Estimates show that fewer than 0.5% of all companies are still in business at the 100-year mark. What is inestimable is the value and depth of experience that length of time lends to a business like Ferriot. With a rich history spanning 95 years in injection molding, Ferriot consistently strives to maintain its position at the forefront of manufacturing innovation, including sustainable practices.
As the push for sustainability as part of modern manufacturing practices continues to grow, Ferriot proudly reaffirms its unwavering dedication to eco-friendly practices and materials. This commitment extends far beyond Ferriot’s own operations, actively supporting and encouraging customers in their sustainability journeys.
Our approach to sustainability
At Ferriot, sustainability starts with smart design and efficient processes. The comprehensive end-to-end project management approach helps significantly reduce the carbon footprint of each manufactured product. Constant innovation and seeking eco-friendly solutions meet the evolving needs of customers and the planet.
Ferriot’s commitment to sustainability is not just about meeting current standards but pushing the boundaries of what’s possible in eco-friendly manufacturing. The company strives to be a leader in this field, setting an example for others in the industry to follow.
Eco-friendly materials in injection molding
While the specific resins used are typically specified by customers, Ferriot takes an active role in influencing decisions toward more sustainable options. The company is particularly excited about recent developments in bio-based resins and eager to test these innovative materials with OEMs looking for more environmentally friendly solutions.
There is almost always an option for parts production to incorporate “regrind,” or previously used or molded resin that has been ground for reuse. Some formulations mix a percentage of regrind with virgin material. This practice not only promotes sustainability but also offers cost benefits to customers, because regrind is typically less expensive than virgin material. This creates a win-win situation that aligns economic interests with environmental responsibility.
It’s worth noting that many of the resins Ferriot works with, such as polypropylene used in one of its proprietary product lines American Original™ Shake & Scallop Siding, are 100% recyclable. This commitment to recyclability extends throughout the production process, to help products have a reduced environmental impact even at the end of their lifecycle.
Recycling and waste reduction
Ferriot takes a proactive and comprehensive approach to recycling and waste reduction. The company meticulously recycles scrap and continuously seeks innovative ways to reuse materials in-house. When in-house reuse isn’t possible, Ferriot partners with specialized brokers to ensure scrap is properly recycled and repurposed.
This commitment to recycling and waste reduction isn’t just about managing waste – it’s about contributing to a circular economy where materials are reused and recycled rather than discarded. By finding new uses for what might otherwise be considered waste, Ferriot helps conserve resources and reduce the overall environmental impact of the manufacturing process.
Our tooling engineers are fully equipped to identify ways that companies can redesign parts for lighter weight without sacrificing integrity, and that also use less resin. For example, two possibilities might include removing undercuts or making walls thinner to save money and be more environmentally conscious.
Energy conservation efforts
One part of a comprehensive sustainability plan goes beyond material selection and into the energy consumed at corporate offices and manufacturing facilities. The company has implemented several innovative measures to significantly reduce energy consumption over the long term:
- Daylighting: Strategically placed skylights maximize natural light during daytime hours. This reduces reliance on artificial lighting and creates a more pleasant working environment for employees.
- Smart LED Lighting: Advanced LED lighting systems automatically activate when plant lighting dims below a predetermined level. This ensures energy efficiency without compromising worker safety or productivity. The use of LED technology itself represents a significant energy saving over traditional lighting methods.
- Nitrogen Generation: State-of-the-art nitrogen generation systems extract nitrogen from the air for use in the injection molding process. This technology offers multiple benefits:
- Improves part quality (eliminates defects and blemishes) by removing oxygen and moisture from the processing system.
- Reduces scrap, thereby minimizing waste.
- More cost- and energy-effective than purchasing bulk liquid nitrogen.
- More environmentally friendly, as it eliminates the need for transportation and storage of liquid nitrogen.
These energy-saving initiatives not only reduce environmental impact but also improve operational efficiency, demonstrating that sustainability and profitability can go hand in hand.
Innovation and the future of eco-friendly injection molding
Ferriot is deeply committed to staying at the forefront of sustainable manufacturing. Ongoing research and development efforts focus on adapting to new eco-friendly materials and technologies. Innovation is key to creating a more sustainable future for the injection molding industry.
The company constantly explores new materials, processes and technologies that can reduce environmental impact without compromising on quality or performance. This includes investigating biodegradable plastics, exploring more efficient molding processes and looking at ways to further reduce energy consumption and waste in operations.
Ferriot recognizes that sustainability is an ongoing journey, not a destination. As such, the company is always open to new ideas and collaborations that can help further sustainability goals. Active engagement with customers, suppliers and industry partners facilitates sharing knowledge and best practices in sustainable manufacturing.
The importance of customer collaboration
While Ferriot is committed to sustainability, true progress requires collaboration with customers. As mentioned earlier, the resins used in products are often specified by customers. This presents an opportunity to engage in meaningful dialogue about sustainable options.
Ferriot actively works with customers to educate them about the latest developments in eco-friendly materials and processes. The company encourages consideration of sustainable alternatives and is always ready to conduct trials with new, more environmentally friendly materials.
This collaborative approach ensures that Ferriot is not just implementing sustainable practices in its own operations, but also influencing the broader supply chain towards greater sustainability.
Collaborating with Ferriot
Ferriot’s commitment to sustainability is ingrained into our corporate goals and values. From choice of materials to energy-saving initiatives, or recycling practices to innovative manufacturing approaches, we strive to use our resources wisely, while delivering high-quality products.
Ferriot believes that sustainable manufacturing is not just a responsibility, but an opportunity – an opportunity to innovate, to improve efficiency and to create products that are better for both customers and the planet. Businesses are invited to partner with Ferriot to work on creating more sustainable solutions that meet the needs of today while preserving the planet for tomorrow.
