Above and Beyond

Debottlenecking Project in Kallo Expands Capacity to Meet Customer Demand

Fri, 13 Aug 2021 04:00:00 +0000

Nominated by: Chris Svoboda, VP, Human Resources and Adam Pingel, Manufacturing

When you’re part of customer’s supply chain, you can only risk disappointing them once. If you can’t keep up, they will find another way to meet their needs – leaving you out.

This was precisely the type of situation the Kallo team wanted to avoid.

For more than 25 years, the site has offered hydrolysis, a unique custom manufacturing technology to customers, enabling them to balance outputs for their molecules and maximize the value of their portfolio. Hydrolyzed molecules offer optimum heat stability and color as per market feedback. The reactor used in the hydrolysis process, R115, originally had a capacity that was much more than what was needed when the equipment was first brought online.

“As business has grown, we saw that overall production capacity had begun to diminish, putting our ability to meet existing customers’ needs at risk,” said Sofie De Moor, Business Development Manager. “At the same time, there has been very strong growth in consumer end-markets and we didn’t want to turn away new customers who were knocking at our door and pass up the opportunity to earn their business.”

Seeing a very strong demand for fatty acids early in the year, the team knew they would need to quickly identify and implement a solution to increase production capacity. Hydrolyzed fatty acids are used in a wide variety of consumer products in markets that are booming, such as household cleaning, personal care and nutrition.

Maarten Mys and Frederik de Troyer are relatively new to the Process Technology department and led the focused improvement program. Both joined Monument about a year ago – but instead of this being a drawback, their ability to provide new perspectives was a benefit to the project, prompting the team to take a step back and question how the whole system had been running.

They began by using a planned shutdown to isolate the reactor and refining columns used to understand which component was slowing the process. After making some urgent repairs needed to R115, capacity was able to be increased. Once the system was brought back online, the team then pushed the operating parameters of the reactor to increase conversion, bringing capacity from 75 MT/day up to 82 MT/day.

Believing that the source of the bottleneck was in the refining columns being used, the team then turned their focus to K106. By temporarily replacing this with the oversized column K112, capacity was expanded to 93 MT/day – and with these tests being done on a live plant, it was imperative that product quality be maintained throughout the process.

Encouraged by these results, the team worked to validate that the new reactor settings would work with the default system that used R115-101-106. These tests have shown to be successful, with capacity of the larger train increasing to 90 MT/day. The improvement program is still ongoing and involves additional process optimizations, modifications, and small investments being made to the primary system. A related improvement project is also in progress on the second, smaller train, with the ultimate goal of reaching capacity of 125 MT/day for both trains.

“This project has been an excellent example of how taking a step back to look at the big picture and testing creative solutions can deliver significant rewards. We can now comfortably meet the needs of existing customers and pursue new business development opportunities,” said Sofie.

Baytown Takes on Supporting Haltermann Solutions’ Refining Capabilities

Tue, 04 May 2021 04:00:00 +0000

As part of the Monument Chemical family, Haltermann Solutions is always looking at the big picture, seeking ways to continuously optimize operations, improve customer service, and pursue growth opportunities.

“Haltermann has been using three different sites for blending, storage and shipping and we’re not as efficient as we should be. We knew that it would make sense from both a financial and resource perspective to consolidate these activities in one location,” said Quinntine Dunford, Director of Manufacturing for Haltermann Solutions.

“We have certain products that can only be blended in Texas, so we kicked off a project in 2019 to find a location that met all of our requirements and evaluated several sites, including those owned by Monument,” he said. “We looked at what it would take to bring the work to each location with the goal of moving all of our activities there and scaling up operations. However, this would require capital investment, and we still needed to be able to blend smaller volumes of test and reference fuels for our automotive customers in the meantime.”

“We decided to move blending operations to Baytown and asked if they would be willing to take on smaller blending projects. The entire team there – especially Kurt Griffith, Site Manager, and Vernon Harris, Operations Manager – has gone ‘Above and Beyond’ for Haltermann Solutions, taking on the work of safely blending our fuels without having all of the permanent equipment and resources in place,” Quinntine said.

William Hairston, Outplant Manager for Haltermann Solutions, was responsible for overseeing consolidating the three sites into one, including moving all of the necessary equipment to Baytown. “Starting up operations was a bit of a challenge at first because we didn’t have all of the preferred equipment needed, and the site hadn’t worked with drums and pails before,” he said. “However, they adapted quickly and have delivered great results. Having crews with operator-level expertise involved – something we didn’t have previously – has been outstanding, because they’re able to blend higher quality, on-spec fuels the first time.”

Congratulations to the Haltermann Solutions and Baytown teams for collaborating on a project that brings new opportunities to both groups!

Improving the Manufacturing Process for DBAPA in Bayport

Wed, 21 Apr 2021 04:00:00 +0000

Taking initiative, thinking proactively, and acting collaboratively as a team are all elements of responsibility, a Monument Behavior. With their dedication to optimizing the production process for dibutylaminopropylamine (DBAPA), a team in Bayport exemplified this behavior and was nominated to be featured here by UmairVirani, Commercial Development Manager.

Used in deep offshore drilling applications, DBAPA is a custom manufacturing product made for Clariant and is a top-tier product when compared to the portfolio.

“The Bayport team has been working with DBAPA for years and knew the manufacturing process could be improved, but we were unable to make any changes because of contract limitations,” said Virani. “When we renegotiated the contract in 2019, we got the green light to make improvements – and more importantly, Monument owns the optimized product, which we can now make and sell to multiple customers.”

So, how was the Bayport team able to optimize the manufacturing process, and what improvements have they seen as a result?

Bobby Rundberg, R&D Chemist, explained, “We started working with DBAPA in 2014 in a batch process. This hydrogenation requires cobalt, which is an expensive catalyst. Cobalt doesn’t have good utilization in batch mode, but as we’ve refined the process over time, we’ve also identified opportunities to optimize the overall catalyst usage. We are now able to produce DBAPA in CSTR (continuous stirred tank reactor) mode, which has resulted in significant improvements in loading and using the catalyst, optimizing the process for a seamless experience.”

“Processing DBAPA in CSTR mode means we’re now able to make 2,520 pounds (1,145 kg) of product an hour, up from 1,100 pounds (499 kg) per hour,” said Romain Vidal-Michel, Campaign Team Leader. “Running the process continuously in CSTR mode is also more efficient, less work for our crews, and safer, because we’re working with smaller quantities of DBAPN feed reacting at any moment in the process. It’s taken years to get where we are, but we’ve been very methodical in our approach and are now able to produce 2 million pounds of high purity material over one single campaign without issues.”

As a result of these process improvements – including the ability to schedule shorter campaign runs – the Bayport site has been able to evaluate other amine projects in the same reactor. Some of these are based on acrylonitrile/cyanoethylation chemistry, one of Bayport’s key capabilities. “Instead of something taking 21 days, we’re now able to make a truckload a day, which opens up our ability to run other projects,” said Dottie Linkugel, Production Scheduler. “We can also scale back on the amount of catalyst used if we need to run a shorter campaign.”

Congratulations to Kris Sturgul, Bayport Site Leader, and the entire team involved, on safely implementing these impressive process improvements and opening up new production opportunities at the site!

Keeping Haltermann Solutions’ Blending Capabilities Running During the Pandemic

Thu, 04 Mar 2021 05:00:00 +0000

When Haltermann Solutions lost blending providers for its test and reference fuels last summer, the team had to quickly react to keep supplying the automotive industry, one of its largest market segments.

What could have been a major setback resulted in an excellent example of why Haltermann Solutions prides itself on the strength and dedication of its team, and its responsibility and commitment to customers.

William Hairston, Outplant Manager, was nominated to be featured here by Don Phillips, Vice President and General Manager of Haltermann Solutions. “William selflessly went ‘Above and Beyond’ to keep us afloat during the COVID-19 Pandemic, taking on the blending of several products himself to ensure these met the precise specifications and high quality standards for which Haltermann Solutions is known,” said Don. “This was particularly critical in the summer months, because the high temperatures can lead to instability of vapor pressure, making the blending process more difficult.”

“William spent several days laboring in the high heat and humidity, and hours shuttling samples to the lab and consulting with our quality folks to get the job done,” added Quinntine Dunford, Director of Manufacturing for Haltermann Solutions. This selfless service and dedication to getting customers products that meet their needs – and on time – embodies the characteristics required of the business to be seen as a consistent, reliable partner.”

Celebrating Yellow Belt Success in Brandenburg

Thu, 04 Mar 2021 05:00:00 +0000

Six Sigma methodology is all about using data to make processes more efficient or economical, which fits right in with Monument always challenging customers and employees to imagine what’s possible. Recently, a Lean Six Sigma Yellow Belt project was completed remotely to optimize the purchase and inventory of raw materials used at the site.

Raw materials buyer Drew Esarey earned his Yellow Belt as a result of his involvement with the project, which began during the pandemic. “After a few late-night phone calls from the plant with concerns about very low product levels, we knew the ordering process could be improved,” he said. “The goal of this project was to minimize or eliminate potential ‘stockouts’ of raw materials on site, specifically Magnesol.”

After gathering six months’ worth of usage data, the team calculated how much Magnesol should be in inventory before being triggered to place the next order based on several factors. “The improvements to our process came from implementing a Kanban system,” Drew explained. “Kanbanis a Japanese word meaning ‘sign board.’ Kanbans are usually cards or other visual cues, and the one we implemented is a piece of neon green card stock placed on a certain numbered pallet of Magnesol.”

By implementing this system, the team expects to have a more efficient ordering process that will also ensure adequate product supply is available on-site at all times.

Looking back on the project, Drew is thankful to have been nominated for the team and the opportunity to further develop his leadership and analytical skills. “My greatest learning was around just how important it is to have good data, especially data that is accurate and unbiased,” he said. “And at the risk of sounding cliché, another thing I learned is that it really does take a team to have a successful project. The team in our Polychem unit, our shipping team, and our Master Black Belt, Kent Steele, all helped throughout the process and their support was invaluable.”

Bicycle Leasing Program in Kallo Increases Employees’ Mobility

Fri, 11 Sep 2020 04:00:00 +0000

Have you ever been stuck in traffic and looked enviously at people quickly passing by on bike?

Biking is a popular way of commuting to work in Belgium, especially around the Antwerp Harbor area, where road construction projects are often underway, and traffic jams are common during peak travel times. Earlier this year, Monument Chemical Kallo introduced a bicycle lease program as part of a plan to increase employees’ mobility – allowing them to combine exercise with a means of traveling to work that has the added benefit of being better for the environment.

“Several companies offer bicycle leasing programs to employees, but Monument has gone ‘Above and Beyond’ by paying a large amount of the monthly lease fee,” said Kim De Wilde, HR Officer in Kallo. “Employees can choose from a wide range of bicycles – such as racing and mountain bikes, as well as speed and electric bikes – with most options being available at no additional cost to employees.”

Most eligible employees have already chosen to take advantage of the leasing program. Feedback from participating employees has been very enthusiastic with comments like the following:

“Introducing the bicycle lease plan will make my life healthier and sportier. After all, instead of driving to work every day by car, I'll take the bike to go to work.”
“I opted for a racing bike as I also regularly cycle team-related in my leisure time.”
“For me, an electric bike was a nice option because the distance for commuting with a normal bike is just a bit too far. So, it looks like I'm going to cycle to work very regularly now.”
“We think this is a very nice gesture and a good investment of Monument Chemical for its employees.”

Many employees in Kallo see the ability to use the leased bicycles for both professional (commuting) and private use as a valuable benefit. In many cases, being able to avoid traffic backups means employees can get to work – and back home – more quickly than if traveling by car!

Kim credits the existing infrastructure in Kallo in encouraging employees to take advantage of the leasing program. “We have changing rooms and showers on-site, so employees can quickly freshen up or change clothes,” she said. “And with electric bikes being a popular choice of employees who have a longer commute, we also plan to install a battery-charging station soon.”

Using Science to Inspire Students

Mon, 20 Jul 2020 04:00:00 +0000

A memorable demonstration – such as smashing hot dogs with a hammer after immersing them in liquid nitrogen – can stick with you for years. This is true for Taylor Huffines, who is always reminded of the freezing properties of liquid nitrogen after seeing this on one of his favorite TV shows as a kid. Now, he’s using this “wow factor” to inspire the next generation of students with science.

“Growing up, I loved watching shows like Bill Nye the Science Guy and Mr. Wizard, and they always had some kind of demonstration to illustrate a scientific principle,” said Taylor, a QC Lab Coordinator at Monument’s Brandenburg site. “I wanted to do something students could follow along with at home before moving to a more advanced concept.”

Taylor recently recorded a video for Meade County’s 4-H Summer Science Enrichment Program, using glow sticks to demonstrate the first law of thermodynamics – which says that matter and energy cannot be created or destroyed, they can only change form. He then provided a more in-depth explanation of how a glow stick works before showing how the chemical energy created by activating the components is converted into light energy. Taylor also used beakers filled with hot water and cold water to illustrate the impact of thermal energy on a light source before creating a life-size glow stick in the lab.

Here is a link to Taylor’s video.

Although this type of demonstration would typically be done in-person, making it available as a video on YouTube means that it can be enjoyed by students beyond just those in the 4-H program. Since the video was posted, Taylor has received a lot of positive feedback from colleagues eager to replicate the demo at home, not to mention his own family. “My kids loved it and my wife shared it on social media,” Taylor said. “Partnering with 4-H to do the video was a great experience, and I’d be happy to be involved with more of their programs.”

Thank you, Taylor, for going “Above & Beyond” to create a memorable demonstration for students – who just might become Monument employees in the future!

Haltermann Team Successfully Changes Course to Focus on Diesel Market

Tue, 30 Jun 2020 04:00:00 +0000

The market for Diesel Specialty Test and Reference fuels isn’t something most people are familiar with, but it represents a significant growth opportunity for Haltermann Solutions.

When new engines are developed, they require extensive testing to be approved by the United States Environmental Protection Agency (EPA). Diesel fuels are used in these tests to evaluate the performance of large engines, such as those used in semis and construction equipment. Manufacturers of engines for semis offer warranties for 750,000 miles or more, so they need to prove that their engines can run in a variety of conditions – an effort requiring millions of gallons of diesel fuel each year.

“The Diesel Specialty Test and Reference fuels market is a substantial piece of business that could double our annual volume,” said Don Phillips, Vice President and General Manager of Haltermann Solutions, in nominating this story. “We’ve wanted to grow in this industry, but the timelines associated with validation testing and industry panel approvals are very lengthy. Because of this, we didn’t anticipate having any sales until at least 2021.”

Watching the global automotive market closely, the Haltermann team was quick to act when they saw a downturn begin last fall as gas consumption also declined. “We recognized these as red flags and were able to pivot and focus on accelerating our diesel strategy to stay ahead of the market,” said Ed Hennessy, Director of Sales for Haltermann. “Our team made the most of existing relationships with the testing labs and other industry connections in the push to become an alternative supplier of test fuels.”

The team’s efforts to demonstrate to test labs that Haltermann has the capabilities, storage capacity, and supply chain to manage the increased demand for diesel fuel is paying off. In late May, Haltermann was officially named as an alternative supplier of Test and Reference fuels. “This is a tremendous accomplishment that took 12 months off the development process,” Ed said. “With this approval in place, we can now begin blending fuels to be analyzed and tested with customers to potentially increase volume before year-end.”

Monument Employee’s Non-Profit Races to Support Its Local Community Amidst Pandemic

Tue, 16 Jun 2020 04:00:00 +0000

Some people like to spend their time outside of work watching TV, traveling, reading. For Ryan Lane, Monument Polychem Operator in Brandenburg, this free time is spent making a difference in communities all over the world. You may recognize his name from one of our past stories, which highlighted how Ryan’s non-profit organization, Global Disaster Outreach (GDO), teamed up with an All-Star Motorsports team to provide hurricane relief efforts in Puerto Rico. (A documentary about these efforts recently aired on ESPN!)

In the wake of the pandemic, GDO was quick to support members of their own community — starting with three major hospitals in Louisville, KY. “We hosted a fundraising event in our area where we matched all donations made by individuals and local businesses,” Ryan explained. “We raised about $10,000 to buy lunches for the frontline workers at UofL Hospital, Mary & Elizabeth Hospital, and Jewish Hospital. With over 2,000 meals as a result, we then went to EMT stations, fire stations, and doctors offices all over Meade County.”

GDO also hosted a lunch program for students, allowing them and their families to come out to enjoy a free meal with the organization’s members, while other funds provided kids with backpacks and supplies they need for school in the fall.

The organization’s current endeavor has the aim of becoming an annual tradition - which shouldn’t be a problem, since just two weeks into fundraising (at the time this article was written), Ryan and his team have already raised about $12,000 of the organization’s $15,000 goal. So what’s the event? A Rubber Ducky Derby!

“We’ve already sold about 1,400 of these little ducks,” Ryan explained. “We’ve had so many businesses who want to sponsor the event in different ways,from banners to t-shirts. More than half of them actually reached out to us to join the effort.” And who can blame them? The event will not only feature rubber ducks racing down the river, but also various local first responders and their vehicles, Food Trucks, and a Car Cruise to make a full day of it.

In addition to cool prize money, part of the funds will also be used to install big flat screen TV’s and iPads at the local nursing and assisted living homes, so the residents can FaceTime their families from all over.

The rest will go toward supporting a lot more GDO efforts throughout the year. “We are hoping this fun annual event will help us throughout the whole year, so we can continue to do even more for our local community.”

Quality Certification Renewed for Brandenburg and Kallo/Belgium

Mon, 08 Jun 2020 04:00:00 +0000

When Monument Chemical promises our customers that we will consistently meet their expectations for quality products and service, we prove it through our daily actions, as well as through our continued ISO 9001:2015 Quality Management System certification.

Each year, our facilities undergo an audit to make sure we are meeting ISO 9001:2015 requirements. This year, both the Brandenburg and Kallo site teams successfully completed this review, despite the challenges of being in the middle of a pandemic shut-down. The effort involves compiling documentation of objectives, roles and responsibilities, policies, procedures, and more. Then, team members from throughout our facilities are interviewed to confirm compliance.

“It’s a year-long process that culminates in meetings with the auditors,” said Leen Props, Quality Assurance Coordinator, for the Kallo site. “This year, we had to do these sessions remotely. We used Microsoft Teams to conduct interviews over four days in mid-April, during the height of the Coronavirus/COVID-19 pandemic restrictions. As a result, the auditor got a good picture of our company’s working methods.”

Brandenburg’s review was conducted around the same time and also done remotely, reported Bonnie Heffernan, Quality Manager for the Kentucky site.

“Maintaining ISO certification is so much more than what is traditionally considered ‘quality,’” she said. “Yes, product quality and quality control [QC] lab functions are essential to the program, but the ISO standard is really focused on a company’s ability to sustainably meet the needs of the markets it serves. This is the purpose of our Quality Management System. For the system to be successful, every individual and functional group across the site must remain engaged in the process.

“The auditor closed the audit, recommending that our certification be continued while citing NO findings and NO opportunities for improvement – a big win,” Bonnie added. “Building a cooperative relationship with our auditors and QSR, the certification body, is a key component of our audit success. This is always true, and it was even more important this year, as we are working under less than ideal circumstances to debut the ‘remote’ audit format.”

Although no findings were listed, the Monument team always takes note of any best practices or ideas for improvement that the auditors provide during the interviews. “It’s important to always look for ways the program and processes can be improved to support the continued success of our business,” she said.

Leen added: “This is a great example of what Monument chemical stands for: being very flexible and adaptable to new situations and always looking for a solution when faced with a new challenge.”