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Innovative Systems and Processes Lower Emissions Efficiently at Best Access Systems
Security is the watchword at Best Access Systems (BAS), headquartered in Indianapolis, IN. Formerly known as Best Lock, BAS is one of the world’s largest providers of access control systems and security hardware for industrial, institutional, commercial, and government facilities. The company has pioneered new and improved products and services to provide customers with practical innovations for their business.Joining the Strategic Goals Program (SGP) was a natural step for BAS, a company with sales of nearly $200 million, and more than 1,600 employees. The SGP advocates the type of progressive agenda that BAS has been practicing for years. One of the best outcomes of participating in the SGP has been the bringing together of state (Indiana Dept. of Environmental Management [IDEM]), local Publicly Owned Treatment Works (POTW), industry (metal finishers), academia (the Clean Manufacturing Technology and Safe Materials Institute [CMTI] through Purdue University), and special interest individuals to work to achieve the goal of finding cleaner, cheaper, and smarter ways to improve the environmental performance of metal finishers. This alliance has improved communications among all parties involved and likewise increased the knowledge of each party as to how the others function and best practices that they can implement. For example, the CMTI recently presented a free on-site drag out seminar for BAS employees and invitees from other companies, which was very effective in demonstrating drag out reduction.
Committed to operating more efficiently both for the environment and the bottom line, BAS has implemented new operating processes in the initial design stage that will eliminate the use of toxic chemicals. For example, in 1988, cadmium and cyanide were eliminated from operations, eliminating 114 pounds of waste. In 1989, the company implemented a Nickel Recovery System (see diagram) to reuse nickel-plating solutions lost to drag out and tank over filling, reducing the sludge’s nickel content by 85% while their production usage of nickel doubled. Unique to the recovery system is a process where nickel rinse water is pumped to a separate holding container, heated and evaporated to become more concentrated, and then added to the plating bath to replace evaporative losses. The heated water prevents downtime, especially during morning start-up. In 1995, they stopped the usage of Perchloroethylene, eliminating 83,819 pounds of air emissions and 38,000 pounds of waste. Switching from “perc” to an aqueous solution to clean parts was not easy, given the small size of some components. BAS invented new techniques using centrifugation to overcome this.
Water savings have also been substantial, with 3.2 million less gallons used and 3.7 million less gallons discharged (a 60% decrease), through the use of flow restrictors, automatic bath solution leveling systems and the new nickel recovery system. Sludge production has dropped by 30%. Emissions have been reduced by 78%.
For its efforts, Best Access Systems has received numerous awards including the Indiana Manufacturers Association Environmental Stewardship Award, and the Governor’s Award for Excellence in Pollution Prevention. They are currently participating in the IDEM Partners for Pollution Pledge and Governor’s Toxic Reduction Challenge. With their pro-active approach, it is a secure bet they will continue to excel in the business world and the Strategic Goals Program.