ifu Hamburg GmbH, member of iPoint Group, HTW Berlin and UKOM jointly supported SMEs in using the MFCA methodology to achieve higher material efficiency. Our consultants provided support in the analysis process and practical consulting within the SMEs. The project was funded by the “Deutsche Bundesstiftung Umwelt” (DBU) as part of the research project “MFCA mobil”.
This case study focuses on how iPoint helped Junker Filter GmbH to reduce the use of resources in their filter systems by using the MFCA method. Junker Filter GmbH manufactures filter components from technical textiles.
The case ZERO® Design
One of the company’s core products is the ZERO® Design product series, which is produced to meet ever-increasing emission limits. Such filters are primarily used in the food, beverage and pharmaceutical industries. These models consist of seamless filter bags with absolute fitting accuracy, which are encased in plastic at the ends. The plastic is cast by hand using a limited number of molds. At the start of the project, 32 minutes are required for the production of 4 filters each, including curing.
Automation of processes to increase production efficiency
The basic aim of the project was to carry out a material flow cost analysis (MFCA) of the ZERO Design product line. This is intended to show whether, where and how resources can be saved in the production process. It is expected that the systematic recording of all key figures of the production technology will increase the interdepartmental system understanding within the company. At the same time, it should be shown where the greatest value-added losses occur during production. Within the framework of MFCA, the modeling of different scenarios is to examine how production efficiency can be significantly increased by automating individual work steps.

Develop a model for the manufacturing processes
First, all material flows of the ZERO Design product line were recorded. For this purpose, all parameters of costs, working times and losses in the running operation were determined step by step: From the receipt and sampling of the individual textile fabrics as well as the subsequent seamless production, to the receipt of the plastics for the molding as well as the joining and gating of the components, to the quality inspection and delivery of the filters. A model was developed and parameterized from the actual data determined for the manufacturing processes. This enabled scenario analyses to be carried out for changeovers in the various production processes. In detail, the following were of interest:
- A varied filter bag length
- Manual versus automated operation of the casting station
- Variation of casting molds
- Variation of material quantities
All scenarios calculated for the casting station took burr formation on the cast filter heads into account. Burr formation influences the material requirement as well as the time for manual reworking. At the same time, it is a safety factor for high quality.
“As a highly specialized technology company, it is of enormous importance for us to continuously expand our know-how. In doing so, investments in the expansion of our production processes must be as sustainable as they are profitable. For the analysis and strategic planning of our manufacturing processes, the MFCA methodology convinced us. Moreover, the associated coaching showed us how we can optimally use our environmental key figures as a unique selling proposition (USP) in product tenders.”
Julian Nuss, commercial manager
Result: For total transparency of the cost structure
The results of the material flow cost analysis led to complete transparency of the cost structure of their filter hose production for Junker Filter GmbH. On the material side, significant losses in plastic casting and the subsequent rinsing processes could be identified as hotspots. In addition, a high time expenditure in the manual casting process was demonstrated. The optimization potentials broken down in the scenario analyses led to the following recommendations:
- optimized geometry of plastic castings reduces the need for raw material with a manageable investment in new molds.
- reduction of total production costs by 20%: Increased number of casts per cycle (8 instead of 4) reduces the number of rinsing operations while providing higher efficiency per worker.
- savings of 40% in total product costs: an even higher increase in productivity could be achieved by automating the casting station on a rotary basis. After a significant investment in the company’s infrastructure, 41 filter bags could be produced in 40 minutes in the rotary run.
The detailed data collection in the context of material flow cost analysis provides Junker Filter GmbH with valuable information for anchoring the material flow management methodology in the company across all processes. In addition to process optimization, the data can be used for CO2 evaluations in the future.
If you want to read another case study on MFCA, then click here.
About the Company
“Products of tomorrow to increase productivity and protect our environment” is the corporate motto of Junker Filter GmbH. Since 1956, the Sinsheim-based company has been developing technologies and products for the use of technical textiles in the latest dedusting systems and in solid-liquid separation. With innovations in filtration, Junker Filter internationally offers a cross-industry range of products and services from individual customization to series production.
- Products & Solutions (99)
- Trends & Technology (99)
- News & Updates (68)
- Challenges (67)
- Sustainability (48)
- life cycle assessment (44)
- Compliance (29)
- Energy efficiency (29)
- carbon footprint (23)
- circular economy (23)
- echa (21)
- Resource efficiency (19)
- SCIP (19)
- LCA (18)
- material efficiency (18)
- Umberto (17)
- Climate Change (16)
- Material flow cost accounting (15)
- material flow analysis (12)
- Renewable energy (11)
- Process Optimization (10)
- environmental product declaration (9)
- Ecodesign (8)
- Efficiency (8)
- Transparency (8)
- Trends (8)
- life cycle inventory (8)
- Customer driven-sustainability (7)
- Eco label (7)
- Ecological footprint (7)
- Ipoint suite (7)
- Lca databases (7)
- Supply chain (7)
- Survey (7)
- Sustainable development (7)
- automotive (7)
- blockchain (7)
- Reach (6)
- Renewable heat (6)
- research (6)
- China (5)
- Corporate carbon footprint (5)
- Digitalization (5)
- Industrial ecology (5)
- Materialflusskostenrechnung (5)
- carbon footprinting (5)
- carbon neutrality (5)
- digital product passport (5)
- waste management (5)
- Climate protection (4)
- Cobalt reporting (4)
- Dematerialization (4)
- EPD (4)
- GHG reduction (4)
- Green construction (4)
- OECD (4)
- Okobilanzierung (4)
- Social metabolism (4)
- Sustainable transport (4)
- carbon neutral (4)
- construction industry (4)
- germany (4)
- Big Data (3)
- Brexit (3)
- Chemical industry (3)
- Conflict minerals (3)
- Corporate Social Responsibility (3)
- Database (3)
- Due diligence (3)
- E-mobility (3)
- Environmental product declarations (3)
- Eutrophication (3)
- IFEU (3)
- ISO 50001 (3)
- Industrial sector (3)
- Innovation (3)
- Leed (3)
- Life cycle management (3)
- Medical device (3)
- Photovoltaics (3)
- Ressourceneffizienz (3)
- Social media (3)
- building sector (3)
- greenhouse gas inventory (3)
- svhc (3)
- transport sector (3)
- water footprint (3)
- 20-20-20 Objectives (2)
- 3D printing (2)
- BASF (2)
- Christian-Doppler-Laboratory (2)
- Competence center (2)
- Conflict minerals reporting (2)
- Cycling (2)
- E-car (2)
- Electric car (2)
- Emerging economies (2)
- Environmental impact (2)
- Environmental management (2)
- Environmental performance (2)
- Environmental sustainability index (2)
- European commission (2)
- Fish (2)
- Gate to gate (2)
- Global warming (2)
- Governance (2)
- Green business 2 (2)
- Green investment (2)
- Human rights (2)
- ISO-14051 (2)
- Inatba (2)
- Integrated reporting (2)
- Integrative approach (2)
- Knowledge economy (2)
- LCA data from suppliers (2)
- Life cycle thinking (2)
- MFA (2)
- Manufacturing industry (2)
- Okobilanz (2)
- Renewable Resources (2)
- Sdgs (2)
- Software (2)
- Steady state economy (2)
- Sustainable business (2)
- Sustainable lifestyle (2)
- UK REACH (2)
- Umberto for carbon footprint (2)
- Umweltbundesamt (2)
- Wastewater treatment (2)
- Water management (2)
- agriculture (2)
- best practice (2)
- biodiversity (2)
- biomass (2)
- building standards (2)
- carbon emissions (2)
- carbon intensity (2)
- carbon relocation (2)
- collaborative consumption (2)
- consistency (2)
- corporate material flow modeling (2)
- cost savings (2)
- developing world (2)
- eLCAr (2)
- energiewende (2)
- energy (2)
- esankey (2)
- food industry (2)
- green jobs (2)
- holistic approach (2)
- milk (2)
- modern slavery (2)
- okobilanzdaten (2)
- productivity (2)
- resilience (2)
- sankey diagram (2)
- seafood (2)
- transport (2)
- 2012 (1)
- 3 scopes (1)
- ACHEMA (1)
- AI (1)
- Abfallwirtschaft (1)
- Ankara (1)
- B2B (1)
- BMBF (1)
- BREEAM (1)
- Bachelor program (1)
- Bauwesen (1)
- Brazil (1)
- CFC (1)
- CO2-Fußabdruck (1)
- Carbon Accounting (1)
- Central america (1)
- Circular Economy Action Plan (1)
- Club of Rome (1)
- Co2 Pricing (1)
- Commercial Sector (1)
- Comparative life cycle assessment (1)
- Compliance agent (1)
- Composite indicator (1)
- Construction (1)
- Consumer goods (1)
- Consumption (1)
- Country Attractiveness (1)
- Creative sustainability (1)
- Critique of the green economy (1)
- Csr report (1)
- Dairy (1)
- Dashboard of sustainability (1)
- Data (1)
- Data collection (1)
- Davos (1)
- Decarbonization (1)
- Denmark (1)
- Design (1)
- Deutschland (1)
- Developing countries (1)
- Dienstleistungen (1)
- Digital twin (1)
- Distributed manufacturing (1)
- Divestment (1)
- Domestic fuel consumption (1)
- Domestic sector (1)
- Duty of care (1)
- Earth Sciences (1)
- Earth summit (1)
- Ecolabelling (1)
- Ecologic footprint (1)
- Ecological resilience (1)
- Education (1)
- Efficiency measures (1)
- Effizienzfabrik (1)
- Ehs (1)
- Emission relocation (1)
- Ems (1)
- Energieeffizienz (1)
- Energy Intensity by Sector (1)
- Energy contracting (1)
- Energy efficiency directive (1)
- Energy transition (1)
- Engineering excellence (1)
- Enhipro (1)
- Environment (1)
- Environmental Contracting (1)
- Environmental Engineering (1)
- Environmental balance (1)
- Environmental capital (1)
- Environmental labeling (1)
- Environmental management accounting (1)
- Environmental profit and loss statement (1)
- Environmental standard (1)
- Environmentally Weighed Material Consumption (1)
- European Comission (1)
- European Green Cars Initiative (1)
- Evaleau (1)
- Events (1)
- External effects (1)
- Fifa (1)
- Fishery (1)
- Fmd (1)
- Food footprint (1)
- Food production (1)
- Ford (1)
- Forest ecosystems (1)
- France (1)
- Free trade (1)
- Freighter travel (1)
- Full cost accounting (1)
- GHG mitigation (1)
- Ghg reduction goals (1)
- Global compact (1)
- Global justice (1)
- Global warming potential (1)
- Green building (1)
- Green business models (1)
- Green consumers (1)
- Green deal (1)
- Green new deal (1)
- Greenwash (1)
- HVAC (1)
- Happy life years (1)
- Harmonization (1)
- Harze (1)
- Hdpe (1)
- Human development index (1)
- Human trafficking (1)
- ILCD Handbook (1)
- IPCA (1)
- IPCC (1)
- ISO 14015 (1)
- ISO 14031 (1)
- ISO 14064 (1)
- ISO 14067 (1)
- ISO-14000 (1)
- ISO-14008 (1)
- ISO-14025 (1)
- ISO-14046 (1)
- Impact category (1)
- Incentive (1)
- Incentive based pay (1)
- Incineration (1)
- India (1)
- Industry-4-0 (1)
- Information design (1)
- Input output (1)
- Input output databases (1)
- Input output economics (1)
- Inreff (1)
- Intellectual property (1)
- Internalization of externalities (1)
- International standards (1)
- Interplant collaboration (1)
- Iso 14001 (1)
- Jevons paradox (1)
- Klimawandel (1)
- Konsumguter (1)
- Kuznets curve (1)
- LIFE AskREACH (1)
- Lieferkettengesetz (1)
- Life cycle analysis (1)
- Life cycle perspective (1)
- Life style (1)
- Linkedin (1)
- Living planet report (1)
- Long-Term Pay (1)
- Material consumption (1)
- Material flow modeling (1)
- Material flowcosts (1)
- Material footprint (1)
- Medical device regulation (1)
- Metal industry (1)
- Mexico (1)
- Monetize external costs (1)
- Montreal Protocol (1)
- Municipal solid waste (1)
- Natural Cost Accounting (1)
- Nature conservation (1)
- Nitrate pollution (1)
- Nutrients balance (1)
- Nutrients cycle (1)
- OECD Environment Policy Committee (1)
- Okobilanzdatenbanken (1)
- Okolabelling (1)
- Okologischer fusabdruck (1)
- Online Resource Efficiency Platform OREP (1)
- Operational efficiency (1)
- Outsourcing (1)
- PET (1)
- Pas (1)
- Pcf (1)
- Philippines (1)
- Pilot program (1)
- Plastic industry (1)
- Polio (1)
- Pollution haven hypothesis (1)
- Process engineering (1)
- Process improvement (1)
- Process system engineering (1)
- Product management (1)
- Product stewardship (1)
- Product sustainability (1)
- Production based CO2 Productivity (1)
- Production planning (1)
- Produktlebensdauer (1)
- Prop 65 (1)
- Protection proprietary data (1)
- Qatar (1)
- Quality (1)
- Quality journalism (1)
- Rapid prototyping (1)
- Refuse derived fuel plant (1)
- Renewable energy in manufacturing (1)
- Renewable methane (1)
- Renewable process heat (1)
- Renewable raw material (1)
- Resource flows (1)
- Retailer (1)
- Rio20 summit (1)
- Rolf Dobelli (1)
- Sap (1)
- Sfdr (1)
- Shopping rage (1)
- Smart grid (1)
- Social ecological resilience (1)
- Solar thermal energy (1)
- Sorgfaltspflichtengesetz (1)
- South africa (1)
- Soy milk (1)
- Stakeholder management (1)
- Supermarket chain (1)
- Sustainability indicators (1)
- Sustainability performance (1)
- Sustainability strategy (1)
- Sustainable architecture (1)
- Sustainable construction (1)
- Sustainable living (1)
- Sustainable process index (1)
- Sustainable resins (1)
- Sustainable resource management (1)
- Sydney (1)
- System analysis (1)
- Telecommunications (1)
- Tobias viere (1)
- Total material consumption (1)
- Treibhauspotenzial (1)
- Turkey (1)
- UK CA (1)
- University (1)
- Upcycling (1)
- VDMA (1)
- Vertical cooperation (1)
- Waste prevention (1)
- Water abstraction rate (1)
- Water extraction (1)
- Wind power (1)
- World cup (1)
- World vegan day (1)
- Yet (1)
- Zero carbon city (1)
- Zero emission mobility (1)
- academia (1)
- acidification (1)
- air quality (1)
- aluminum (1)
- amazon (1)
- antarctic ozone hole (1)
- apocalypse (1)
- apple (1)
- assessment (1)
- atmospheric carbon measurement (1)
- background database (1)
- battery change station (1)
- bike sharing (1)
- bio capacity (1)
- bio-economy (1)
- biocapacity (1)
- biological gas treatment (1)
- blogs (1)
- books (1)
- business opportunity (1)
- car (1)
- carbon free city (1)
- carbon leakage (1)
- carbon management (1)
- carbon management 2 (1)
- carbon reduction (1)
- carbon tax (1)
- carbon-neutral travel (1)
- cargo shipping (1)
- carton (1)
- certification (1)
- change (1)
- climate impact (1)
- climate neutral (1)
- co2 fusabdruck (1)
- cogeneration (1)
- combined reporting (1)
- commons (1)
- cooperation along product (1)
- cradle to cradle (1)
- de-growth economy (1)
- digital battery passport (1)
- ecarus (1)
- eco design (1)
- ecoinvent (1)
- ecological tax reform (1)
- ecosystem disturbance (1)
- efficiency investment (1)
- efficient construction (1)
- energy efficiency in production (1)
- energy sources (1)
- environmental accounting (1)
- environmental impact data (1)
- environmental management system (1)
- environmental performance indicator (1)
- environmental technology verification (1)
- environmentally friendly raw materials (1)
- esg (1)
- fashion (1)
- food loss (1)
- food sector (1)
- geopolymer cement (1)
- green Christmas (1)
- green buildings (1)
- green paradox (1)
- green production (1)
- greenhouse (1)
- handprinting (1)
- holistic sustainability (1)
- lca recommendations (1)
- lca-software (1)
- lcia (1)
- lifecycle (1)
- logitech (1)
- management models (1)
- material flow balance (1)
- material losses (1)
- material-flow-accounts (1)
- media (1)
- modeling (1)
- nuclear phase out (1)
- policy instruments (1)
- politics (1)
- post oil age (1)
- product environmental footprint (1)
- production circle (1)
- ressource efficiency analysis (1)
- saving potentials (1)
- scope 3 (1)
- season's greetings (1)
- smart meter (1)
- social cost accounting (1)
- stranded assets (1)
- sustainability control (1)
- sustainability projects (1)
- sustainable products (1)
- tajikistan (1)
- textile industry (1)
- textile refinement (1)
- toyota (1)
- trade (1)
- transport emissions (1)
- uk-rohs (1)
- umweltbilanz (1)
- urban carbon emissions (1)
- velib (1)
- volvo (1)
- waste air treatment (1)
- waste hierarchy (1)
- wastewater (1)
- water stress (1)
- wind gas (1)
- world statistics day (1)
- zero growth (1)
- Ökologischer Fußabdruck (1)