BY JOHN O’REILLY Circle Pines, a Minnesota-based injection-molding company, more than doubles its vendor report card score in only two years by aggressively boosting its performance in energy conservation, packaging materials, health and safety audits, and other areas. Few things in this world can be factually characterized as truly “unique”—as in “one of a kind,” Read more
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BY JOHN O’REILLY
Circle Pines, a Minnesota-based injection-molding company, more than doubles its vendor report card score in only two years by aggressively boosting its performance in energy conservation, packaging materials, health and safety audits, and other areas.
Few things in this world can be factually characterized as truly “unique”—as in “one of a kind,” “nothing like it anywhere else.” But for Eric Eichten, “unique” is an absolutely spot-on summation of the three-year-old Uponor Sustainability Report Card questionnaire process.
“We have had customers who’ve required this sort of vendor survey maybe one time—like when we are just starting a relationship,” says Eichten, who serves as customer relations lead at Advanced Molding Technologies (AMT) in Circle Pines, Minn. “But for the most part, sustainability has been almost an afterthought. The focus Uponor has devoted to sustainability—and the value their management ascribes to it year-in and year-out—is not something I have seen elsewhere.”A plastic-injection molder, AMT has been supplying Uponor engineered plastic pipe fittings for use in the latter’s crosslinked polyethylene (PEX) piping systems for more than two decades. In fact, AMT founder and owner Brett Nelson previously worked with Uponor (then known as “Wirsbo”) at another vendor before launching AMT in 1999.
Press room: AMT injection molding presses on the company’s molding floor.
Uponor Engineered Polymers category manager Loren Boerboom, whose Supply Chain team works with Eichten, describes AMT as a “very sophisticated company and a strong supplier. Technology-wise, they are top notch, and they adhere to our demanding standards for fittings.”
Nonetheless, three years ago, when AMT management received the inaugural version of the now-annual sustainability questionnaire, it came as a bit of a jolt, recalls Eichten. “I don’t know that ‘surprised’ is the right word, but I can’t say we were expecting all the questions it asked. The survey was an eye-opening experience, to say the least.”
Tool room: Where AMT’s injection molds are cleaned and maintained for customers.
That first year, 2017, AMT earned 12 points out of a possible 53 on the 23-question form, earning a “C rank.” The next year, the company more than doubled its total to 25 (again out of 53), raising its rank to “B.” (Survey questions are kept the same from year to the next, “so that we are comparing ‘apples to apples,’” says Boerboom.) In 2019, AMT increased its point total again, to 27, further bolstering its “B” rank.
Rather than regarding that first questionnaire as an imposition—let alone an abuse of the leverage a buyer might hold over a long-time supplier—AMT quickly embraced the process as “motivational,” according to Eichten. “The Uponor survey has shown us where exactly we need work, where we could improve.”
Proactive approach
What most impressed Boerboom and the other members of his team was the proactive manner in which AMT used its survey results to pursue internal improvements. “They actively reached out to our company, holding meetings with our sustainability people to get ideas: ‘What can we do to align with Uponor when it comes to sustainability?’”
Over the past three years, AMT has achieved improvements in numerous areas, but three are particularly notable:
- Corporate social responsibility (CSR): In 2017, AMT had no formal, written CSR or sustainability policy. Led by its CEO and the company’s human resources department, AMT built one from scratch in 2017-2018, generating five additional points on the second survey.
“We want to be a great injection-molding company,” says Eichten, who has worked at AMT the past seven years, five of them on the Uponor account. “When we had to answer that question ‘no’ in 2017, we also recognized it as a huge opportunity to improve. Brett and our HR people worked the better part of a year on the new statement,” which now lives in the company’s employee handbook.”
- Reductions in energy consumption: In AMT’s injection-molding process, large amounts of energy are expended heating the tool. An ongoing problem was the amount of heat lost during the process: Cut that heat-loss total, and a significant amount of energy could be saved.
“To reduce heat loss, we added insulator plates where we have a steel tool sitting on top of the steel platen of an injection-molding machine,” explains Eichten. “So, instead of heating the machine, most of the heat is now concentrated by the insulator on the molding tool.”
Although it is difficult to quantify the precise energy savings, Eichten estimates that this simple move to insulation has had a substantial, positive impact. “We believe that it saves us roughly 30 minutes at the startup of a tool,” he explains. “Then, over the course of a production run, we need less energy to maintain a set temperature in that tool.”
- Reductions in packaging materials and shipping distances: AMT maintains approximately 80,000 square feet under roof in two buildings located cater-corner to one another in Circle Pines. Injection molding is done in one facility; packaging, the other. Bulk product movement between the two is done with large, palleted and—here’s the key—reusable plastic cartons, called “gaylords,” the name of their manufacturer.
“The plastic pallets are filled at our production facility,” says Eichten, “and the contents are transported to the second building for packaging, while the gaylords return to the first building for repeat refilling. We use the same cartons over and over.”
“Long way to go”
AMT management recognizes that much of the “low-hanging fruit” in process improvement has already been plucked, and that future improvement projects will be larger, perhaps more complicated, and most likely more costly. As an example, Eichten points to replacing more than 80,000 square feet of fluorescent lighting in the two facilities.
“We want to substitute LED lights, and that is a much larger, more costly and difficult process to tackle,” he continues. “But the LED switch may also have greater impact in the long run in terms of energy savings.”
In its aggressive move to embrace sustainability, AMT “still has a long way to go,” Eichten concedes. “We are aware of a lot of large projects out there that we definitely want to complete. But we are also looking forward to taking those next steps.”
Every year for over a decade Milwaukee Tool has invited members of the trade media and social influencers to their Brookfiled, WI headquarters for the first look at all the new tools coming that year. This is a two day event that has grown a lot o=ver the years, we here at Mechanical Hub are Read more
Every year for over a decade Milwaukee Tool has invited members of the trade media and social influencers to their Brookfiled, WI headquarters for the first look at all the new tools coming that year. This is a two day event that has grown a lot o=ver the years, we here at Mechanical Hub are proud to say we have attended each year the traditional New Product Symposium (NPS) has happened in the past. NPS is the event we first learned of Milwaukee Tool’s now famous FUEL line of tools, even their M18 and M12 series known everywhere for their huge offering of tools and impressive performance.
This year NPS was in danger of happening at all because off the COVID-19 pandemic. Like everything and everyone these days, Milwaukee Tool was challenged with having to simply “figure it out”. Well, they sure did! The PIPELINE series of broadcast events debuted on August 20th to all of Milwaukee’s fans, not just the media and influencer crowd!
Here is a brief recap of some of the tools we all got our eyes on for the first time in episode 1. If you’d like to watch PIPELINE episode 2 on Sept 10, sign up here.
M18 FUEL COMPACT IMPACT WRENCHES
LAUNCH DATE: NOVEMBER 2020 FRICTION RING: 2854-20, 22, 22CT; 2855-20, 22 PIN DETENT: 2855P-20, 22
Milwaukee Tool continues to transform cordless expectations with the introduction of new go-to impact wrench solutions when accessing tight spaces. Measuring at only 4.8” in length and delivering up to 250 ft-lbs of nut-busting torque, Milwaukee’s next generation M18 FUEL Compact Impact Wrenches deliver the performance needed in tight applications where larger impact wrenches cannot fit.
M18 FUEL SECTIONAL MACHINE FOR 5/8″ AND 7/8″ CABLE
2818A-21, 2818B-21, 2818-21
The M18 FUEL Sectional Machine for 5/8″ and 7/8″ Cable is the most portable and most powerful sectional machine for 1-1/4″ – 6″ drain lines. The POWERSTATE Brushless Motor and REDLINK PLUS Intelligence delivers the power to clear heavy roots up to 150 ft out, providing more power than corded even at the maximum capacity of the machine. The sectional machine ensures the easiest transportation and setup on all jobs by being lightest weight and most compact tool in its class, and offers carry strap connection points for hands-free transportation. The M18 REDLITHIUM High Output HD12.0 Battery Pack powers through multiple jobs on a single charge, and increases safety by providing power anywhere without the use of extension cords.
M12 FUEL 1.6 GALLON WET/DRY VACUUM
LAUNCH DATE: OCTOBER 2020 0960-20, 0960-21
The first 12V wet/dry vacuum of its kind, this new solution delivers 18V performance on a 12V platform. The most compact wet/dry vacuum available today, and operating up to 2X quieter, it provides up to 40% more suction to easily complete all quick and service-oriented clean-up applications.
M18 FUEL PACKOUT 2.5 GALLON WET/DRY VACUUM 0970-20
Milwaukee Tool is proud to introduce the most powerful small capacity 18V wet/dry vacuum, fully compatible with the PACKOUT Modular Storage System. The M18 FUEL PACKOUT 2.5 Gallon Wet/Dry Vacuum delivers up to 60% more suction than other 18V wet/dry vacuums, giving users the performance and power they need to quickly clean up a wide range of materials.
MX FUEL TOWER LIGHT
LAUNCH DATE: EARLY 2021 MXF041-1XC
The MX FUEL ROCKET Tower Light/Charger is the most portable 10′ light for both indoor and outdoor use, provides up to 27,000 lumens of task and area lighting, and withstands the harshest jobsite environments. Whether it needs to be moved across rough terrain during early phase construction or across pan decking for early morning concrete pours, the 8″ all-terrain wheels ensure you can easily roll across uneven ground. It can be set up in seconds to a max height of 10′ with a motorized mast, and collapses back down to 44″ for easy transportation and storage. Once it is in place, 4 outriggers can quickly be deployed to provide more stability on uneven surfaces. The four multidirectional light heads give users the ability to cast up to 27,000 lumens of TRUEVIEW High Definition Output in several directions.
MX FUEL DRUM MACHINE LAUNCH DATE: NOW! MXF501-1CP
The MX FUEL Sewer Drum Machine w/ POWERTREDZ is built with POWERTREDZ Lift Assist technology which makes it easier for one person to transport the machine up and down stairs, as well as in and out of service vans. In addition, the machine has the power to clear roots 200 ft out while containing the mess with a fully enclosed drum.
Keep an eye out on our social media and here on the site for coverage of episode 2!
Some talented people seem to have the ability to create anything. Regardless of what they apply themselves to, the end result is always stunning. Upstate New York is home to one of these independent, relentless creative minds. In Jimmy Diresta, genius, vision, originality and the spirit of craftsmanship come together. Known best for creating functional Read more
Some talented people seem to have the ability to create anything. Regardless of what they apply themselves to, the end result is always stunning. Upstate New York is home to one of these independent, relentless creative minds.
In Jimmy Diresta, genius, vision, originality and the spirit of craftsmanship come together. Known best for creating functional art of all variety, he’s an inventor, artist, fabricator, TV personality, podcaster, author, video producer, prolific YouTuber and social media star.
Diresta was hired by Bulleit Whiskey to create store displays resembling a vintage wooden trailer, the first of which is now in a large liquor store in Louisville, KY.
Whether he’s hand-crafting tools or building a wooden canoe, Diresta’s work is unique and always documented on his YouTube channel.
“I’ve been a lifelong maker,” said Diresta. “It started in elementary school, and I’ve done nothing else since.”
His most widely-known project was fabrication of an AK-47-themed guitar, or “Gattar” for musician Wyclef Jean. According to the rapper, the functioning musical instrument symbolizes music as a weapon. The ubiquitous Kalashnikov was chosen because, since its inception in 1947, it has come to symbolize “revolution.”
Crazy guitars aside, in Diresta’s mind, his greatest creation has been his YouTube channel.
“I capture, edit, and market all my own content and have attracted an audience that appreciates the work I do,” said Diresta, referring to his 1.8 million subscribers. “There are 329 million channel views, and it’s become my online portfolio.”
That portfolio has attracted attention from a lot of big names. Diresta has collaborated with a wide variety of companies, including DeWalt, Bulleit Whiskey, Carhartt, Carolina Shoe, Guinness and others.
A hammer with Jimmy’s name water-jetted through its head was a gift from blacksmith Paul Pinto.
More creative space needed
As Diresta’s online presence grew, he found himself with a good problem – he needed more space.
“In 2004 I bought a farm in the country with intentions to build a barn, to become my main workshop,” he explained. “I was working in the city at that time, and it wasn’t until I started making money on YouTube that I could fulfill the dream.”
In 2017, Diresta took the plunge, beginning construction on the 40×72 pole barn – called, simply, the Black Barn – that would ultimately become an event space, rather than the workshop he’d initially envisioned. The barn is now where he hosts blacksmithing and woodworking classes on the weekends.
Jimmy Diresta, YouTube sensation and co-host of several TV shows, in his new shop.
Like many of the things that Diresta is involved with, the construction project became a group effort between a number of other creators and social media influencers.
Kyle Stumpenhorst (@RRBuildings) was hired to build the frame and roof, using construction of the building to launch his own YouTube channel. David Parraguirre (@TheMexicanCarpenter101) completed the building, including flooring, paint, exterior, windows, and layout of half-inch radiant tubing at 12-inch centers before the shop’s slab was poured.
“I chose these craftsman for the project because they’re meticulous and extraordinarily talented,” said Diresta. “I wanted the job done right, and I wouldn’t have been as meticulous on a construction project myself.”
Every time he brought up construction of a pole building, people recommended installing a radiant heating system to combat the big winters in upstate New York. Diresta had the radiant tubing installed but held off on the boiler.
During construction of the barn, work halted for an extremely rainy day. Diresta salvaged that day by hosting a meet and greet of sorts, for people in the area that wanted to chat with himself, Kyle or David. In attendance was Moe Hirsch, owner of Moe’s CAMs (Consulting and Mechanical Services) in Pomona, NY.
“Moe’s passion for hydronics was evident immediately, and we discussed the installation of a boiler for the radiant system,” said Diresta. “We left it there for almost two years, but in 2019, I contacted Moe, and he came back out to the farm to begin designing a system.”
(L-R) Ari Rosenbloom, Lead Technician, Moe Hirsch, Jimmy Diresta, Mordy Schwartz, Apprentice, and Meir Kirshenbaum, apprentice/scheduling.
No T-stats
Hirsch started with a heat load calculation. The building has blanket insulation on the walls and spray foam in the ceiling. Diresta wanted to maintain 60°F indoors on a regular basis with the ability to bring the space up to 70°F during events.
Hirsch found the load to be 105 MBH. His plan was to install a Viessmann condensing boiler and a single Taco VT 2218 circulator in Delta-T mode to serve the 12-loop radiant system.
Hirsch uses only one pump, a Taco VT2218, across the whole hydronic system.
“I use Taco delta-T circulators on all my radiant jobs, but having a pump respond to return water temperatures was especially important on this project,” said Hirsch. “I used a 20°F delta here. Nobody is walking around in the shop with bare feet, so if there’s a slight surface temperature inconsistency, it’s irrelevant, and a small price to pay for the efficiency gained by wringing every last drop of condensate out of the heat exchanger.”
The Black Barn doesn’t have a thermostat. Jimmy simply controls the temperature of the building via the boiler’s mobile app, which is linked to the unit’s outdoor reset control. Rather than the boiler getting an open/close signal, it receives direct feedback, and sets a supply water temperature based on the outdoor reset control.
The hydronic system is quite simple. Jimmy wanted as few moving parts as possible. A single circulator serves the entire system. It pumps directly into and out of the high volume, low pressure drop boiler, and circulates the slab. There are no mixing valves or closely-spaced tees. On a -5°F design day, supply water temperatures reach 100°F. Never more.
Additionally, a Taco 4900 air separator is installed high on the near boiler piping. Though this installation was new, Hirsch finds the slightly wider fitting to fitting width of the 4900 to be a big advantage in replacement situations.
A Taco 4900 air separator is used for air elimination in the radiant system.
“The width of this air separator allows me to cut out most failed separators and install the new one without having to add pipe,” he explained.
Hirsch also installed a 20-gallon Axiom glycol feeder with Hercules antifreeze mixed to provide protection down to 0°F.
Refuge from the cold
“In one respect, this job was no challenge at all,” explained Hirsch. “Jimmy was extremely accommodating. He had prepped and painted the wall behind the boiler, there was ample space to work in, and there were no steps to navigate, no molding to protect, etc. On the other hand, everything outside was covered in ice for the duration of the project, and the job is very remote with no supply houses within an hour-and-a-half. But Jimmy understood all of this and was patient.”
Hirsch explains several of the hydronic system components to Diresta.
Like all the appliances on the property, the new boiler is propane-fired. A master switch in the mechanical space allows Diresta to disconnect the hydronic system and use generator power.
“Ice storms aren’t uncommon here and can disrupt power supply,” said Hirsch. “The boiler draws very little power and the single ECM pump uses just a bit more. Jimmy can run this entire heating system on the smallest emergency generator.”
The boiler install was wrapped up in mid-December, with plenty of heating season left for Jimmy to appreciate the improvement.
“Everyone said I’d be foolish if I didn’t install a radiant system in the shop,” said Diresta. “I was told that it’s the most economical and comfortable option for of heating a big open space like this. Now that it’s operational, I can’t agree more! It’s always comfortable, even if it’s 10°F outside. And that’s what I was looking for, a refuge from the cold.”
“Just like David and Kyle, Moe is a master of his craft,” continued Diresta. “The three of them delivered exactly what I was hoping for, and more. They’ve created a beautiful, useable, comfortable space that has allowed me to expand and diversify my operation here on the farm. In a lot of ways, this is a culmination of a dream for me, and I’m proud of what we’ve all created here.”
A highly efficient, environmentally friendly and safe system should be the outcome of all condensing appliance installations. The system is made up of many components and all must work together to achieve the goal of providing the end user with the best possible system. A high efficiency condensing appliance by itself does not mean a Read more
A highly efficient, environmentally friendly and safe system should be the outcome of all condensing appliance installations. The system is made up of many components and all must work together to achieve the goal of providing the end user with the best possible system. A high efficiency condensing appliance by itself does not mean a highly efficient, environmentally friendly and safe system. The boiler, water heater or furnace must be installed as per manufacturer’s instructions then combustion performance must be tested, and controls properly set for that application. The system, which the appliance is connected to, must also be designed and installed properly. This may consist of proper pipe sizing, pump sizing, duct sizing and other considerations.
All condensing appliances produce condensate. A condensing appliance operating in full condensing mode will produce up to one gallon per hour for every 100,000 BTU/hour of input. This can total over 2,000 gallons of condensate in a heating season. Even more if there is a condensing water heater. This condensate is acidic and will have a pH of somewhere between 1.8 and 4.5. Any condensate below 5 to 5.5 can and will cause damage if not treated before disposal. The actual pH of the condensate from the appliance is dependent on several factors including but not limited to chemical makeup of the gas, proper adjustment of the combustion process and any contaminants in the combustion air.
When condensing boilers and furnaces were first introduced, they were oftentimes replacing old cast iron boilers and atmospheric furnaces that were vented into a chimney. Because the new appliance was direct vented, the old gas fired water heater with the 3” vent was now venting into an 8” plus masonry chimney. And we all know what happened then! That’s right, it rained inside of that chimney. The resulting condensate ate away the mortar, the bricks and the metal vent itself. So new codes were put in place to govern proper chimney venting to prevent damage from acidic condensate. The same acidic condensate that we make with condensing appliances by the way. And what happens?
Non treated condensate will damage and destroy cast iron, galvanized, copper and other types of metallic piping. If it is going into your septic system, then you run the risk of destroying the bacterial environment which is crucial to a properly operating septic system. If you are disposing of it into a public sewer system, then it is contributing to the potential damage and higher maintenance costs to that system including piping and the treatment facilities. If you are disposing of it directly to the ground it will kill plant life in the general area and put acidic liquid into the ground water.
Treating this condensate with a quality condensate neutralizer is an easy and effective way to avoid the above issues. A neutralizer should contain a proven high-quality media to provide effective neutralization. The media should consist of calcium carbonate and magnesium oxide. Marble chips from the big box store are not the answer. These marble chips work for a very short period. The reason for this is that while marble does contain some calcium carbonate, it is also made up of many other minerals which make it harder thereby reducing its neutralizing capacity. You should be able to easily visually inspect the neutralizer to determine if it needs recharging. The neutralizer should be easy to recharge. Most neutralizers should be recharged annually when the appliance receives its annual preventive maintenance service.
Let’s make this necessary accessory a part of every condensing appliance system.
Mike Bernasconi is VP, Technical Operations, Neutrasafe Corporation. For more info, www.neutrasafe.com.
This Northern California plumber’s tenacity matches the company name through hard work, perseverance and a willingness to learn and to keep getting better at her craft. Self-employed and co-owner of Bulldawg Plumbing, Red Bluff, Calif., Laura Nobert’s (@bulldawg_plumbing) real first experience in the trades was working for a few years in general construction with a Read more
This Northern California plumber’s tenacity matches the company name through hard work, perseverance and a willingness to learn and to keep getting better at her craft.
Self-employed and co-owner of Bulldawg Plumbing, Red Bluff, Calif., Laura Nobert’s (@bulldawg_plumbing) real first experience in the trades was working for a few years in general construction with a company that did remodeling in San Francisco. “That job introduced me to power tools, jackhammers, sheetrock, etc. I started as a laborer and grunt and absolutely loved the challenge, and found the work incredibly fulfilling,” says Nobert.
In a yoga-like move, Nobert works to loosen a fitting.
Although Nobert is a first-generation tradesperson, she credits family first. “I had a twin sister who always had my back and supported and encouraged me no matter what my endeavors, successes or setbacks.”
She said it. When asked when was the last time she said she had a great day, she was probably crawling out from under a house.
One such setback—an unfortunate incident a bit later in her foray into the trades—Nobert had an industrial accident where she fell from a significant height and landed directly on her head. “The doctors said it was a miracle I wasn’t dead or paralyzed, but I definitely was injured and was pretty much in bed for three years,” says Nobert.
Shortly after recovering, Nobert made neon signs and worked with hot glass, which was fulfilling, creatively. “But when I got the opportunity to try plumbing, I jumped at the chance, both boots in. Luckily, the idea of learning such a valuable and challenging trade TOTALLY eclipsed my lifelong ‘poop fear.’”
For the past eight years she’s been killing it as a plumber working mainly service work and drain cleaning. “I love the satisfaction that comes from solving a complex mystery or the feeling that comes with overcoming extreme physical challenges to get the job done,” says Nobert.
Yet, being a woman in the trades has its share of funny looks—from others. “When I knock on a door, I almost ALWAYS get met with confused or incredulous looks. Sometimes people blurt out stuff like, ‘Is the real plumber still in the van?’ Or: ‘You’re the WHAT?!’”
A real facet of working in a male-dominated industry, Nobert feels like she is under a higher level of scrutiny than male counterparts. “I’ve noticed that when I work with men, people will automatically talk to them first or make comments like: ‘Oh, is she your sidekick?’ Some will laugh at the idea of me crawling under a house, because they think it’s a joke. Oh, and I worry that if I ever need to find another job, seeing a female name on my resume might keep companies from considering me.”
Being a mentor or trailblazer for other women to follow in the trades, Nobert never really stopped and considered it. But perhaps she is already. “I guess I’m more of a one-on-one kind of person because I usually just focus individually on the people I come in contact with. Like when I work for women who seem interested in the trade/tools/mechanics, I try to explain things, show them how things work, how to do it themselves, etc. More often, I encounter women who are intimidated and scared by the whole process. Often, it’s just because no one has ever explained or showed them how things work, so the topic is just a big, scary mystery. I have a lot of compassion for those women, so I try to help them feel more secure by explaining things—showing them how to shut off water and gas supplies, clean aerators, etc. I always tell them they can call me if they have questions or are nervous about anything.”
And the best advice she can give anyone, “I would tell any person wanting to enter the trades that the desire to learn and the willingness to work hard and not give up are traits that really make a difference.”
That willingness to learn is so critical. “I know that blue collar work used to be kind of an embarrassing career and that tradespeople were considered uneducated but I feel as though shows like Dirty Jobs have really helped to elevate the trades to new levels in the United States. Social media accounts—like Mechanical Hub—are continuing to make great strides in promoting the trades and sharing the knowledge so that important progress continues. I think that encouraging pride and respect for the trades definitely increases its appeal,” says Nobert.
In fact, social media has had a great influence on Nobert (@bulldawg_plumbing). “I am so grateful I found this community on Instagram because it’s made a huge difference in my life and career as a plumber. It’s given me the opportunity to learn so much more than I ever would have without it—seeing what other people achieve inspires me to keep learning and trying to improve my skills and abilities. There are just so many talented tradespeople on Instagram. I love how supportive people are towards each other and how they are willing to share their knowledge so freely. It’s amazing to have a place to share this passion with other people.”
In closing, the last time Nobert said it was a great day? “I was probably crawling out from under a house, hanging out with my daughter, or playing with my son.”
Oh, and the name Bulldawg? “I’ve had two bulldogs in my life; they are an impressive breed. They never give up, even when they are in pain, and I really admire that kind of heart and tenacity,” says Nobert.