Web Site: www.bentonfoundry.com
A PUBLICATION BY BENTON FOUNDRY, INC.
rior to 1996 at Benton Foundry, iron was melted in a cupola. This non-water cooled, coke-fired unit was limited to around 55 tons per day and could only operate one shift per day. At the end of the shift, the doors at the bottom would be opened, dropping out the remaining coke, iron, slag and limestone. The area would be cooled and cleaned up. Every night a crew would reline the inside with refractory, close the doors, install a sand bed above the doors and start the melting process all over again. The operation required a three-man charging crew, cupola tender and two more at night, to reline and prep.
Today, Benton Foundry melts with medium frequency electric induction furnaces. These furnaces, built by Inductotherm, have capacity to melt 300 tons per day and can operate 24 hours per day. The furnaces have load cells and fiber optic controls, providing much improved chemistry and temperature control. The furnaces also have demand control technology to monitor and control our electricity consumption. Today’s system only requires a crane operator and furnace operator on each shift.
Also, with respect to the environment, the cupola had a wet scrubber pollution control system that required a lot of maintenance time and care. The new furnaces are controlled by a baghouse which is tested every five years per the Pennsylvania Department of Environmental Protection. The most recent test recorded a discharge rate of 0.001 gr/DSCF versus a permit level of 0.005 gr/DSCF. In other words the permit is 0.005 gr/DSCF, and we tested at 20% of that number at 0.001. Compared to the old collection permit of 0.018 gr/DSCF, we are 94% below previous permit levels. For you old-timers, these numbers are well below what the cupola was permitted for.
ne of the largest issues facing the USA is a self-inflicted financial disaster headed our way, on multiple fronts. Just like you can’t spend more than you make and live on credit cards, the federal government cannot spend more than it takes in year after year. The issue is going to blowup sooner than later. The State and Local Governments have to balance their budgets. Here are some myths and realities on the situation.
Myths about the Deficit and Debt
No Attempts at Reform have succeeded since the 1980’s
pioid addiction is a long-lasting (chronic) disease that can cause major health, social, and economic problems. Opioids are a class of drugs that act in the nervous system to produce feelings of pleasure and pain relief. Some opioids are legally prescribed by healthcare providers to manage severe and chronic pain. Commonly prescribed opioids include oxycodone,
fentanyl, buprenorphine, methadone, oxymorphone, hydrocodone, codeine and morphine. Some other opioids, such as heroin, are illegal drugs of abuse. Opioid addiction is characterized by a powerful, compulsive urge to use opioid drugs, even when they are no longer required medically. Opioids have a high potential for causing addiction in
some people, even when the medications are prescribed appropriately and taken as directed. Many prescription opioids are misused or diverted to others. Individuals who become addicted may prioritize getting and using these drugs over other activities in their lives, often negatively impacting their professional and personal relationships. It is unknown why some people are more likely to become addicted than others.
Opioids change the chemistry of the brain and lead to drug tolerance, which means that over time the dose needs to be increased to achieve the same effect. Taking opioids over a long period of time produces dependence, such that when people stop taking the drug, they have physical and psychological symptoms of withdrawal (such as muscle cramping, diarrhea and anxiety).
Dependence is not the same thing as addiction; although everyone who takes opioids for an extended period will become dependent, only a small percentage also experience the compulsive, continuing need for the drug that characterizes addiction.
Opioid addiction can cause life-threatening health problems, including the risk of overdose. Overdose occurs when high doses of opioids cause breathing to slow or stop, leading to unconsciousness and death if the overdose is not treated immediately. Both legal and illegal opioids carry a risk of overdose if a person takes too much of the drug or if opioids are combined with other drugs.
Misuse of prescription opioids and heroin affects more than 2 million Americans and an estimated 15 million people worldwide each year. The prevalence of opioid misuse and addiction is rapidly increasing. In 2016, more than 20,000 deaths in the United States were caused by an overdose of prescription opioids and another 13,000 deaths resulted from heroin overdose. Drug overdoses are now the leading cause of death in U.S. adults under age 50 and opioids account for more than half of all drug overdose deaths.
Opioid addiction is a complex disorder, and non-genetic factors also play a critical role. It is likely that a combination of health, social, economic and lifestyle factors interact with genetic factors to determine an individual’s risk.
Reprinted from Genetics Home Reference:
PA Get Help Now Hotline 1-800-662-4357
Headache – Eat plenty of fish. Fish oil helps prevent headaches. So does ginger, which reduces inflammation and pain.
Hay Fever – Eat lots of yogurt before pollen season. Also eat honey from your local area daily.
Arthritis – Salmon, tuna, mackerel and sardines are high in omega oils, which can help joint discomfort.
Upset Stomach – Bananas can help settle an upset stomach and ginger is good for nausea.
Colds – Garlic can help clear a stuffy head, it is also good for cholesterol.
Cholesterol – Avocados contain Mono unsaturated fat, which is considered a healthy fat.
Ulcers – Cabbage contains chemicals that are good for ulcers.
Natural Holistic Health
Congratulations to Amanda Hartman (above), Benton Foundry’s 1st shift Employee of the Quarter.
Amanda is also our 1st Shift Employee of the Year!
Amanda works in our Core Room as an Assistant Supervisor. She earned her Associate Degree in Applied Science in Automated Manufacturing Technology from Penn College while working as a core assembler. She has been employed since 2011. Amanda lives outside of Benton with her daughter Payton. She enjoys spending time with her daughter and their animals when she isn’t working.
Congratulations to Ray Campbell (below), Benton Foundry’s 2nd shift Employee of the Quarter.
Ray has been employed at the Foundry since 2010. He currently works in our Melt Department. Ray is both a Crane and Furnace Operator. He has also poured iron and worked in our Grinding Room as a Cleaner Operator. Ray lives in Benton and he enjoys hunting and working on cars and trucks in his spare time.
Congratulations to Tyler Hartman (left), Benton Foundry’s 2nd & 3rd Shift Employee of the Year!
Tyler works in our Maintenance Department. He has been a Maintenance Technician since 2017. Prior to 2017, Tyler worked in our Melt Department and has been employed since 2010. While in the Melt Department, Tyler was an Iron Pourer, Furnace Operator and an Assistant Supervisor. Tyler and his wife Kristy live outside of Lairdsville, with their daughter Peyton. Tyler enjoys spending time with his family, woodworking and riding ATVs in his spare time.
Our lab once again completed the Iron Casting Research Institute testing with great results. Our lab is consistently one of the best performers in this round robin testing.
Six employees recently completed their Level 1 UT
certification through WTTI. Kudos to all of you!
For calendar year 2019, we produced more molds and more tonnage than any year in our history. These levels beat all previous records.
Great job to everyone for this achievement!
A thank you to all core assemblers for all the extra hours put in over the last year!
Thank you and good job to all!
Eric Malcein was accepted into PCT Precision Machining for a trip to Germany.
From Jim Stapleton (BAM) – Industrial Hygiene Services Audit – Congratulations to Benton Foundry and all involved with the safety program. The audit results were zero deficiencies with your Self-Insured Accident & Illness Prevention Programs; this is not typical by any means. According to the state audit department approximately 90% of all audits result in at least one deficiency.
Benton Foundry Annual Sales Meeting
Thursday, October 24, 2019
From Left to Right: Ernie Priebe, Dennis Raber, Sue Hanna,
John Harvey, Lori Nafus, Lynn Miller, Brock Smith and
Mary Alice Green
Where would you find the Sea of Tranquility?
Answer will be in 1st Quarter 2020
3rd Quarter Question & Answer:
“Failure is the condiment that
gives success its flavor.”
~ Truman Capote