Estes has always been a proponent and practitioner of sustainable manufacturing. It just makes good business sense – for us and our customers.
Our Lean initiatives focus on reducing waste in time, material and practices and are part of our long-term business model. As part of our strategy, we use an engineering methodology known as Design for Manufacturing and Assembly (DFMA). With DFMA, Estes designs and engineers customer products from the outset with an eye toward limiting potential manufacturing and assembly obstacles.
Recently, Estes began working with the Purdue Manufacturing Extension Partnership (MEP), a service of Purdue University that provides manufacturing solutions, including clean and sustainable processes, to small and medium-sized enterprises. Purdue MEP will help Estes audit operations to find ways to improve existing and implement new sustainable initiatives.
With the European Union’s adoption of the European Climate Law in July 2021, sustainable manufacturing has transitioned from an aspirational goal to a business imperative. The law strives for Europe’s economy and society to be climate neutral with net-zero greenhouse gas emissions by 2050. To that end, the law requires European companies to report information on their carbon footprints and environmental impacts. Most important for U.S. manufacturers, European enterprises must include in their reporting all those manufacturers within their global supply chain.
As a result, American manufacturers with European clients, like Estes, must stay ahead of the sustainability curve to continue getting European business and keep environmental policies transparent. At the same time, stateside customers benefit because we are developing efficiencies to control costs.
Estes’ sustainable practices are rooted in a commitment to cost-effectiveness and efficiency, running the gamut from common sense to cutting edge. For example, on the practical side we use waste heat from our fabricating machines to heat the shop during winter months, conserving energy and decreasing our carbon footprint. In the shipping bay, Estes recycles and reuses wooden pallets and plastic knock-down containers to reduce reliance on cardboard boxes.
On the fabricating floor, we use nesting software to maximize the use of our work materials and improve efficiency by reducing scrap and waste. After analyzing a part’s shape and dimension, the software automatically determines the most efficient way to fit multiple parts onto a single metal sheet for processing. Once the pattern is established, we can complete the application with using as much of the sheet metal as possible for optimal material utilization and minimal waste.
Our more advanced solutions put scientific principles to work for sustainability. Estes laser welding applications rely on nitrogen gas as a shield gas to prevent atmospheric contamination in the weld area. In addition to controlling the temperature of the weld pool, nitrogen removes debris from the weld zone and ensures a stable laser beam. To provide all the nitrogen needed for the operation, Estes uses a nitrogen extractor that separates and purifies nitrogen gas from the air, providing a cost-effective supply of high-purity nitrogen for welding.
Sustainability is becoming more important than ever for design, manufacturing and sheet metal fabrication. But our sustainability initiatives are driven by something deeper than manufacturing economies and good environmental outcomes. As a faith-based company, we understand that we are called to be good stewards with our talents – “to cultivate and tend” the world we live in. For Estes, sustainability is more than just good business; it is a product of our core philosophy to be, first and foremost, an organization built on principle and staffed by people of high character. It’s who we are. It’s what we do.
In addition to positive impacts on the environment and manufacturing economies, sustainable manufacturing continues to be a significant aspect of Estes’ commitment to provide cost-effective fabrication for our customers.
