It is necessary to open this post with a caveat: it may end in similar fashion as the previous post. Although I may not be able to determine the exact manufacturing procedure of the Everyday Nalgene or the precise environmental impacts of this process, I can address the topic to my full capacity in a way that allows important conclusions to be drawn.
As stated in the last post, I learned that Nalgene purchases Tritan copolyester from Eastman by speaking with a worker at Nalgene. She informed me that Eastman ships the copolyester via trucks, but did not know where exactly the copolyester came from. I assume that it comes from West Elizabeth, PA, which is home to the Eastman manufacturing site that is closest to Nalgene’s primary factories in Rochester, NY. According to Google Maps, 301 miles separate West Elizabeth and Rochester. I found several different numbers of mpg for both diesel and gasoline powered tractor-trailer trucks or eighteen-wheelers, but most ranged from four to eight mpg. Assuming that on average the trucks that deliver Tritan copolyester from Eastman to Nalgene get approximately six mpg, over the 301-mile trek, about 50 gallons of gasoline or diesel are consumed by one truck delivery alone!
The 301-mile delivery route that brings Tritan copolyester resin pellets from Eastman's manufacturing site in West Elizabeth, PA to Nalgene's factories in Rochester, NY.
The Tritan copolyester is shipped to Nalgene in the form of resin pellets. The Nalgene worker unfortunately could not tell me the manufacturing process that transforms the resin pellets into the Everyday Nalgene for legal reasons (which is why this information was not on Nalgene’s website). However, she was a bit more helpful than Ms. Odham of Eastman by informing me the Nalgene employs the injection blow model process to produce their bottles and recommended doing a Google search to learn more about this method, and thus the environmental impacts it generates.
injection blow molding process
Injection blow molding is used to manufacture large quantities of hollow plastic objects, such as the Everyday Nalgene. In the case of the Everyday Nalgene, the process begins with the melting of the copolyester resin pellets. A nozzle injects this molten form into a hollow mold with a core rod in the middle. The core rod then rotates and opens which sends air into the mold to inflate the bottle into its final shape. Once the bottle has cooled, the rod rotates again so that it can be ejected and the bottle can stand freely on its own.
By learning the steps of this process, as well as keeping in mind the “bottle manufacture” component of the graphs pictured at the end of the last post, I have learned that it takes a large amount of energy to produce a Nalgene. Lots of energy must be used to melt the copolyester resin pellets, as well as during the cooling process. Machinery operations, such as the rotation of the core rod, also require energy. I spoke with several Nalgene workers in attempts to learn about Nalgene’s energy provider, but each worker either said that they were unaware of the issue, could not release that information, or connected me to another voicemail. Regardless, I think it is probable that the Nalgene factories use a mixture of traditional fossil fuels, mainly those used to generate electricity, as well as heating oil. If Nalgene invests and uses sustainable energy sources, such as wind or solar powered electricity, I’m sure that they would be eagerly sharing it in attempts to get more customers. For example, their website’s “responsibility” section would have publicized this information with pretty pictures of windmills and phrases such as, “Here at Nalgene, we are fore-leader in the use of renewable energy sources.” However, there is no material of this kind.
Not only is the energy use a component of the environmental impact of the actual manufacturing process, but the land affected by the factories is also a major issue. When a a factory is built it eliminates land that could remain in its natural ecosystem state. Animals and plants are either displaced or killed in the process. After it is built, it continues to have a ripple effect on the surrounding environments as well. For example, it will release toxins and other pollutants into the air, as well as emit runoff into nearby water systems. It is important to note here that although there are government regulations of factory pollution, they are only regulations, not complete restrictions. There are limitations set on the amount of pollution generated, which in itself implies that there are vast impacts caused by the pollution. Also, the limitations are not very stringent and we have a long way to go to reduce, or hopefully eliminate entirely, pollution generated by America’s business industry. A step in this process would be providing the information about the environmental impacts generated and the processes that generate them to the public, rather than keeping it shrouded in secrecy. Despite the secrecy, keep in mind that the manufacturing process still has major environmental effects.
thenalgene 