MasterMold, LLC makes component parts for manufacturers of recreational vehicles, utility equipment, and agricultural equipment who use the components in their end products. Because of the wide variety of industries and customers it serves, MasterMold must be poised to respond to its customers’ growth by increasing production levels on demand.
Executive Vice President Jon Butts manages environmental compliance at three production facilities. “Environmental management is just one of the many hats I wear,” says Butts. MasterMold has multiple environmental needs. Permitting is high on Butts’ list, and so is passing routine inspections.
To help MasterMold meet its environmental compliance needs, the SCS Engineers team assessed the company’s air permitting needs with an eye toward future increases in customer demand. The team helped turn around a permit application quickly so MasterMold could continue to meet its customers’ production expectations without interruption and remain compliant with environmental rules and regulations. Butts stated:
Then SCS Engineers helped me collect and organize data for emission calculations in one place. They created an easy-to-use tool that my staff updates monthly so we’re prepared for an on-site inspection anytime. I can demonstrate compliance, pass inspections quickly, and get back to focusing on my customers.
Butts got the opportunity to test the new tool during the company’s latest inspections. MasterMold has undergone routine inspections by the Wisconsin Department of Natural Resources (WDNR) and the U.S. Environmental Protection Agency (USEPA). Both agencies checked the company’s compliance status with its air permit at its largest plants. “I had everything organized right at my fingertips,” Butts says. “I was ready for the inspections. I now know exactly where all of our emissions come from and exactly how they change over time.”
Thanks to the tool SCS Engineers helped me build, MasterMold passed its latest inspections in just a few hours with no citations. I’m confident I will pass on-site inspections and gain and grow inspectors’ trust in MasterMold’s business practices. Now I’m in a position to influence the process, take proactive steps, and partner with my inspector instead of responding reactively.
—Jon Butts, Executive Vice President, MasterMold, LLC | Johnson Creek, WI
SCS Engineers met a tight, non-negotiable regulatory deadline to get the new plant on-line while meeting non-toxic effluent standards.
Everyone enjoys before and after pictures; just look at the results New Hanover County’s program is producing. This and other County programs are helping this North Carolina county reduce reliance on landfill disposal while creating a comprehensive and sustainable solid waste management system that is protective of the environment.
In 2016 a new wastewater treatment plant was commissioned at the New Hanover County Landfill. The new facility processes approximately 65,000 gallons per day (GPD) of leachate using state-of-the-art ultrafiltration (UF) and reverse osmosis (RO) technologies to meet or exceed federal and state treatment standards.
The raw leachate is pre-treated in an existing aerobic lagoon followed by a sequencing batch reactor (SBR) to reduce organic constituents. The pretreated effluent then flows into the membrane system. Using state-of-the-art membrane filtration technology, including ultrafiltration (UF) pictured at lower left, and a reverse osmosis (RO) system, pictured lower right, to produce crystal clear, effluent discharged to an upper tributary of the Cape Fear River.
The new facility can process 75,000 GPD and the Wastewater treated through the new system meets state Drinking Water standards for quality.
Tough surface water discharge standards and predictable performance in cold weather drove the design to use UF/RO systems. The results are impressive; metals including arsenic are BDL, ammonia <0.2 ppm, and TSS < 2 ppm. The system produces approximately 13,000 GPD of RO concentrate that is pumped to the working face and safely disposed of in the landfill. The County has certified operators that have played a big role in getting the plant shaken down and running smoothly.
“New Hanover County is an industry leader in adopting proven technologies to better manage solid waste, and protect the environment. This kind of planning and approach can benefit many other public works departments,” stated Bruce Clark, PE, BCES, LEED AP®, and SCS Engineers National Expert on Waste Conversion.
As Joe Suleyman, the County’s Environmental Management Director put it, “Let’s face it – people move to New Hanover County because they love to be in, on, or near the water. Our technical staff is composed of very talented folks who have environmental science and biology backgrounds. They believe in what they’re doing to help protect our delicate coastal environment, and this state-of-the-art system is a huge stride towards meeting our own expectations and those of the citizens we serve.”
See more case studies, services, and professionals on the SCS Engineers – Liquids Management Website