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This eBook has been a long time in the making and continues to be a work in progress. Based on more than 30 years of carbon dioxide (CO2) technology development and commercialization, this eBook provides manufacturing engineers and managers with practical knowledge, tools and techniques for developing and implementing innovative CO2-enabled lean and green (clean) manufacturing processes, products and production lines. This eBook shows how CO2 technology can transform your product manufacturing operations using a holistic implementation approach – design for cleanability, build clean, and maintain clean protocols.

CO2 technology is very unique with regards to its utility in product manufacturing. CO2 technology embodies numerous useful and beneficial forms, implementations, and functions. Gas, liquid, solid, and supercritical fluid-based CO2 processes provide stand-alone and in-situ cleaning, extraction, disinfection, modification, thermal control, and lubrication capabilities. Moreover, CO2 technology is used with other innovative tools such as atmospheric plasma, laser, and robotic automation to provide highly robust processing platforms. Effectively implemented, CO2 technology significantly reduces multiple forms of lean and green manufacturing wastes including factory space, labor, material inputs, processing time, energy, wastewater, and other non-productive by-products.

CO2 technology unconstrains the manufacturing process and product development engineer to imagine new forms of clean manufacturing tools and processes. This is due in large part to a unique combination of complimentary qualities: dry, non-toxic and non-corrosive chemical nature; inherent material and process compatibility; and multiple modes of utilization. As such, CO2 technology can be readily adapted to, or integrated directly into, almost any conventional manufacturing and assembly platform - process, tool, and production line - to provide in-situ cleaning, cooling, or lubricating functions. In this regard, this eBook is relevant to OEM product development engineers investigating opportunities to develop new and differentiated commercial manufacturing and assembly tools for new or existing end-users, markets and applications. Clean manufacturing tool and process integration opportunities include robotics, precision grinding, portable drilling, welding, adhesive bonding, laser processing, wire bonding, thermal spray coating, optical coating, injection molding, and progressive stamping, among many more possibilities.

Moreover, this eBook provides a basic understanding of important clean manufacturing principles and practices, and a simple and straightforward manufacturing waste minimization assessment process. Clean manufacturing practices include the optimization of product design, and manufacturing and assembly processes. Clean manufacturing practices protect the product from the environment and people, and protect the environment from the manufacturing processes. Particularly relevant to production and environmental managers, clean manufacturing waste minimization assessments are useful for identifying and prioritizing lean and green waste reduction opportunities, developing and implementing new projects, and validating performance once implemented. Lastly, environmental, health and worker safety matters are considered including carbon footprint and CO2 chemical safety.

Over the past many years I have designed and developed many practical CO2 solutions that have improved product manufacturing for my customers, many comprising Fortune 100 and 500 companies. These companies have benefited from higher product yields, increased productivity, decreased material inputs, lower energy and water usage, and reduced regulatory burden. All of these businesses have improved the environmental quality and safety for their employees, customers, and communities.

These industry-proven CO2 solutions - methods, procedures, tools, and techniques - are the foundation for this eBook, aptly entitled CO2Mechanics.Blog. It is my hope that you find this eBook useful for ideating, developing, and implementing cost- and performance-effective CO2-enabled clean manufacturing programs, processes, and tools for your factory or for developing new CO2-enabled product offerings to sustain your existing commercial products.

David P. Jackson

The CO2 Guy

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