottom, leading to waste and the need for additional labor to meet RCRA disposal requirements. This added cost and complexity to the lab’s operations.
Bob Tome, Intertek’s Manager of ES&H, was looking for a better solution. After attending an industry seminar hosted by TCEQ’s Pollution Prevention Group, he discovered an environmentally compliant pumping system that was more efficient, safer, and less expensive than traditional spigots. He implemented this system, which allowed technicians to safely transfer up to four gallons per minute directly from upright drums without the need to tip or handle them manually.
This change simplified the cleaning process, improved worker safety, and eliminated the risk of spills and fumes. It also enabled full drainage of the drums, meeting RCRA standards with less than half an inch of residue left at the bottom. This significantly reduced waste and the need for costly disposal services.
According to Tome, the savings were immediate and substantial. A pump costs about $300 less than a spigot and lasts up to ten years, compared to spigots that needed frequent replacement. Over time, the cost savings added up, while the lab also improved efficiency, reduced waste, and enhanced its sustainability efforts.
“I’m really impressed with the results,†Tome said. “Not only did we save money upfront, but we also made our operations cleaner, safer, and more sustainable.â€
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