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Understanding the Total Systems Approach to Chemical Supply

<p>Total Systems Approach is a core concept for Americo Chemical. Total Systems Approach, or TSA, informs each of our products and services. It’s how we generate value for each client—above and beyond the value offered by most chemical suppliers.</p>
<p>Total Systems Approach is a framework used in many industries to optimize performance. Let’s break it down.</p>
<ul>
<li>TSA takes a wide view of the challenge. Instead of focusing exclusively on the immediate problem, a Total Systems Approach analyzes each step that comes before and after a problem.</li>
<li>Industrial processes tend to be complex with many factors impacting performance. A Total Systems Approach to problem-solving investigates interactions within a system or process, identifying not just the ‘<em>what’</em> but the ‘<em>hows’</em> and ‘<em>whys’</em> that result in a given outcome.</li>
<li>Total Systems Approach is not a solution itself. It’s a framework for solving process problems with an emphasis on value delivery. We use a Total Systems Approach as a lens to view industrial challenges in order to find creative and effective improvements.</li>
</ul>
<h2>A Collaborative &amp; Integrated Approach to Process Optimization</h2>
<p>One of the core concepts of TSA is the “un-siloing” of people and information. In many organizations, departments work in isolation from each other. Purchasers and supply chain analysts rarely engage with production or operations teams, for example.</p>
<p>In many ways, these siloes are efficient. Everyone can “stay in their lane” and keep working toward their team’s goals. The downside becomes apparent when process improvements are required.</p>
<p>Changing a manufacturing process has far-reaching implications. It’s not just the operators that are affected. Purchasers, warehousing teams, managers, and executives may all have different points of view on what value generation looks like.</p>
<p>Total Systems Approach attempts to capture feedback from stakeholders in every affected department, making the complete picture visible to everyone involved. This is crucial for sustainable value generation. Affecting change across an organization involves stakeholder buy-in at every level. Without breaking down silos to create consensus, change management and process optimization are unlikely to stick.</p>
<h2>Emphasis on Continual Improvement</h2>
<p>A core concept of Total Systems Approach is continual improvement. The course set by TSA is never fixed. Optimization is a variable process—a meandering path rather than a straight line. A Total Systems Approach focuses on iteration and experimentation.</p>
<p>Iterative improvements help turn what can be large and disruptive changes into smaller and more manageable units. It also allows for a feedback cycle of optimization. Once one improvement has been implemented and proven successful, TSA encourages operators to begin the process anew. The result is a phased series of improvements, building upon insights and data collected from each previous integration.</p>
<h2>Delivery of Long-Term Value</h2>
<p>Rather than providing short-term fixes, a Total Systems Approach emphasizes long-term value delivery. The TSA process emphasizes sustainability of change. Improvements must be resilient. Consider the classic fable of the Tortoise and the Hare. Sometimes a quick fix can offer immediate cost savings while delivering less long-term value. For example, cutting production costs by switching to a cheaper material may improve margins in the short term, but runs the risk of impacting quality and brand reputation over the long run. TSA “wins the race” by delivering efficiency gains that will continue to deliver value for years to come.</p>
<h2>Data-driven decision-making</h2>
<p>A Total Systems Approach is evidence based. Testing and data collection are integral to the process. TSA implementors may seek out both qualitative and quantitative data including insights from equipment operators, readings from industrial sensors, and manual tracking of processes and outcomes to evaluate quality and value delivered.</p>
<p>This data gets combined, analyzed, and incorporated into a findings report that proves how the value generation plan will overcome operational challenges.</p>
<h2>Examples of Total Systems Approach in Action</h2>
<p>You may be wondering what Total Systems Approach looks like in practice. Let’s explore some hypothetical examples pertinent to chemical supply and metal fabrication.</p>
<h3>Manufacturing Process</h3>
<p>Your business fabricates and sells wear parts for heavy equipment. This involves shaping 400 series stainless steel. The exceptional hardness of this material poses a production challenge as it rapidly wears out cutting edges. This means higher production costs and reduced productivity due to frequent tool replacement.</p>
<p>You engage Americo Chemical to provide a value generation plan using a Total Systems Approach. They work with your team to inspect equipment, understand your process, and evaluate weak points in your system. Through operator interviews and data collection, Americo Chemical notes that your generic metalworking fluid lacks coolant and protectant properties that might reduce tool wear.</p>
<p>Our expert formulators produce a custom-blended metalworking fluid designed for your specific system. The fluid offers measurable improvements to cooling and tool lifespan. While the initial cost of the custom fluid is higher than a generic solution, the increase in productivity from reduced tool wear—necessitating fewer equipment maintenance hours each week—more than compensates for the added cost.</p>
<h3>Wastewater Management</h3>
<p>Your fabrication process relies on a closed loop irrigation system to clear shavings and debris from the cutting surface. Using a closed loop systems reduces the frequency of wastewater disposal, but it’s causing problems. As the water becomes polluted with metal shavings, metalworking oils, and other debris, it risks damaging pipes and clogging filters in your system.</p>
<p>Additionally, the process water’s composition is complex and particularly dirty. Disposal proves increasingly expensive as environmental regulations tighten. The tank gets flushed and refilled each week. Time spent flushing and refilling adds up, contributing to a full shift of lost productive time each month.</p>
<p>After meeting with your team, Americo Chemical installs sensors in your equipment to track flow rate, contamination, and debris accumulation. After collecting enough data, they propose a plan to pre-treat your process water. Adding a flocculant reduces free-floating debris that can damage pipes and filters. Instead, the debris clumps together in the primary reservoir, simplifying wastewater processing. Other additives help neutralize metalworking fluid contaminants and balance pH. Americo Chemical trains your operators to handle each of these additives, ensuring safe and effective usage.</p>
<p>As a result of these additives, tank flushing may be delayed to every second week without risking damage to equipment. Disposal costs also drop as the wastewater’s complexity is reduced. Your facility’s productivity improves by several hours per month. Profitability improves as wastewater disposal costs decrease.</p>
<p>Americo continues to monitor your equipment with its sensors, adjusting the formulation to provide better performance over time.</p>
<h2>Quality Management &amp; Total Systems Approach</h2>
<p>Quality management is closely related to Total Systems Approach. Quality management focuses on delivering better products and services through improved processes, much like TSA. Better products demand higher price points and grow brand awareness and reputation. These are long-term drivers of growth and profitability.</p>
<p>Americo Chemical is proud of its ISO 9001:2015 certification, indicating the highest standard of quality management expertise. Through our extensive experience in both quality management and Total Systems Approach, we deliver value to each and every client in a way most chemical suppliers simply can’t.</p>
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Total Systems Approach: A Value Driven Problem-Solving Framework

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Innovations in Wastewater Treatment Chemicals

<p>Humanity’s first environmental disaster came as a result of improper water management.</p>
<p>The first large-scale cities emerged in the Middle East along the so-called fertile crescent. This region provided ample space for farming, supported with irrigation ditches pulling water from the Tigris and Euphrates rivers.</p>
<p>Unbeknownst to early farmers, the river water was slightly saline. Over generations, dissolved salts in the water accumulated in the soil. This resulted in declining crop yields culminating in ecosystem collapse. The region’s capacity for farming remains impacted to this day.</p>
<p>The importance of wastewater management may not have been clear to farmers circa 10,000 BC, but it’s certainly appreciated by manufacturers today. Wastewater management has ethical and economic implications for businesses around the world. As legislation around water use and pollution continues to grow in scale and scope, the importance of proper management continues to increase.</p>
<p>Let’s look at the wastewater treatment industry: its history, current regulatory context, and technologies employed both past and present.</p>
<h2>The History of Wastewater Management</h2>
<p>Wastewater management as a discipline began thousands of years ago, almost as long ago as the aforementioned Fertile Crescent societies themselves. Examples of drainage ditches and aqueducts throughout the ancient world demonstrate a recognized need to keep “good water” separated from sources of contamination.</p>
<p>We have to jump forward to the Renaissance before we see more familiar industrialized wastewater management begin to emerge. In the early 17th century, alum production began to ramp up in England. Primarily valued as a dye fixer in the textile industry, alum was a valued resource since antiquity. When shale deposits likely to contain alum were discovered on the British Isles, England imported skilled Italian alum producers to kickstart its industry.</p>
<p>To extract alum from shale, the shale ore must be pre-treated then soaked in water. Water acts as a solvent for alum, which is then purified into a solid salt through evaporation.</p>
<p>Therefore, much of the wastewater generated by the extraction process evaporated into the air—a convenient method for disposal to be sure! The remaining wastewater, often in the form of ore-contaminated sludge, was dumped unceremoniously into nearby rivers.</p>
<h3>Wastewater management in the industrial age</h3>
<p>Wastewater management in 17th century England was almost as crude as techniques employed in ancient Rome. By the 18th century, the Industrial Revolution and its industrial-scale waste problems necessitated innovation.</p>
<p>Wastewater generated from processes like coal mining is far more damaging than that from historic industries like alum production. The 18th and 19th century demonstrated the toll of unregulated industry on the environment as ecosystems rapidly degraded in the face of unfettered pollution. However, with these environmental challenges came meaningful change. The Industrial Revolution ushered in the first chemical treatments of wastewater. Highly basic chemicals like lime would be used to neutralize acidic water before disposal. Bioreactive wastewater treatments like anaerobic digestion helped improve sewer and septic management. By the end of the 19th century, chlorination was increasingly common. The Industrial Revolution set the stage for today’s technological and legislative contexts in wastewater management.</p>
<h2>History of American Wastewater Legislation</h2>
<p>Though a patchwork of toothless regional pollution and water conservation laws existed in America from the late 19th century, it would take until the mid-20th century for a more comprehensive legal framework to emerge.</p>
<p>The Federal Water Pollution Control Act was tabled and passed in 1948. This legislation focused more on research and funding than enforcement.</p>
<p>In 1972, the Clean Water Act superseded the Water Pollution Control Act. The Clean Water Act was both more comprehensive and more focused on enforcement. It introduced a permitting structure for polluters, introduced fines and enforcement measures for violators, and regulated the discharge of pollutants into bodies of water.</p>
<p>The Clean Water Act received two amendments in 1987 and 1990 respectively. The 1987 amendment required states to develop their own water quality management plans. It also attempted to tackle pollution from diffuse sources like urban runoff and agricultural waste.</p>
<p>In 1990, the Act was expanded further with additional enforcement mechanisms and a broader general scope.</p>
<h3>State and local legislation</h3>
<p>Federal legislation is only one piece of the complex puzzle that is water pollution law. States have broad power to enforce their own environmental policies. Some municipalities have even more stringent regulations on top of both state and federal guidelines. This patchwork of regulation spanning all levels of government makes wastewater management complex and often costly.</p>
<p>The stringency of wastewater legislation varies widely by jurisdiction. As a general trend, states with highly industrial or natural resource-based economies have looser water laws, while highly service-based states like California and New York have particularly challenging laws.</p>
<h2>Innovations in wastewater treatment</h2>
<p>Today’s wastewater management techniques extend far beyond the rudimentary technology of yesteryear. Wastewater processing techniques are more effective, efficient, and safer than ever before. Here are a few of the top innovations affecting today’s water management industry.</p>
<h3>Smart Sensors and Controls</h3>
<p>Smart sensors affect nearly every industrial process today, Wastewater is no exception. One aspect of wastewater management is continual monitoring and testing. In many cases, this is still a manual process to be scheduled and conducted by operators periodically.</p>
<p>With the advent of smart sensors and controls, this process may be automated in many cases. Smart sensors can automatically collect data on things like flow rate, turbidity, temperature, and even levels of particular pollutants like heavy metals. This data can be broadcast in real time to provide operators with up-to-date information.</p>
<p>Smart controls can take automation a step further. They are capable of making adjustments to flow rate, increasing or decreasing chemical dosing, or turning on or off filters, aerators, and other equipment as needed based on live sensor data.</p>
<p>A fully “smart” wastewater management solution can allow your operators to focus their full attention on production, eliminating costly maintenance time.</p>
<h3>Advanced Oxidation Processes</h3>
<p>First developed in the 80s, advanced oxidation processes (AOPS) are chemical procedures that use reactive hydroxyl radicals to fragment complex organic pollutants into simpler, easier-to-manage molecules.</p>
<p>AOPs rely on oxidants like ozone or hydrogen peroxide to function. When dosed with the right combination or sequence of oxidizing reagents, powerful hydroxyl radicals form in the wastewater. These bind aggressively with most organic and some inorganic chemicals to produce simpler, less polluting compounds. This technique is extremely efficient at reducing the complexity (therefore, the disposal cost) of wastewater. However, it may prohibitively expensive when dealing with large quantities of wastewater. Ongoing research and development have resulted in more cost-effective solutions. Indeed, today’s AOPs are more efficient and effective than ever. As this technology continues to develop, it’s sure to remain an important option for waste management.</p>
<h3>Green and Biodegradable Process Chemicals</h3>
<p>In some cases, wastewater management involves trading a toxic pollutant for a less toxic option. While there’s a net improvement to water quality, if the process chemical itself is dirty, it limits its efficacy.</p>
<p>Cleaner, greener, biodegradable chemicals can simplify multi-stage waste processes. Take chelating agents for example. A conventional chelating agent is effective at neutralizing metal ions, but may persist in the environment for generations. Their long-term effects on wildlife and the environment are under scrutiny. In many cases, the chelating agent itself must be degraded or neutralized with an additional process.</p>
<p>A biodegradable solution reduces concerns about environmental persistence. Depending on your local regulatory environment, biodegradable chelating agents can hasten disposal processes and lower disposal fees.</p>
<h2>The future of wastewater management</h2>
<p>Wastewater management technology continues to change and improve. There are many exciting ways that the industry continues to innovate. Here are a few of the top ways that chemical wastewater management is expected to change over the coming decades.</p>
<h3><strong>Resource Recovery and Circular Economy</strong></h3>
<p>It’s not always the case that wastewater must be disposed of wholesale. In many cases, the pollutants or contaminants present in wastewater have other potential applications. Consider wastewater runoff from agriculture, which has degraded water quality in streams and rivers due to residual fertilizers and soil nutrients.</p>
<p>What if that fertilizer and nutrition could be captured instead of wasted? This recovery-focused model of wastewater management is an emerging science supported by general technological advancement in the field.</p>
<p>Manufacturers are familiar with closed loop processes. The idea of recovery-focused waste management uses the same concept. Whether through physical or chemical separation and extraction, expect more and more wastewater processes to re-use or repurpose “waste” materials.</p>
<h3><strong>Advanced Membrane Technologies</strong></h3>
<p>The use of specialized membranes to filter and treat wastewater is nothing new. The issue with membrane-based management has often been cost. Traditional manufacturing processes for advanced membranes have proven slow and costly. Advancements in 3D printing are enabling more rapid and cost-effective production, while also opening up opportunities for superior performance. 3D printing allows manufacturers to produce highly specialized membranes with unique pore structures. This custom approach to membrane manufacturing may be a major breakthrough in wastewater filtration.</p>
<h3><strong>Artificial Intelligence and Machine Learning</strong></h3>
<p>The list of fields that won’t be impacted by AI is far shorter than the list of those that will. Wastewater management is very much on that list of impacted fields.</p>
<p>Even so-called “smart sensors” aren’t that bright yet. They can be configured to respond to specific process conditions like temperature, flow rate, or concentration of debris. What they cannot do is adjust their own parameters to continually improve performance.</p>
<p>As facilities become steadily “smarter,” the capacity to not only collect but analyze and apply insights from data will become more prevalent across the manufacturing sector. Imagine sensors that can calibrate chemical dosing down to the millilitre based on the precise complexion of the water to be treated—all without operator intervention. The outcome may be a significant reduction in chemicals used, as well as more consistent output from your wastewater process.</p>
<p>This is just one way that AI and machine learning may impact wastewater management in the years to come.</p>
<h2>Conclusion</h2>
<p>Wastewater management has come a long way since the early days of agriculture. In fact, it’s come a long way since the ‘90s! As both environmental regulations and wastewater management technologies continue to develop, watch for exciting advancements in the industry. Staying on top of wastewater management can help you stay ahead of increasingly aggressive management and disposal requirements.</p>
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Custom Chemical Blends: Tailoring Solutions to Industry Needs

<p>Many manufacturers who choose to use commodity chemicals for their process will cite cost as the primary reason: common chemical blends are cheaper than custom solutions.</p>
<p>If you asked our customers, many would say they choose custom chemicals for the same reason: cost!</p>
<p>While the up-front cost of investigating a facility, identifying a solution, and producing a custom solution is indeed more expensive than using a generic solution, the long-term view is quite different. Custom chemicals are a proven and effective way to improve manufacturing efficiency and product quality—two factors that directly impact margins.</p>
<p>Even two facilities running identical equipment will have specific needs that custom chemicals can address. Perhaps one facility’s equipment has more wear and tear as they keep their line running longer. Maybe each facility machines slightly different grades of steel. Factors like ambient temperature and altitude can have subtle effects on manufacturing processes.</p>
<p>Custom chemicals can address and account for each of these minor differences. Benefits may be immediate or long-term: reduced operating costs, increased equipment longevity, or even improved product quality.</p>
<h2>How Americo approaches custom chemistry</h2>
<p>Americo believes in the power of quality management to enhance processes and improve ROI. As an ISO 9001:2015 certified company, we specialize in quality management and process engineering. By improving product quality, our clients have an opportunity to grow and improve their brand reputation and awareness. They may be able to raise prices and improve margins, competing on quality rather than struggling in a price-based, commodified race to the bottom.</p>
<p>It&#8217;s part of what we call a Total Systems Approach to chemistry. Total Systems Approach involves research and analysis to uncover unexpected sources of value. It&#8217;s a repeatable process we employ to affect long-term positive change for manufacturers of all kinds.</p>
<p>For example, a Total Systems Approach may involve installing sensors to monitor particular attributes and outcomes during your manufacturing process. Data from the sensors combined with information provided by operators and our own professional analysis will inform which additives and adjustments will make your chemicals more effective. Perhaps overheating during the cutting process wears down tools too quickly. Additives with cooling and hardening properties may improve the longevity of tools and equipment, resulting in lower maintenance costs.</p>
<h2>Common additives for manufacturing chemicals</h2>
<p>There are many additives used in manufacturing chemistry. Let&#8217;s look at some of the most common types of additives and how they can benefit your process.</p>
<h3>Metalworking fluids</h3>
<ul>
<li><strong>Corrosion inhibitors</strong> like borates and phosphates prevent rust and corrosion. These can protect your equipment or workpieces, reducing costs and product quality.</li>
<li><strong>Biocides</strong> prevent the growth of harmful bacteria, fungi, and other organisms in fluids. This extends the usable lifespan of fluids while reducing odor and protecting workers from potential health concerns.</li>
<li><strong>Anti-foaming agents</strong> reduce the formation of foam and bubbles. Foaming can reduce the effectiveness and coverage of fluids as well as cause equipment issues and cleanup challenges.</li>
<li><strong>Cooling agents</strong> can prevent overheating issues and increase the longevity of cutting tools.</li>
</ul>
<h3><strong>Metal Coatings</strong></h3>
<ul>
<li><strong>UV stabilizers and absorbers</strong> protect the coating from degradation due to ultraviolet light exposure, extending the life of the coating.</li>
<li><strong>Anti-corrosive agents</strong> like zinc phosphate and chromates are used to protect the metal substrate from corrosion.</li>
<li><strong>Hardening agents</strong> such as crosslinkers react with the polymer matrix to form a harder, more durable coating.</li>
<li><strong>Plasticizers </strong>are added to increase the flexibility of the coating, reducing the risk of cracking or peeling.</li>
<li><strong>Pigments and dyes </strong>provide color and other properties such as corrosion inhibition or light reflection.</li>
</ul>
<h3><strong>Process Water Solutions</strong></h3>
<ul>
<li><strong>Scale Inhibitors</strong> like phosphonates prevent the formation of scale, which can clog pipes and reduce heat exchange efficiency.</li>
<li><strong>Antimicrobials </strong>control microbial growth in the water, which can lead to biofouling and degradation of water quality.</li>
<li><strong>Flocculants and Coagulants </strong>are used to aggregate suspended solids for easier removal from wastewater.</li>
<li><strong>pH Adjusters </strong>maintain the optimal pH level for the process, ensuring the stability of the water solution and preventing corrosion or scaling.</li>
</ul>
<h2> Your Partner in Custom Chemistry</h2>
<p>Our commitment to quality and deep experience in manufacturing processes throughout the United States make us an ideal partner for your chemical supply needs. Our blending facility is ready to take your order! Whether you need general chemical supply, toll blending of an existing custom solution, or quality management and process chemical engineering, we&#8217;re available to help.</p>
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Why Custom? How Custom Chemicals Save You Money

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<p>Value-focused customization is at the core of what we do. Our custom-engineered chemicals are tailored to the unique needs of each facility and process. This high level of customization allows Americo products to consistently outperform generic solutions from leading competitors.</p>


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Understanding the Total Systems Approach to Chemical Supply

Innovations in Wastewater Treatment Chemicals

Custom Chemical Blends: Tailoring Solutions to Industry Needs

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