Crown Beverage PackagingOlympia, Wa.

Can Manufacturing Process

• Plant History

• Contacts List

• Process Orientation

• Plant Safety Program

• Pollution Prevention

Olympia Plant #76 The Plant originally opened for Business in 1959 with 35 employees manufacturing 11oz. Beer Cans for the Olympia Brewing Company.

In 1966 the original size of the Manufacturing area was more than doubled. By 1968 the number of employees surpassed 200.

Olympia had grown to incorporate a Lithography department, a complete Beverage End operation, and a (3) Line 2pc manufacturing department.

In 1994 the Plant was upgraded. A new building addition was put on the Plant to house our new High Speed Decorators and state of the art Necking operations, a rebuilt Washer was added to increase the needed output. New palletizing equipment was installed. The Plant was now a 2 line high speed operation producing more each day than with the older 3 line operation.

In 1998 the End operations were consolidated into another plant, as End Production ceased at Olympia. The workforce was cut in half.

Today the Plant employs 115 people including hourly and salary.

The plant typically runs on a continuous shift 7 day operation

Customers:DPSG/7up– Sacramento, Pepsi Northwest – Olympia, Pepsi Mt Angel, Pepsi Yakama, Pepsi Delta BC, Shasta – Tukwila, COTT – Surrey Canada, Molson/Coors – Vancouver Canada , Craft Brewers

• Plant Manager – Dan Joanis• Plant Superintendent‐ Cam McClary• Plant Engineer/ EH&S Coordinator‐Mark Kirschenheiter• Plant H.R. Manager / Safety Coordinator‐ Lena Beach • Plant Accountant‐ Cathy Allen

Olympia Plant Contacts

A look inside the Olympia plant…

60: Cupping Press

40: U

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70: Body Makers & 80: Trimmers60: Cupping Press

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70: Body Makers & 80: Trimmers60: Cupping Press

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90: Washer 100: Dryer

120:Turnover

110:UV/BRC

170: Oven

150: Decorators & 160: Varnish

70: Body Makers & 80: Trimmers60: Cupping Press

40: U

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90: Washer 100: Dryer

120:Turnover

110:UV/BRC

170: Oven

150: Decorators & 160: Varnish

70: Body Makers & 80: Trimmers60: Cupping Press

40: U

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90: Washer 100: Dryer

120:Turnover

180: LSM

110:UV/BRC

170: Oven

150: Decorators & 160: Varnish

70: Body Makers & 80: Trimmers60: Cupping Press

40: U

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l Man

drel

90: Washer 100: Dryer

120:Turnover

180: LSM

190: IBO

110:UV/BRC

200: Waxer220: Flanger & 210: Necker230: Light Tester

170: Oven

150: Decorators & 160: Varnish

Camera Inspection

14 Stage Necking

Neck Forming and Inspection

70: Body Makers & 80: Trimmers60: Cupping Press

40: U

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90: Washer 100: Dryer

120:Turnover

180: LSM

190: IBO

250: Palletizer

290: Warehouse Shipping

240: Vision Systems

110:UV/BRC

200: Waxer220: Flanger & 210: Necker230: Light Tester

170: Oven

InternalExternal

150: Decorators & 160: Varnish

PlantSafetyProgram

AnnualTrainingMonthlyCrewMeetingsS.A.F.E.CardProgramJobHazardAnalysisS.O.P. ’sBestPracticesDaily,Weekly&MonthlySafetyInspections

MeasurementEH&SDashboardTracksMonthlySafetyPerformances

Since1995,Crownhasreduceditsgenerationofdangerouswasteby99.9percent!

Annualdangerouswastegenerationhasfallenfrom382,760poundsin1995to412poundsin2013

PollutionPrevention:Acommitmenttocontinuousimprovement

Howwedidit:PlantPollutionPreventionProgram

‐ PlantPollutionTeam‐EstablishAnnualGoals‐MeetQuarterlyMeetings‐ReviewGoals

PollutionPreventionProjectsPast&Present1.OnsiteI.P.A.Distiller(2012ReclaimIsopropylAlcohol)‐ reducedIPAuseby7,585lbs/yearfrom20112.InstalledPortableRentalD.I.Tanks (2013ChemicalElimination,WaterReduction&Safety)3.FishBio‐Assay(#1788303/27/2013ProfileG05402S)4.InstalledI‐TraxIBOOvenMats(2013NaturalGas&Electricalsavings)5.InstallupgradeIBOOvenBurner(T.B.I.9/2014)6.Water‐basedPartsWasher(Ultra‐SonicCleanerinstalled2014)7.Switchedtolow‐VOCinks

CrownP2casestudy:RentedD.I.Tanks

Solution• Lease Portable Deionized Water  Regeneration Tanks  (Siemens)

• Mfg. and install, user friendly tank storage rack with cam lock hose connections, to house portable D.I. tanks while in operation.   

BenefitsProduction / Quality / Cost

• Maintenance‐ Reduced maintenance , reduced downtime , no maintenance cost 

• Exposure‐ Removes potential hazardous contact with acids by elimination of acids from the plant 

• Water Quality‐ Consistent & Reliable 

• Water Usage‐ Eliminating the regeneration procedure of old columns, 

Annual water savings:  260,000 gallons per year

Returnoninvestment:CostSavingsRentedD.I.TanksOld Plant‐Owned D.I. Columns

• Acid                   $3,900• D.I. Resin          $1,072• Water Usage    $550• Labor                 $600• Rental Fee          N/A• Service Fee         N/A MONTHLY TOTAL                $6,122

Rented Portable D.I. Tanks          

• ACID                    N/A• D.I. Resin            N/A• Water Usage     N/A• Labor                  N/A• Rental Fee         $700• Service Fee       $2,700• MONTHLY TOTAL                $3,400

Monthly Savings    $2,722ANNUAL SAVINGS    $32,664

WemusttakecareofourCustomers.