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techniques to reduce or reuse wastes highlighted above, it disposed of about 290 tons at a cost of $18,000 ($62 per ton). This was a saving of $72,000 annually (not including the increase in disposal costs per ton) and an 88 percent reduction in total waste volume. In addition to reduced disposal costs, selling the used Gaylord boxes generated approximately $36,000 annually. Since employees saw the results of their efforts, most were committed to STARTEX s continuous process improvement efforts to reduce waste. A monthly newsletter to employees included articles from the new material conservation team (formerly the waste reduction team) that highlighted overall waste reduction successes. The articles also showed amounts and disposal costs of wastes still produced, and encouraged employees to nd solutions to waste problems. Customers reacted very positively to the clean shop appearance that resulted from the waste reduction efforts and good housekeeping practices at STARTEX. Customers from the medical industry who were required to audit STARTEX s operation were particularly pleased with the clean results. The most signi cant factors contributing to the waste reduction success at STARTEX were
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Forming a team, composed of employees from throughout the operation, to focus
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on waste reduction. Training employees. Communicating to employees through an in-house monthly newsletter providing updates on waste reduction efforts, recognition of company-wide accomplishments in reducing waste and encouragement to employees to be ever mindful about reducing wastes, cutting costs, and keeping a clean shop.
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31.6 Additional Information
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32.1 Industry Overview
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67,413 metal operations in the United States 2,065,244 employees $386.4 billion in annual sales 8.2 tons of solid waste generation per employee Major waste streams: metals
The U.S. primary metals industry includes 5000 companies with combined annual sales of about $140 billion. Large companies include Nucor and U.S. Steel (steel); Alcoa (aluminum); and Phelps Dodge (copper). The industry is highly concentrated; the 50 largest producers hold more than 90 percent of the raw steel market. Secondary production of products from raw steel and other metals is also concentrated. Demand comes largely from the manufacturers of durable goods like motor vehicles, machinery, containers, and construction steel. The pro tability of individual companies depends largely on ef cient operations, because most products are commodities sold based on price. Big companies have large economies of scale in production. Accordingly, most producers of secondary products buy raw metal from the large producers. Small companies can compete by operating ef cient local minimills or producing specialty products. The industry is highly automated; average annual revenue per worker is close to $300,000.
The industry includes manufacturers and processors of steel, iron, aluminum, copper, and specialty metals like titanium, molybdenum, and beryllium. Steel products account for about 50 percent of the market. Companies are involved in three major types of activities. Primary processing is the separation of metal from ores in a furnace to produce slabs or ingots of metal. Secondary processing involves mainly the rolling or drawing of metal slabs into sheets, plates, foil, bars, and wire. Foundry operations produce metal shapes by pouring molten metal into casts or molds. Some producers have fully integrated operations, from mining raw materials to manufacturing nished products, but most operate in just one type of activity. Steel production rst involves converting iron ore or scrap iron into molten steel. The ore-based process uses a blast or oxygen furnace in a blast mill, and the scrapbased process uses an electric arc furnace in a minimill. Next, molten steel is poured and solidi ed in a continuous caster to produce semi nished products, like steel slabs, billets, and blooms. These materials are put through a mechanical and heat-treatment process known as hot rolling, and some hot-rolled sheets are rolled again at lower temperatures (cold rolling) to form nished at products such as plates, coils, or sheets, or long products such as wire, bars, rails, or beams. These products may then be coated with protective anticorrosion material. The production of aluminum, copper, and other metals is similar. Metal is separated from an ore by melting it. Metal alloys are produced by adding various elements to the main metal. For example, 17 percent chrome and 8 percent nickel are added to iron to create stainless steel. The different properties and characteristics of metal are produced by altering the chemical composition and the different stages of the process, such as rolling, nishing, and heat treatment. Primary production of metals requires large amounts of ore and large amounts of energy, so producers often locate near ore deposits (copper companies); coal elds; or sources of cheap electricity (aluminum companies). To ensure a supply of raw materials, many primary producers control their own ore deposits. Transporting the nished product is typically by rail. Producers can make thousands of different products because metals can be made in many different grades of hardness or other properties. A producer of castings and forgings, such as Citation, sells 20,000 products to 2000 customers. The technology of making metals with desired physical and chemical properties is highly complex. Modern production technology allows better control of the process and is more energy-ef cient, but is also expensive to install. Many modern plants are highly automated, partly to reduce the need for expensive labor. Computerized inventory systems are used to track thousands of products at multiple locations. Industries in the primary metal manufacturing subsector smelt and/or re ne ferrous and nonferrous metals from ore, pig, or scrap, using electrometallurgical and other metallurgical process techniques. Establishments in this subsector also manufacture metal alloys and superalloys by introducing other chemical elements to pure metals. The output of smelting and re ning, usually in ingot form, is used in rolling, drawing, and extruding operations to make sheet, strip, bar, rod, or wire, and in molten form to make castings and other basic metal products. Primary manufacturing of ferrous and nonferrous metals begins with ore or concentrate as the primary input. Establishments manufacturing primary metals from ore and/or
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