Sustainable Solutions for Industry - Henkel · Henkel Leadership in Sustainability In 2011, Henkel...

Sustainable Solutions for Industry

Henkel_Sustainablility_Brochure_Final.indd 3 21/8/13 10:29:06 AM

21/8/13 10:29:08 AM

The Sustainable Solutions for Industry brochure is printed on 100% Recycled Paper that is made from post consumer recycled fibre and processed without the use of any additional chlorine or chlorine compounds using Environmental Management system ISO 14001.

Content

w Henkel – Leadership in Sustainability 4

w Henkel - Our Experience/Your Solutions 6

w Sustainable Product and Solutions 8

Loctite® Health & Safety

Loctite® Technologies and Solutions

w Sustainable Manufacturing and Maintenance Solutions 14

Loctite® Manufacturing Excellence Workshop

Maintenance Reliability Workshop

Surface Engineering Workshop

w Energy Efficiency Solutions 20

Pump Efficiency

Operation Stop Leak

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HenkelLeadership in Sustainability

In 2011, Henkel introduced its Sustainability Strategy 2030. Central to this strategy is the simple but challenging ambition to triple our efficiency by either delivering three times more value with the same environmental footprint or reducing the footprint by one third while delivering the same value, in other words, achieving more with less.

For this strategy to be successful Henkel will need to pioneer new solutions, adjust our strategies and challenge the way we run our business and operations.

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Achieving more with lessIn turn, the roll out of this strategy will have wide ranging benefits for our customers such as the new products and services we will develop, the contribution our efforts will make to their own sustainability programs and, in a wider context, the flow-on effect of a reduced ecological footprint within the communities in which both Henkel and our customers operate.

Our aim is to work together with our suppliers, customers and consumers to develop viable solutions for the future because by doing so we will be contributing to sustainable development for all and to our company’s economic success.

External ratings Ratings and indexes 2012

Henkel’s performance in sustainability impressed external experts again in 2012. At the same time, recognition at the regional level is gaining in importance alongside the international ratings and rankings.


Our Experience - Your SolutionsWhile Henkel is committed to achieving sustainability within our own business operations, we are also committed to and supporting our customers to achieve and improve their endeavours in sustainability. To achieve this goal we will focus on:

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Sustainable Partner Solutions• Improvingoperatingefficiency

•Reducingyourfootprint

•Reducingwasteandleaks

•Decreasingredundancies


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Sustainable Product Solutions•Health&Safety(H&S)AnaerobicProducts

Loctite® Technologies & Solutions

•Threadlocking

•ThreadSealing

•Retaining

•Gasketing

•Bonding

•SurfaceEngineering

Sustainable Manufacturing & Maintenance Solutions•Loctite® Manufacturing Excellence

•MaintenanceReliabilityWorkshop

•SurfaceEngineeringWorkshop

Energy Efficiency Solutions•PumpEfficiency

•OperationStopLeak


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SustainablilityProduct andSolutions


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New Anaerobic Adhesive - Locitite® HealthandSafety(H&S)With the new Loctite® Anaerobic Health & Safety products, Henkel contributes to greater safety intheworkplacebyofferingtheworld’sfirstnon-hazardousanaerobicproductrange.Byusingthese products you will be raising the standard of your employees work life through improved health and well-being.

Loctite® 2400 ThreadlockerApplication:

•Lockingboltonapumpflange

Loctite® 2700 ThreadlockerApplication:

•Lockingnutonagearboxdifferential

Loctite® 5400 Thread SealantApplication:

•Sealingpipethreadandvalve

Loctite® 5800 Flange SealantApplication:

•Sealing2-partgearboxhousing

Loctite® 6300 Retaining CompoundApplication:

•Bondingballbearingontoashaft

* Available via our industry supplier partners.

For more completed product range, please visit www.loctite.com.au and www.loctite.com.nz

Typical Values

Product 2400 2700 5400 5800 6300

Application Threadlocking Threadlocking Thread Sealant Flange Retaining Sealant Compound

Strength Medium High Medium Medium High

Colour Blue Green Yellow Red Green

Fluorescent Fluroscent Fluroscent Fluroscent Fluroscent

Viscosity 3,000mPas 500mPas 27,000mPas 150,000mPas 350mPas (Brookfield)

Thixotropic Yes No Yes Yes No

Tensile Shear 9 Nmm 18 Nmm 11 Nmm 12 Nmm 20 Nmm Strength

Service Temp Up to 150°C Up to 150°C Up to 150°C Up to 180°C Up to 175°C Range

Package Size 50ml 50ml 50ml 50ml 50ml 250ml 250ml 250ml 300ml 250ml


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Loctite® Technology SolutionsWhen compared to conventional mechanical methods, Loctite products and solutions have proven to be more cost effective and consistently achieve cost savings of 20-30% or more depending on the application.

Anaerobic Adhesive Technology > Less waste and leaksThreadlocking

•Preventfastenerloosening–nutsandboltsarelocked against vibration and thermal expansion

•Sealagainstcorrosionandleaking

•Reduceinventorycosts

Thread Sealing

•Completecontactbetweenthreads,100%seal

•Willnotcreep,shrink,shredorblocksystems

•Easydisassembly

•Preventscorrosion

Retaining

•Significantlyimprovesstrengthofassembly

•Loaddistributedevenlyoverjoint

•Loosertolerancesrequiredresultinginlessdistortion and easy disassembly

•Resistscorrosion

Gasketing

•Fillallvoids

•Lowercostperapplication

•Easeofuse

•Nogasketcreeporcompressionset

•Lowerinventorycosts

Cyanoacrylate Adhesive Technology > Reduce footprintBonding

•Singlecomponentformulationcureatroomtemperature

•Bondtoawidevarietyofsubstrates

•Haveexceptionallyfastcurespeeds

•Resistanttotemperaturesupto120°C

•Lowodour(insomeseries)=improvedworkersafety (classifiednon-irritant)


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Surface Engineering Technology > Operation EfficiencyMetal Surface

Loctite® Fixmaster° Polymer Composites repair, rebuild and restore damaged machinery andequipmentpermanentlyandwithouttheneedforheatorwelding.

•Lowshrinking

•Canbedrilled,tappedormachinedaftercure

•Superadhesiontometal,ceramic,wood,glassandsomeplastics

•Excellentresistancetoaggressivechemicals

•Choiceofmildsteel,aluminiumornon-metallicfillers

•Createdurablerepairs


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Protecting Surfaces

Loctite® Nordbak Polymer Composite Compounds utilize the superior wear properties of ceramic andtheconvenienceoftwo-partepoxiestoprotectequipmentlikepumps,chutesandaugersinharsh industrial environments. Available in trowelable and brushable formulations with special filters for tough conditions, Loctite Nordbak products stand up to every corrosion, abrasion and wear problem you can encounter and are ideal for all those large-scale repairs that have to last.

•Restorewornsurfacesoruseonnewpartstoextendlife

•Providesuperiorprotectionfromenvironmentalimpact

•Eliminateandbreakcorrosion/erosioncycle

•Non-shrinkingandnon-sagformulations

•Highcompressionstrength

•Goodchemicalresistance

•Widerangetailoredtospecificapplications


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Rubber Repair & Protection

•Achievepermanentlyflexible,impactandvibrationresistantassembliesofdifferent materials

• Joinandsealpartsthathavelargegapsoraresubjecttohightemperatures

•Conveyorbelts

Grouting, Floor & Concrete Repair

•Mountingofheavyequipmentorsettinganchorbolts

•Restoreoldconcreteorcrackedfloor

•Createbarriersagainstchemicalattack

•Guardagainstslipperypedestrianorvehicleareas

Lubricant & Anti Seize

•Combatwearandseizingcausedbyfriction

•Resisthightemperatureandtoughoperatingconditions


Sustainable Manufacturing &Maintenance Solutions

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Optimumproductioncapabilityrequiresyourequipmentandmachinerytooperateefficientlyand reliably with minimum downtime due to unscheduled maintenance or component failure andyouremployeestohavetheknowledge,skillsandresourcestorespondquicklyshouldredundant downtime occur. Regular, scheduled maintenance by trained staff with access to products and resources including specialist expertise is a strong foundation from which you can achieve your production targets.

Loctite® Manufacturing Excellence The Loctite Manufacturing Excellence program allows companies to realize significant, documented reliability improvements by proactively addressing reliability at the base mechanicalcomponentlevel.Reliabilitydrivengainsachievedthroughgreaterequipmentavailability and efficiency can have a strong and positive financial impact for the organization as a whole and lead to the production process achieving greater sustainability.

TheSustainableBenefitsofLoctite® Manufacturing Excellence •Reduceddowntime

•Reducedrepairtime

•Reducedresourceuseandinventorycosts

• Increasedproductivity/uptime/OEE

• Improvedoutputquality

•Reducedwaste

•Dramaticallyreducedair/hydraulicleaks

• Increasedenergysavings

• Improvedsafety

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MANUFACTURING RELIABILITY

PROACTIVE“Prevent the unpredictable”

PREDICTIVE“Replace prior to failure”

PREVENTATIVE“Protect from failure”

REACTIVE“Fix after failure”


Maintenance WorkshopThe Loctite® Maintenance Workshop does more than identify problems in your plant. It teaches the mechanical basics and failure fundamentals to help empower your people with the proper tools, skillsanddocumentationrequiredtomakeyourtotaloperationsmoreefficient.

TheSustainableBenefitsofMaintenance Reliability WorkshopsReduce Energy Costs/Consumption

•Airleak1mm@6bar@$0.14perkWh=$330lostperyear

•Looseconnectoron480volt,30amp,3phasemotor=13%moreenergyneedstorun

Reduce Fluid Consumption

•Hydraulicleak@1drop/second@$2.06/l=$4,225lostperyear

•Reducecleanupanddisposalcosts

Improve Reliability

•Qualityproduction

•Extendmeantimebetweenfailure

•Reduceminorstoppagesforadjustments

•Fewerneedlessvariablesforplannedmaintenance

•Enlargedreliabilityculture

Save Time & Improve Safety

•Reduceroutinemaintenancetasks

•Reducestandardrepairtimes

•Reduceredundantrepairs

• Improvesafetybyeliminatingpersonalinjuryhazards

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Loctite®Live - Mobile Training Facility


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Proof of Cost Reductions

AIR LEAK COST CALCULATOR

Diameter of Opening Air Loss (1/min) Energy Loss (kW) Additional Energy (mm) Costs*($/year)

1 72 0.3 330

3 666 3.1 3408

5 1854 8.3 9125

Line pressure at 6 bar.*Basedon8000openinghours/yearandenergycostsof$0.14/k/Wh

OIL LEAK COST CALCULATOR

Leakage Rate Loss Per Day (litre) Loss per Year (litre) Annual Costs*($/year)

1 drop in 10 sec 0.56 204 422

1 drop in 5 sec 1.12 409 844

1 drop per sec 5.62 2048 4225

Priceforhydraulicfluid:$2.06/I.Source:BavarianEnvironmentalProtectionAgency,guideline“DruckluftimHanderk”

Didyoueverwonderhowmuchcompressedairoroilleaksstealfromyourbottomline?Our Calculators reveal the truth behind the numbers.

On-site Technology WorkshopThis two hour workshop covers common maintenance challenges and the appropriate Loctite® product solutions. At the conclusion of training your staff will be able to immediately apply the skills they have learned with confidence.

Key Loctite® Maintenance Workshops features• Plant pre-survey to identify maintenance needs

•Tailormadehands-ontrainingtofityourspecificneeds

•Reviewofcommoncausesoffailureandprevention

•Customizedcontent–aimedattroubleshootingandeliminatingkeyproblemsinyourplant

•Detailedmodulesthatexaminemechanicalbasics

•Principlesandapplicationsofmachineryadhesives

•Solutionstoreduceredundantmaintenance

• In-plantfollowupandsupport


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Surface Engineering Workshop

Allplantandequipmentissubjecttotheeffectsofwear,abrasion,corrosion,andchemicalattackshorteningtheexpectedservicelifethroughequipmentandcomponentfailure.Surfacesexposedtocontinual and incremental attack fail due to substrate reduction and loss of structural integrity.

The Sustainable BenefitsoftheSurface Engineering WorkshopSave Resources

•Reclaimwornparts/lessnewpartreplacement

•Reduceroutinemaintenancetasks

•Reducestandardrepairtime

•Reducecosts

Improve Reliability

•Extendmeantimebetweenfailure

•Fewerneedlessvariableforplannedmaintenance

•Enlargedreliabilityculture

Loctite® Surface Engineering Workshops offer:

Pre-plant Survey

•Workshopscanbetailoredtomeet your needs through a plant tour and pre-workshop survey

Key Reasons for Assets Failure

•Reviewofcommonfailurecauses and prevention

•Solutionstopreventassetsfailure

•Solutionstoextendlifeofassets

Hands-on Training

• Jobrelatedandproductspecific

•Variousapplicationscoveralltrades

•Trainingmaterialssupplied

•Conductedon-site


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Seizure Prevention Made Easy The Situation

Seizedpartsrequireoxyordisccuttingwhichoftenneedstime-consuminghotworkpermits and can damage expensive components.

An Australian mine with underground operations was trying to address this problem and was seeking reliable and cost efficient solution that can also be used on alloy parts. Anti-seize is an essential product for mining maintenance operations to ensure that components can be easily dismantled.

The Sustainable Benefits

•Loctite®HeavyDutyAnti-Seizeisametal-free,non-hazardousanti-seize product that can be used on all alloys and has a temperature rating of 1315 °C

•ThemaintenanceteamissafefromOH&Srisks

• Ithelpstoreducecostandincreasereliableperformance

solutions

Rebuilding & Coating Solution for PumpsThe Situation

The efficiency of a 1400kilowatt water circulation pump has fallen due to cavitation and wear and tear on parts. The cost of replacement is high so alternatives are considered. On review of the situation it is decided to use Loctite® Fixmaster SuperiorMetalPuttyandNordbakBrushableCeramic.


•Resistancetothewaterflowinsidethepumpisminimized

•600megawattsofelectricity(energy)issavedperpumpperyear

•Thisenergysavingtranslatesintoacostsavingof$39,656.00eachyear

for two pumps

•Productivitygainsof8%achieved

solutions


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EnergyEfficiencysolutions


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Energy Efficiency for the Future

“TheGovernment’splanforacleanenergyfutureresponds

to climate change science and is economically responsible.

The plan has four elements: A carbon price, renewable energy,

energyefficiencyandactionontheland…”

Source: Overview of the Australian Government Clean Energy Legislative Package

“Developmentmeetingtheneedsofthepresentwithoutcompromisingtheability

offuturegenerationstomeettheirownneeds.”

Source: Guiding Principles – Sustainability Council of New Zealand

TheAustralianGovernmentandindustryarecommittedtodevelopingstrategiesandimplementing programs that deliver energy savings and clean, renewable and sustainable energy for future generations.

Henkel’s commitment to a sustainable future is evident in its range of Loctite® products which we continue to develop to deliver sustainable solutions for industry such as greater energy efficiencies, improved machine reliability, decreased necessity to replace parts, reduced downtime and maintenance, and a lower ecological footprint.

SustainableBenefitsofLoctite® Products

•Reduceenergycosts•Reducefluidconsumption•Reclaimwornparts•Reduceresourceusage•Improvereliabilityandsafety


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Reclaiming a Horizontal Split Casing PumpThe Situation

TheproblemencounteredofWaterUtilityStationwas36”HorizontalSplit

Casing Pump badly eroded at the wear ring area and the volute and needed

to repair immediately. A repair process was undertaken using Loctite® Superior

Metal followed by coating with Loctite®BrushableCeramictorepairthewornout

areas and gain more level of Pump efficiency.


•Loctite® products restored the efficiency of the pumps at a lower cost than

replacement

•Thecustomerwasabletoreclaim$100,000pumpbyusingLoctite®

solutions

Pump Efficiency ProgramMostindustrialcentrifugalpumpscarrysignificantcapitalequipmentvalueandthereforeitisimportant to extend their useful lives and ensure that they run efficiently and reliably. Proactive maintenance can reduce the risk of breakdowns, increase pump reliability and longevity, and extendtheMeanTimeBetweenFailure(MTBF).

ByapplyingtheidentifiedproductsolutionsandtechniqueslearnedinaLoctite® Pump Workshop, your personnel will have the knowledge and the tools to do the following:

• Increasepumpefficiency

•ExtendtheMeanTimeBetweenFailure(MTBF).

• IncreasepumpefficiencyandensurethatpumpsrunclosesttotheirbestEfficiencyPoint(BEP)

•Eliminateleaks

•Eliminateerosionandprotectagainstchemicalattack

•Reducecomponentconsumption


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Operation Stop Leak ProgramAllindustrialfacilitiesrequireoillines,airlinesorgaslineswhicharesubjecttowearandtear,damage, failure, vibration or loosening. An unseen or unheard leak which is allowed to remain unchecked will increase operating costs and decrease your operating efficiency.

Loctite’s Operation Stop Leak is an effective, plant-wide survey utilising state-of-the-art equipmentincludingultrasonics,specialtydetectionlightsandfluorescentdyestodetectthelocation of any leaks. Every leak, including fittings, valves, flanges and hoses is tagged with a number, location, severity and costed.

Sustainable Benefits of the Operation Stop Leak Program

•Reduceenergyconsumption

•Reducecosts

•Monitorsprogressofquantitiesanddollarssaved

•Promotesshiftfromreactivemaintenancetoproactivemaintenance

Saving over $27,000 by stopping an oil leakThe Situation

A leading automotive component manufacturer knew their production costs were increasing due to oil leaks. What they did not know and could not determine was just how costly the leaks were. Operation Stop Leak revealed the true costs associated with these leaks including clean up, recycling and disposal costs.Whenmultipliedoverseveralleaksthecostimpactquicklybecomeobvious. The Loctite® Operation Stop Leak Program saved the company more than$27,000inthefirstyear.


•Earlyleakdetectionviaaproactivemaintenanceprogram

•Costandvolumecanbedeterminedforsingleormultipleleaks

•Allcostvariablesareconsidered

•Traininginleakstoppageandrecommendedchemicaltools

solutions


Henkel Australia Pty Ltd135-141 Canterbury Road,Kilsyth, Victoria 3137Tel: 1300 88 555 6

www.loctite.com.au

Henkel New Zealand LtdPO Box 58 493, Botany Manukau, Auckland 2163 New ZealandTel: +64 09 272 6710Fax: +64 09 272 6711

www.loctite.co.nz

The data contained herein are furnished for information only and are believed to be reliable. We cannot assume responsibility for the result obtained by others over whose methods we have no control. It is the user’s responsibility to determine suitability for the user’s purpose of any production methods mentioned herein and to adopt such precautions as may be advisable for the protection of property and persons against any hazards that may be involved in the handling and use thereof. The discussion herein of various processes or compositions is not to be interpreted as representation that they are free from patents owned by others or as a licence under any Henkel patents which may cover such processes or compositions. We recommend that each prospective user test his proposed application before repetitive use, using this data as a guide.© Copyright 05/13 , Henkel Australia Pty. Ltd. All rights reserved.


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