Industry Information Archives

June 5, 2023, marks the 50^th anniversary of World Environment Day. Each year, this passion project of the United Nations brings together more than 150 countries working toward one theme. The theme has been different every year, with this year’s theme being “Solutions to Plastic Pollution.” Consumers have many options when it comes to protecting the environment and reducing waste (recycling being the foremost). But what can manufacturers do? One of the biggest trends in manufacturing right now is going “green.”

Green Manufacturing

There are many ways to go green as a manufacturer including:

Implement an Environmental Management System (EMS) — With an EMS in place, manufacturers can store, organize, review, and evaluate their environmental impact and performance as it relates to regulatory requirements as well as internal objectives and goals related to compliance, pollution prevention, resource conservation as well as reduced costs and increased efficiencies too.
Leverage Renewable Energy — Renewable energy isn’t just solar power. There are many options for renewable resource options including rain, wind, ocean power, bio energy, etc. When utilized, all have the ability to reduce the use of non-renewable resources such as coal, oil, or gas.
Partner with Eco-Friendly Suppliers — Uniting with other eco-friendly companies not only promotes internal goals of going green but also promotes the business of the partners and suppliers with the same objective.
General Energy-Saving Practices — These are easier to implement and follow if going green as a manufacturer seems like a big chore.

Turn equipment off when not operating.
Open up windows and doors for natural light.
Switch to LED lights.
Make sure there are recycling options in lunch and breakrooms.
Consider implementing earlier work hours in the summer to avoid additional operating costs with the AC turned on.
Work to ensure predictive maintenance is a #1 goal for increasing the lifetime value and durability of production machinery.
Go digital. Auto deposit paychecks where possible or use electronic apps for internal messaging and communications.

Check out these manufacturers who have found ways to go green and are seeing the positive results from it!

SC Johnson closed down 2019 on a high when 100% of their factories sent zero waste to landfills.
Patagonia uses recycled materials in over 60% of their fabrics and is working to remove all nylon from their clothing since it’s made with petrochemicals.
Hudson Technologies “spent two years and over $2 million in research, development, capital costs, and training to ensure all our operations and products met stringent environmental standards” including replacing traditional chlorinated lubricants with biodegradable lubricants and removing solvent-based metal cleaners from their operations.
Bombardier has pledged over 50% of their R&D investments toward the goal of greener aircraft, among many other activities in their ESG (Environmental, Social, and Governance) plan.
New Belgium Brewing is a Certified B Corporation (cool!) who only uses sustainable vendors and ensures 99.9% of their waste doesn’t end up in a landfill.

We’re not the only ones talking about increased sustainability across the industry either. We heard so much about it at industry events over the last year that we’ve previously written about how early adopters are already reaping the benefits. The list goes on and on! Find more Green Manufacturers here and here!

A reader of our How It’s Made articles asked if we could share our knowledge about recycling. As a result, we adapted our How It’s Made article this month to an article titled “How It’s Done.”

In recognition of National Recycling Day on November 15, this edition will focus on what happens in a recycling facility. Before (or after) you read on, check out an earlier article we posted to help you understand just What Can Be Recycled.

As you read through the process below, keep in mind that states and cities vary in their abilities to recycle. However, the general process outlined here can be followed for mixed material recycling centers.

Step 1: Collection

Recyclables are collected from curbside or drop-off locations then delivered to the recycling/recovery facility.

Step 2: Facility Arrival

The trucks unload recyclables into a yard or storage area.

Heavy equipment pushes the material onto a conveyor belt or into a hopper which then feeds a conveyor belt.

Step 3: Presort

In this area, workers manually remove materials that are not recyclable or would damage the facility equipment.

Examples include: dirty paper/cardboard, scrap metal, plastic bags, bulky & oversized plastics, e-waste, hoses, toys etc.

Step 4: Screening

Throughout the entire process, large rollers screen out materials. These rollers are essentially augers with blades. The build, size, and spacing of the blades pushes forward desired recyclable materials and undesired materials downward.

Often, the first material screened is large cardboard. These screens can also filter out materials considered too small for recycling.

Step 5: Sorting

Workers manually sort non-recyclable products from mixed materials. Workers will also pull out any materials that are difficult for equipment operations.

As a result, we have sorted various products into specific materials. These products are now moving on a series of conveyors to specific places within the facility. Those products include:

Newsprint
Mixed Paper
Cardboard
Plastic

So, what else is left? Glass and metals.

Step 7: Metal Magnification

Giant magnets pull tin cans, iron containers, or steel containers from the conveyor belt. After this, another conveyor belt takes these containers to a specific area of the plant. Plastic, aluminum, and glass containers continue down the line.

Step 8: Screening

In this step, screens break the glass and separate it from plastic. A conveyor takes the broken glass to the glass processing department. This department breaks the glass down even further for additional processing or shipment out.

Step 9: Eddy Current Separator

This sorts aluminum from the mixed product through the use of an electric current. In addition, a conveyor takes the aluminum product to another area of the plant for processing.

Step 10: Sorting

More manual sorting by operators within the facility occurs here to gather any other products which are not recyclable.

At this point, plastic containers and small pieces of paper or film are all we have left.

Step 11: Optical Sorting

In this area, machines determine different types of unsorted materials. The machines identify different materials based on how light reflects from the material’s surface. This step determines the material type, color, and shape. Air pulls recognized material downward (or upward) onto another conveyor belt.

This step uses optical sorting machinery. One sorter will target paper. Another sorter will target plastic film. Upon completion of optical sorting, we should be left with just plastic containers. Therefore, each type of product or material has been sent to its own storage area. For instance, plastic bottles and containers are in one area. Similarly, cardboard is in another area.

So, what happens next?

Step 12: Baling

Baling machines operate with very high levels of pressure to compact materials into bales. Yes, like hay bales but made of different materials and square in shape. Wire wrapped around ensures the bales stay together.

Fun fact: These bales can weigh as much as 1 ton!

Baled product is ready for pickup and delivery to recyclers specialized in the materials. For an understanding of those processes, check out the links below:

As wild as it seems, we can trace back the invention of jet engines to 150 BC with the development of the aeolipile. And it is truly the aeolipile’s technology that allowed Dr. Hans von Ohain and Sir Frank Whittle to invent the jet engine as we know it today, albeit it separately and unbeknownst to each other. Additionally, it was Sir Frank Whittle’s jet engine that provided the United States of America the initial technology to build their own jet engines.

Sir Frank Whittle was an English aviation engineer as well as a test pilot in the Royal Air Force. It was in 1930 that he received his first patent on turbojet propulsion and, in just ten short years, he was able to construct, prove out, and secure his first contract of purchase for what was then called the W1 Whittle engine. It was May 1941 when the first historic flight with this new technology occurred.

This leads us to the fall of 1941 when a group of GE engineers in Lynn, Massachusetts received a secret present from King George VI via wooden crates on aircraft, as part of a contract from the U.S. War Department. Inside of the crates were parts of the first jet engine ever flown by the allies; a Whittle engine. The goal of this gift? To improve the handmade engine, bring it to mass production and help win the war.

Over 1000 people worked on the clandestine project, but only a select few knew the goal and what was being built. Those that did know were told they couldn’t talk to anyone about the work being performed. If they did, the consequence was death. As a result, they were called the “Hush-Hush Boys.”

With a timeline of 6 months, the team of engineers and technicians were tasked with redesigning the jet engine for commercialization. The accomplishment was completed in five months and in the fall of 1942, the first official aircraft flight occurred, powered by two jet engines, producing a total of 2,600 pounds of thrust.

Interested in learning more? I highly recommend the following.

Read here about Joseph Sorota, the last of the Hush-Hush boys and a key player in this engineering feat.
Find an image of the first US Jet Engine here as well as a magnificent video made by GE.

The Jet Story:

The manufacturing industry is one of America’s great invisible strengths. They keep our stores stocked, our transportation systems running, and our people employed. And while this entire industry could use better recognition, today’s article will focus solely on Black Owned Manufacturing Companies that are experiencing tremendous growth.

Electro Soft Inc

Located in Pennsylvania, this family-owned manufacturer has over 35 years of experience creating customized electronics for a variety of industries including aviation, defense, and transit. They offer a plethora of services such as custom panel builds, cable assembly, wire harness assembly, PCB builds, and military electronics. They do all of this while highlighting Just In Time (JIT) Delivery to increase productivity.

James Wallace became an innovator at a young age after inventing his own air conditioner. How did he do it? He utilized his existing fridge and converted it into an air conditioner. Later in life, he pursued an engineering degree at Penn State and created his first design debugging secure communications equipment for the National Security Agency. His daughter also started her career at an early age. Karla would cut wires at home, making ten cents an hour, and later in life she worked at every business location her family opened. She graduated college with a focus on business, shipping operations, and logistics. The family legacy continued onward and is still expanding today. They are known for their specialty services and quality production.

Find out more about their history here.

Maroon Sausage Company

This gem is right in the heart of Brooklyn, New York.

Howard Allen founded Maroon Sausage Company when he fell in love with the diverse populations surrounding him. As a result, he drafted a dream plan for the company to begin. His desire to bring Jamaican food to the local market while also offering it to surrounding markets online. To do just that, he created the perfect product… Jamaican Jerk Chicken Sausage.

Brooklyn has jerk chicken everywhere – the environment made it accessible, but Howard and his friend created the idea of having a mobile food business. The only requirement? It had to be sausage. They knew of a similar company, but they also knew they could take it to a whole new level. In 2014, the project became solely Howard’s as his friend stopped the project to follow a new path. Daily, Howard still tried to curate the beloved recipe they have on the market today. The esteemed judges (his children and mother-in-law) became quality testers until he took his product to the streets by hosting tables at local markets.

Did he have a cooking background? Nope, this creative director took his marketing skills to a new level by creating a holistic project. They held fundraisers during food truck events in support of halting human trafficking, and this turned into a weekly partnership as his company grew in the city.

Get ahold of some sausage of your own here.

Nerrido Foods

While we’re on the topic of food, let’s talk about the Nigerian delight of Nerrido foods. Ufuoma Okharedia, a mother and wife, is the CEO and Founder of Nerrido. When she left Nigeria, she realized there was a gap with availability to traditional African meals. She sought to create accessible authentic African foods and sourced authentic ingredients locally. As a result, she shared her joy of cooking online while also selling blends of tomato stew for jollof rice. This sauce is all in one: pasta, curry, pizza, jollof rice, you name it!

Not only did she share her joy of cooking, but she also began to teach others how to make traditional and authentic dishes. This enabled her to bring the Nigerian tradition overseas while creating access for others to do the same. Ufuoma aims to inspire others to cook with confidence.

Shop online here.

Takeaway

Manufacturing is truly for everyone, whether you start with an idea sketched onto a napkin or pursued a technical degree. As a society, we need to do a better job of acknowledging how greatly this industry affects each of us. Without modern manufacturing, our technology, education, and scientific knowledge would stall completely, our daily lives would look vastly different, and we wouldn’t be as connected as we are today.

Don’t be afraid to get started in the skilled trades world. Not sure where to start? Connect with us, and we’ll help get you there.

Other Honorable Mentions

Aya Paper Co. – Eco-Friendly Card Company – Sustainable Stationery | Aya Paper Co.
Hella Awkward— hella awkward (hellawkward.com)

How It’s Made – Plastic

Plastic has been around for much longer than most of us know. In its earliest form (some say as early as 1600 B.C.), plastic was produced by Mesoamericans who harvested latex from the Panama Rubber Tree and processed it with liquid from the Morning Glory Vine. However, the production of plastic (as we now know it) started many years later when Polyvinyl Chloride (PVC) was invented during the 1930s. Since then, there have been other types of plastic discovered and invented with each having its own strengths and weaknesses, which ultimately determine the end use.

So, how is it made?

Step 1: Raw Material Extractions

Crude oil and natural gas are extracted (drilled) from the ground then transported to a refinery.

Step 2: Refining

During the refining process, these natural materials are turned into multiple products including ethane and propane (which are the foundation of plastics). The refining process is very similar to how gasoline is made. With the assistance of a high-temperature furnaces, as well as pressure, ethane and propane are broken down into smaller molecules creating ethylene and propylene.

Step 3: Polymerization

In this stage, catalysts (a.k.a. chemicals) are added into the process and bond individual molecules into a polymer. When heated, polymers are incredibly moldable, making them great for plastic products. There are two ways in which this polymerization process can occur, and each way makes its own polymer (or resin), and each resin has its own set of pros and cons (which ultimately determines the end product it’s used in). You can find resin types in the Resin Identification Codes (RICs) on plastic products. Resins include Polyethylene Terephthalate (PET), High-Density Polyethylene (HDPE), Polyvinyl Chloride (PVC) and Polystyrene (PS) among others. PET is the most commonly used plastic in the world.

Step 4: Nurdle Making

You read that right… now it’s on to nurdle making! Nurdles are little plastic pellets made from the resins created in the polymerization process. The process to do so is through melting and cooling operations. Once these lentil-sized pellets are produced, they are shipped from a petrochemical refining facility to manufacturing facilities where they are melted down and formed into a final product.

Step 5: Plastic Forming & Fabrication

Manufacturers compound, mix, and melt the plastic pellets with other ingredients to very specific recipes. When followed, these recipes determine the characteristics and properties of the plastic product. The melted plastic is then formed into shape by plastic forming machinery, which is determined by the application of the product.

Common Machinery Used to Form Rigid Plastic Products Includes:

Injection Molding
Extrusion Molding
Blow Molding
Compression Molding
Thermoforming
Rotational (Roto) Molding
Polymer Casting

If you are a plastics manufacturing company, or someone who has worked in a plastics manufacturing facility, you likely fully understand this process. If not, check out our blog page to see what else we can help you understand better. Regardless of where you rate your plastics knowledge, keep reading because did you know that FlexTrades can help you find the right people for your company and/or the right job for yourself, too, regardless of industry? Check us out online at FlexTrades.com to learn about all that we can do for you.

Manufacturing as an industry has taken some hits over the years, but it’s always proven to be very resilient. Even with the pandemic, the threat of a recession, a retiring (and limited) workforce, as well as supply chain issues, manufacturing came out stronger on the other side of it all. In fact, Deloitte forecasted a 2.5% growth in GDP for 2023. How about that for resilience?

Listed below are four ways manufacturing will stay strong and come out ahead in 2023… and beyond.

Technology:

5G networks, cyber security, cloud adoption, IOT (the Internet of Things), AI (Artificial Intelligence), AR (Augmented Reality), and VR (Virtual Reality) are all investments that manufacturers are finding value in. The implementation of this technology enhances efficiency and effectiveness across the production floor.

Supply Chain Review:

The pandemic really brought out flaws in supply chain management as it relates to manufacturers. As a result, companies are reassessing their supply chain and looking toward ways to become more supply chain resilient. By diversifying vendors and vendor locations, manufacturers will still experience disruptions but not at the levels witnessed in 2020.

Smart Factories:

Manufacturers are seeing that implementing smart technology in their production process reduces operating costs while also improving efficiency. And rather than implement it piece-by-piece, manufacturers are adopting the technology system-wide, wherever possible.

Data & Analytics:

Manufacturers are focused on collecting data. Data, when combined with analytics and technology, provides manufacturers with an opportunity to understand their operations more accurately than ever before. This allows them to see actionable insights in real time without high costs and long waits. In fact, this market is forecasted to grow by 16.5% CAGR (compound annual growth rate) between 2019 and 2026.

What It All Means:

So, what does this mean?

In short, it means that skilled trade work isn’t going away. It means skilled trades workers will still be needed because manufacturing will continue to prove its resiliency and, as a result, continue to grow.

Join the FlexTrades team today to experience top notch pay, the opportunity to travel, and the ability to work and learn new skills with some of the greatest manufacturers in the United States. If you’re new(er) to manufacturing, don’t worry – we have that covered too. Join our ReTool team for the opportunity to upskill and train for the dream job you desire. And if you’re a manufacturer yourself, consider FlexTrades as a labor solutions provider.

When COVID-19 hit, consumers and manufacturers alike quickly learned just how fragile the global supply chain was. They also learned just how important supply chain resilience is. Let’s talk about both now.

What is Supply Chain Resilience?

Supply chain resilience is the ability to withstand and minimize the effects of supply chain disruptions. It is planning and preparing for possible disruptions; the goal of which being fast response and recovery when those disruptions occur. It is not being invincible to interruptions but rather being able to overcome them without a big impact to operations and / or customer deadlines. But how is supply chain resilience accomplished? That’s a great question. Supply chain resilience is going to require big changes by manufactures in three key areas… technology, processes, and people.

Technology:

Reviewing old technology, adopting new technology, and always looking for emerging technologies is critical. Technologies that help overcome supply disruptions include:

Real-time analytical tools
ERPs (Enterprise Resource Planning software that manages the entire business from finance, human resources, manufacturing, supply chain, procurement, and more).
Artificial Intelligence (AI)
Robotics or Automated Systems
Digital Manufacturing Systems
Cryptocurrency like the blockchain
Integration of systems and software across the supply chain including those from suppliers, warehouse systems, stores/customers, etc…

Processes:

New Forecasting Techniques:

Oftentimes, company forecasts focus on their own needs as it relates to demand. If demand is this, we need to do this. But companies need to dig deeper than that. Dig into what the supply chain looks like for suppliers, the demands and risks suppliers could be facing and how those demands and risks will affect operations.
Note: It’s very important to truly understand the products and goods that bring the most value to an organization. Build a commodity management strategy for these products which essentially allows for the management and coordination of all items related to these key products, including procurement, production, and distribution. This can be helpful when facing an inevitable disruption to the supply chain.

Build In Inventory Buffers:

Yes, it can be costly to no longer operate in a just-in-time fashion, but what’s even more costly is missed deliveries and lost customers when there’s no inventory.
Supplier Diversification: This could mean asking existing partners to supply parts from a wider variety of manufacturing locations, or it could mean adding in new suppliers with locations and processes different than that of current suppliers.
Note: To implement multi-sourcing, calculate the revenue impact of the disruptive event (i.e., natural disaster, global or localized pandemic) that occurred.

Nearshoring or Reshoring:

Upon first thought, nearshoring seems to be the opposite of supplier diversification. Many believe supplier diversification means offshore suppliers, but a diversified supply chain is one that focuses on companies locally, regionally, domestically, and globally. The local and regional level can be more expensive, but it also shortens both cycle and delivery times.

People:

Build relationships with 3PLs and contract manufacturers. Diversifying partnerships with 3PLs is vital to the distribution of product, and contracting other manufacturers for the production of a product is important, too.
Upskilling: A manufacturer’s workforce is critical to surviving supply chain disruptions. A cross-trained workforce lessens the need to be reactive in hiring and eases challenges caused by supply chain issues.
Create a commodity management team and a supplier management team. These two teams understand supply chain to its fullest, its pricing (particularly as it relates to demand), and the general manufacturing market while also building great relationships with suppliers for mutual benefit in the future.

Enacting these tools takes time, attention and money in the short term, and it’s hard to commit to spending more money now for a potential risk in the future but the risk is ultimately worth the investment.

What do you think? Do you have any question? Feel free to reach me anytime at kmooney@flextrades.com.

On February 24, 2022, Russia launched a military invasion in Ukraine. The unrest continues today.

As a defense partner and military ally to Ukraine, (the United States established diplomatic relations with Ukraine in 1991 following Ukraine’s independence from the Soviet Union), companies like ours have committed time, energy and resources by providing aid, financial assistance and delivering humanitarian support in Ukraine.

In fact, on February 28, 2023, Ukrainian President, Volodymyr Zelenskyy, addressed American businesses during the National Association of Manufacturers (NAM) board meeting. NAM CEO, Jay Timmons, stated “Manufacturers in America will continue to stand with Ukraine.”

Here are a few examples of American manufacturers supporting Ukraine during this war.

In Manitowoc, Wisconsin, the Wisconsin Aluminum Foundry Co. (WAFCO) drastically increased their production efforts to build 3,000 medical sterilizers for UNICEF. UNICEF has been buying sterilizers from this company since the 1970s.
MSA Safety Incorporate is a leader in the development and manufacturing of safety solutions and products to protect people and infrastructure. Core products include self-contained breathing apparatuses, gas and flame detection systems, and fire and rescue helmets. To support the war on Ukraine, MSA Safety Incorporate donated over $400,000 worth of safety equipment to Ukrainian firefighters.
Schweitzer Engineering Laboratories (SEL) is a leading American company specializing in digital products and systems that protect, control, and automate power systems with the goal of preventing blackouts and improving power system reliability. With their expertise in hand, SEL manufactured equipment to help monitor and manage substation equipment in Ukraine.
In the small town of Lima, Ohio, there is a big production facility (25-acres large) doing big things. In this building, owned by the Army and operated by General Dynamics, you can find about 800 skilled trades personnel disassembling Abrams tanks down to the hull and rebuilding them until they’re good as new again.
AeroVironment out of Arlington, Virginia, generously donated unmanned aircraft systems and drones in addition to ramping up production to meet contract requirements with The Defense Department. This isn’t surprising considering their support after 9/11 led them to become the world leader in small, unmanned aircraft systems (UAS).
General Electric’s Gas Power division has partnered with the U.S. Agency for International Development (USAID) to manufacture for and supply Ukraine a mobile gas turbine power plant. By doing so, this piece of equipment could supply at least 100,000 homes with electricity as well as hospitals, schools, and other critical infrastructure.
In addition to all of these, MANY manufacturers have committed hundreds of thousands, even millions, of dollars to Ukraine to support efforts in defense, rebuilding, emergency and medical services. Check out this list of manufacturers who have already donated and pledged to continue to donate until the war is over.

Of course, this isn’t all the companies in the U.S. supporting Ukraine. Even if we tried to list them all, we wouldn’t be able to. Manufacturing is a complex and interwoven industry supplying anything and everything during war and peacetime.

If you’re looking to support Ukraine, a great place to start is here.

Green Manufacturing

Step 1: Collection

Step 2: Facility Arrival

Step 3: Presort

Step 4: Screening

Step 5: Sorting

Step 7: Metal Magnification

Step 8: Screening

Step 9: Eddy Current Separator

Step 10: Sorting

Step 11: Optical Sorting

Step 12: Baling

The Jet Story:

Electro Soft Inc

Maroon Sausage Company

Nerrido Foods

Takeaway

Other Honorable Mentions

How It’s Made – Plastic

Step 1: Raw Material Extractions

Step 2: Refining

Step 3: Polymerization

Step 4: Nurdle Making

Step 5: Plastic Forming & Fabrication

Common Machinery Used to Form Rigid Plastic Products Includes:

Technology:

Supply Chain Review:

Smart Factories:

Data & Analytics:

What It All Means:

What is Supply Chain Resilience?

Technology:

Processes:

New Forecasting Techniques:

Build In Inventory Buffers:

Nearshoring or Reshoring:

People:

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