At Plastic Bubbles, our commitment to innovation goes hand in hand with our dedication to sustainability. As specialists in plastic injection and blow moulding of rigid packaging, we recognize the significant impact our industry has on the environment. That’s why we have implemented various eco-friendly practices to ensure that our operations are as green as possible. Here’s a look at how we are making a difference.
Supervisory Control and Data Acquisition Systems (SCADA) – Real time production data
Central to any business sustainability strategy is to understand how resources are currently being utilized within your own business. Plastic Bubbles recently commissioned a SCADA system from BMS vision that tracks and monitors in real-time factory production processes. This centralized data gathering system provides detailed reports on how many resources such as labour, materials, energy and water are being used at each stage.
Plant Master is the software that tracks operational efficiency and Energy Master is the software that’s tracks the energy consumption during each process.
With Energy Master we can track and monitor how energy is being utilized throughout our manufacturing process. Real-time data insights give us powerful information as to what is our base load energy consumption and what is the variable energy consumption delta on each machine. This data empowers us to optimize our process parameters to optimally utilize energy and lower operational costs.
In addition to having software that monitors our energy consumption, we continuously invest in state-of-the-art machinery, plant equipment and utilities that not only perform better and improve the quality of our products but also significantly reduce energy consumption. This reduction in energy consumption not only lowers our carbon footprint but also helps us pass on cost savings to our customers.
Waste Reduction Techniques – Best Practices for Minimizing Plastic Waste in Manufacturing
Minimizing material waste is a key focus area for us at Plastic Bubbles. We have implemented several best practices aimed at reducing plastic waste during our manufacturing processes.
One of our primary strategies is to optimize production schedules to minimize downtime, overruns and material waste. Our goal is to generate less than 1% scrap during production. Any defective products that are produced in the process are immediately recycled back into production, ensuring that no polymer material goes to waste. Plastic polymer is 100% recyclable and reusable, so why let such a valuable resource go to waste?
Our second strategy involves recycling all cartons, plastics, metals, glass and oil used throughout our plant. Dedicated waste bins are strategically placed around our production facilities and offices to encourage every employee to recycle. These bins are collected into larger containers and then picked up by specialized waste collectors who provide certificates for safe disposal.
By fostering a Zero Waste culture and promoting recycling practices within our teams, we ensure that everyone sets a positive example and is aligned with our shared goal of reducing waste, cutting costs and ultimately lowering our environmental impact.
Using Fewer Scarce Resources – Conserving Electricity and Water
South Africa often faces electricity outages and water shortages. As electricity and water costs continue to rise and infrastructure and supply struggle to meet demand, the availability of these valuable resources is likely to decline.
For any company operating in such challenging conditions, becoming more self-sufficient is essential for long-term sustainability. Alongside our efforts to reduce energy consumption and material waste, we have also implemented measures to generate electricity and conserve water throughout our manufacturing processes.
Plastic Bubbles has commissioned a grid-tied solar and battery installation on its roof, featuring 738 solar panels and a 60kW battery backup. This system can produce more than 430 MWh annually, reducing our electricity consumption by 25-30% each year.
We have also invested in a new closed-loop chiller system that optimizes our cooling capacity for moulds and reduces electricity consumption by over 30%. This advanced cooling system is designed to use water more efficiently by recycling and reusing it within the system, minimizing wastage. In fact, our water utilization is so efficient that a 5,000-liter water tank can provide enough backup water to run the entire plant for more than a week.
Additionally, we regularly audit our electricity and water usage to identify areas for further improvement. By focusing on using fewer resources, we are not only reducing our environmental impact but also operating more cost-effectively. This allows us to improve our margins and offer our customers even more competitive prices.
Implementing Eco-Friendly Materials – Exploring the use of biodegradable and recyclable plastics.
Another key focus area for Plastic Bubbles is the use of biodegradable and recyclable plastics in our processes. Traditional plastics, which can take hundreds of years to decompose, often end up in landfills and rivers, posing a significant environmental hazard. In contrast, biodegradable plastics break down more quickly and safely in soil and water, while recycled plastics help remove waste from the environment by repurposing it into new materials.
Advances in recycling technology and strict government regulations have increased both the demand for and availability of post-consumer-recyclate (PCR) in our packaging. Through continuous research, sourcing and testing of these materials at our production facilities, we ensure they meet our high standards for durability and performance while also being environmentally friendly.
As the availability and cost of PCR and biodegradable materials improve in the supply chain, Plastic Bubbles plans to incorporate as much of these materials as possible into our production processes. This approach allows us to provide our clients with packaging solutions that are functional, sustainable and cost-effective for the future.
At Plastic Bubbles, sustainability is more than just a buzzword – it’s an integral part of our culture, philosophy and business model.
Plastic Bubbles is leading the way in sustainable practices within the plastic manufacturing industry with its innovative approach to resource conservation, waste reduction, and the use of eco-friendly materials. By leveraging real-time data to optimize energy consumption, implementing robust recycling protocols, generating renewable energy, and utilizing biodegradable and recyclable materials, Plastic Bubbles is significantly minimizing its environmental impact.
These initiatives not only enhance operational efficiency and sustainability but also empower the company to deliver cost-effective, environmentally responsible solutions to its clients, positioning Plastic Bubbles as a pioneer in green manufacturing.
