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Before

“We started to have discussions on bringing all things associated with emissions - Stack Testing, Reporting Services and StackVision with Fortress-level Protection - under one umbrella so to speak and save some money by bundling all those services together for our two facilities.”

After

“We always thought it to be beneficial to have the builders be the testers/maintenance folks also. Who better to work on the equipment, other than the people that built the system?”

Owens-Illinois, a Fortune 500 company, is the world’s leading glass bottle manufacturer.  O-I, its affiliate, and its licensees manufacture approximately one of every two glass containers worldwide. The company’s fleet includes 81 glass manufacturing plants in 21 countries.

ESC Spectrum serves all 15 United States-based Owens-Illinois plants listed below. Two of the facilities – Crenshaw and Brockway – use ESC Spectrum’s full suite of solutions.
  • Waco
  • Tracy
  • Auburn
  • Brockway
  • Toano
  • Lapel
  • Crenshaw
  • Muskogee
  • Los Angeles
  • Streator
  • Portland
  • Danville
  • Windsor
  • Atlanta
  • Zanesville

Overview

The Crenshaw and Brockway plants use ESC Spectrum’s full suite of air emissions compliance solutions, from software and hardware products to Coninuous Emissions Monitoring System (CEMS) shelters to Data Acqusition System (DAS) and CEMS services. The facilities employ the user-configurable, industry-leading StackVision™ Data Acquisition System, paired with 8864 Data Controllers, to meet the monitoring and reporting requirements of the US Environmental Protection Agency (EPA) and state regulators. 

ESC Spectrum’s DASProtect Fortress maintenance and support services ensure StackVision runs efficiently, and the Reporting team supports data review and report preparation activities. O-I employs CEMS shelters, CEMS testing, and maintenance services that ensure their facilities are in good shape.

Challeges

  • Increased Need for Cost Savings and Efficiency
  • Lack of Proficient CEMS Technicians
  • Tight Training Budgets
  • Burden on Environmental Managers to Understand Both Regulations and Compliance Systems
  • Evolving Regulations

Solution

John DeSantis, Environmental Manager of the Crenshaw and Brockway facilities, has worked for O-I for 36 years in various roles. He is responsible for the implementation, maintenance, and oversight of plant Environmental Management Systems. He ensures the facilities are compliant with regulatory standards and are good neighbors within their communities.

When DeSantis started in his current position in 2015, both plants were already using some ESC Spectrum solutions. To solve some of the additional challenges the facilities were facing, O-I expanded their adoption of ESC Spectrum’s products and services during his tenure. 

Over the years, DeSantis’ position changed drastically. “The job morphed from me being responsible for making sure the Responsible Official would be a signatory and then placing regulatory reports in the mail for submittal to having the responsibility of completing all reporting. Then to completing proper, timely submittals along with the responsibilities of stormwater/water permits, waste reduction, and reporting, Title V Permit/Consent Decree compliance and reporting.” DeSantis was held accountable for an ever-increasing array of compliance and reporting activities, with little extra time or staff to complete them. 

DeSantis used the services of other vendors for stack testing and reporting before moving to ESC Spectrum. However, the merger of ESC and Spectrum in 2018 brought two much-needed services under one roof: “We started to have discussions on bringing all things associated with emissions - Stack Testing, Reporting Services and StackVision with Fortress-level Protection - under one umbrella so to speak and save some money by bundling all those services together for our two facilities.” Using ESC Spectrum’s Reporting services team, O-I was able to save money and increase efficiency by using a dedicated reporting team well-versed in regulatory requirements and StackVision DAS. “It was important to me to have that expert ‘safety net’ that not only knows the regulations but also the system we use to comply with the regulations,” explained DeSantis.

The CEMS team created shelters for both plants, including robust instrument air systems, M&C dilution sample probes, Thermo Fisher analyzers, temperature and flow control systems, spare parts, and quarterly field services. “We originally had an Opacity monitor with a logger, and it was placed next to the stack it was monitoring. Out of a Consent Decree handed down by DOJ to O-I, NOx monitoring would need also to take place. Therefore, we decided to house all emission equipment within the CEMS shelter and implemented that during a furnace repair around 2011.”  ESC Spectrum built the shelter, and a smooth implementation followed. “Once the shelter was built, outfitted, and delivered, ESC Spectrum provided an engineer and two technicians, and the shelter equipment install was a smooth process,” said DeSantis.

According to DeSantis, choosing ESC Spectrum’s CEMS testing and maintenance services was easy: “We always thought it to be beneficial to have the builders be the testers/maintenance folks also. Who better to work on the equipment, other than the people that built the system?”

Overall, the benefits to using ESC Spectrum’s products and services provided positive results, from lower costs to passing on industry knowledge, streamlining processes, and ongoing support, training, and networking with other customers. Would DeSantis recommend ESC Spectrum to his peers? “Absolutely,” he stated.
 

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    Published: 2/12/2021 10:56:11 AM

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