New Headquarters and Extrusion Facility
Teel Plastics moved into its new 150,000 square feet manufacturing facility and corporate headquarters in 2007. The building is the first resident in the new Gateway Business Park. The site was designed with sustainability in mind. The much needed space accommodates our expanding extrusion division. The environmentally conscious facility supports the principles of lean manufacturing. The manufacturing area will reach new standards in terms of maximizing efficiency and our ability to service customer's requirements. The new facility brings together two cultures, healthcare and industrial products, providing the opportunity to combine value streams. The facility is built around a hub and spokes concept. This puts operations and administration managers in direct contact with plant personnel at all times. Our new facility utilizes state-of-the-art technologies which reduce our impact on the environment and create a healthy work environment.
We set specific goals for our new facility:
- Energy savings
- Electrical usage
- Natural gas consumption
- Carbon dioxide emissions
Office lighting features T5 fluorescent two lamp fixtures which reduce energy costs 34 percent compared to standard T8 three tube fixtures. 85 percent of the office area incorporates occupancy sensors and natural day lighting reduces heat load and minimizes the need for artificial lighting. The manufacturing area is illuminated by T5HO fluorescent fixtures that reduce electrical consumption 27 percent compared to standard 400 watt metal halide fixtures. The plant incorporates day lighting and white ceilings for increased efficiency.
Compared to the benchmark of the Wisconsin State Energy Code:
- Interior lighting uses 46% less energy than allowed
- Exterior lighting uses 65% less energy than allowed
Heating and Cooling
Office area heating and cooling features cooling units equipped with Variable Frequency Drives to adjust to varying loads, reducing energy consumption up to 50 percent. Heat recovery units capture exhaust air. Building automation software controls all zones of heating and cooling to optimize high efficiency. High efficiency boilers are 88 percent efficient vs. standard boilers at 80 percent. The manufacturing area is equipped with highly efficient heating units. Rejected heat from production line equipment like extruders is re-circulated to offset the heating load. In the summer, the plant is air conditioned, which enhances the production process.
Titanium coating on exterior glass reduces heat transmission and loss 20% compared to standard low E glass, saving on heat and air conditioning costs.
Site development around the new plant, featuring on-site retention ponds, was designed to minimize runoff and lower the volume of waste water the city of Baraboo has to manage. In addition, production wastes and recycling are contained in the building preventing contamination of storm water runoff. Working with the International Crane Foundation, native grasses, sedges and forbs fill the swales, infiltration areas and the perimeter of detention ponds providing a natural habitat for wildlife, filtration for run-off, and helping infiltrate water into the ground more quickly. These plantings also minimize watering and mowing thus reducing maintenance costs and gas usage.
Positive Steps for Teel Process Sustainability:
- Internal material regrind and recyclers are used to achieve less than 1% waste to landfills
- Quick change over for new jobs eliminates down time. Most of the scrap which is generated on the first pass is eliminated
- Variable speed drive compressed air system saves up to 25% of the energy used by a standard compressor
- Frictionless Turbocor chillers reduce energy usage 40% compared to conventional screw type chillers
- Rejected heat from production lines is recirculated to supply heat to the building
- Process water usage has been reduced from 500,000 to 50,000 gallons per day
- Waste water to the city’s treatment plant has been reduced by more than 80 percent
Environmentally conscious manufacturing is a new way of thinking about manufacturing which focuses on the most efficient and productive use of raw materials and natural resources while minimizing the adverse impact on employees and the environment.
New Product Development Facility
In 2010, Teeldas, a subsidiary of Teel Plastics, opened the doors of its custom compounding, analytical lab and extrusion manufacturing facility. Teel Plastics continues to look for unique partnerships to develop and manufacture custom products.