Abbott Laboratories
Abbott Park, IL
Shannon Phillips
Illinois Institute of Technology, Chicago
Abbott Laboratories is a global, broad-based health care company devoted
to discovery, development, manufacture and marketing of pharmaceutical
and medical products, including nutritionals, devices, and diagnostics.
The north suburban Chicago company employs more than 55,000 people and
markets its products in more than 130 countries.
The intern worked on several projects, but the primary focus was on water
conservation projects in fermentation process areas.
Result:
- Approximately 1,000,000 gallons of fresh water per year are being
conserved in the fermentation processes improving wastewater treatment
operations and reducing water usage.
- Automated liquid level controls were added and preventive maintenance
routines were re-assessed in one process room, reducing water usage
and waste by up to 13,000 gallon per product cycle (24-36 hours).
- Four large centrifuges are used to separate concentrated product
from excess water. These centrifuges are flushed with fresh water
for at least 30 minutes as part of the cleaning protocol, about
20-25 liters per minute. Depending on operator availability, the
fresh water could be left running for periods of time, with all
excess fresh water going to the high-COD holding tank for treatment.
A control was placed on the system that automatically turns off
the water supply to the centrifuge flush once it has been idle for
1 hour. The 1-hour time limit ensures that the 30-minute requirement
has been achieved for quality compliance purposes. This could save
up to 2,575 gallons for one centrifuge usage.
- A filter is used to separate product from other components of
the harvest. While running, it is continuously flushed with fresh
water to prevent solids build-up. Operators observed that this is
an excessive amount of clean water, and suggested that a solenoid
valve be fitted to the instrument to let water flush for one minute
every 10 minutes. This project has not been implemented, but is
still in an investigation stage.
- The intern identified the following opportunities to reduce waste
generation and improve energy efficiency:
- Shrink-wrap recycling began in the fermentation warehouse during
2004. Approximately 500 pounds of shrink-wrap per year are diverted
from landfill.
- The returned goods warehouse door was programmed with an automatic
closing device, which will save approximately $2,000 in heating
energy each year.
- Coffee grounds from the Abbott Lake County cafeterias are being
reused as compost for site landscaping. This diverts nine tons per
year from landfill.
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