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3 – Material flow analysis
MATERIAL FLOW ANALYSIS
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3 – Material flow analysis
Strategies for waste minimization
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3 – Material flow analysis
What are materials?
Goods/raw materials (e.g. wood, gravel,
PVC)
Elements (e.g. carbon, cadmium)
Compounds (e.g. benzene, methane)
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3 – Material flow analysis
What is a material flow analysis?
A material flow analysis is a systematic
reconstruction of the way a chemical element, a
compound or a material takes through the natural
and/or economic cycle.
A material flow analysis is generally based on the
principle of physical balance.
Definition of the Commission of inquiry "Protection
of human life and the environment" of the German
Bundestag
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3 – Material flow analysis
Initial situation in a paint shop
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3 – Material flow analysis
Material flows in a car repair shop
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3 – Material flow analysis
How does a balance work?
Input mass =
Output mass
+ Storage
(Without
chemical
reaction)
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3 – Material flow analysis
Material flow analysis and
eco-balances
Eco-balances
Analyse the whole life-cycle of a product
Analyse the ecological effects
Assess the material and energy
consumptions emerging during a life cycle
and the arising environmental effects.
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3 – Material flow analysis
Objectives of a
material flow analysis
Trace the flow of raw materials through the
company to establish connections within the
process
Retrace waste and emissions to the point
where they are generated
Identify weak points (inefficiencies)
Define the basis for evaluation
Edit data in a decision-oriented way
Set priorities for appropriate measures to
minimize waste and emissions
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3 – Material flow analysis
Criteria for the
selection of a material
Quantity of the material flow
Costs of the material flow
Toxicity of the material flow
Legal aspects of the material flow
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3 – Material flow analysis
How to carry out a
material flow analysis?
1. Define the objectives and parameters to be
monitored
2. Limit the balance scope
3. Limit the balance period
4. Identify and define the process steps
5. Draw the flowcharts: material flows – quality
6. Draw up the balances: material flows – quantity
7. Interpret the results and draw conclusions
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3 – Material flow analysis
Material flow analysis of machine
painting
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3 – Material flow analysis
Step 1: Parameters monitored
Paints, solvents, (all process materials)
Step 2: Balance scope
Painting chamber and drying
Step 3: Balance period
1 year
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3 – Material flow analysis
Step 4: Process steps of
machine painting
Process steps:
Pre-treatment
Priming, painting
Drying
Additional equipment:
Steam generator
Exhaust air filter
Cleaning of spray gun and container
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3 – Material flow analysis
Step 5: Flowchart
Representing process steps by rectangles
Representing material flows by arrows
3 – Material flow analysis
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Step 5: Flowchart
Air filter
Pre-treatment
Steam generator
Priming/
Painting
Drying
Cleaning
Balance limit
3 – Material flow analysis
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Step 5: Flowchart
Paint, thinner, filler, tape, filter
film, air, container
Filter,
paint
Air filter
Air, thinner
Air and thinner
Air, paint, thinner
Priming/
Painting
Pre-treatment
Oily
parts l
Parts
clean
Steam generator
Tools
Drying
Parts
wet
Parts
with paint
Cleaning
Water,
detergent
Balance limit
Thinner
Waste
thinner
Dust
containers
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3 – Material flow analysis
Step 6: Balances
Input = output for the whole system
Input = output for the single steps
3 – Material flow analysis
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Step 5: Flowchart
E8, E9, E 10,
E3, E4, E5, E6, E7
A3
A4, A7
Air filter
Priming/
Painting
Pre-treatment
E1
Drying
A1
Steam generator
Cleaning
E2
Balance limit
A2
E11
A6
A4, A5, A8, A9
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3 – Material flow analysis
Quantitative material flow analysis
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3 – Material flow analysis
Quantitative material flow analysis
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3 – Material flow analysis
Step 7: Interpretation
By identifying parameters
Calculation of the so-called “application efficiency":
Dry surface film mass
Efficiency = _______________________
Input solid state mass
In this case for small pieces < 10%
In this case on average < 20%
State of the art?
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3 – Material flow analysis
Typical efficiencies (application
efficiency, expressed in % solids):
Conventional
35-50%
HVLP
50-70%
Airless
40-75%
Electrostatic
50-85%
Rotating disc
75-90%
Dipping
90%
Pouring
95%
Rolling
98%
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3 – Material flow analysis
Evaluation of a
material flow analysis
Flowchart
To illustrate material flows and
process sequences
Pie chart and histogram
To illustrate ratios,
distributions and compositions,
Time-travel diagram
For chronological illustrations
Sankey diagram
To visualize material flows true to scale
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3 – Material flow analysis
Evaluation of a
material flow analysis – 2
Possible parameters:
Efficiency factors (ratio of use to costs)
Quality factors (ratio of real efficiency factor to the
theoretically possible efficiency factor)
Linkage with costs
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3 – Material flow analysis
Data sources
Accounting
Warehousing
Collection of process data
Operational accounting
Personal information (e.g. methods engineer)
Estimates
Measurements
Original documents
...
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3 – Material flow analysis
Measuring water volumes
Water meter
Turbine wheel meter
Rotameter
Induction measuring instrument
Ultrasonic flowmeter
Weir
Measuring at water consumers
(stop watch, bucket)
2,5
q=
0,31 h o
tan o
2g
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3 – Material flow analysis
Recommendations 1
for a material flow analysis
 Carry out the material flow analysis in steps
 An estimate is better than doing nothing at all
 Even with estimates it is possible to improve
 80 – 90% of accuracy is sufficient
 Use simple measuring instruments
 Use indicators
 If necessary, contact the supplier or plant
manufacturer
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3 – Material flow analysis
Recommendations – 2
for a material flow analysis
It is not essential to follow the instructions
or procedures in great detail, a creative
approach is often helpful.
Even by simply working with the balances
you can sometimes achieve improvements.
It is important to translate the results into
the language of the respective target
group (monetary units, kg, pictures,
comparisons, etc.)