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NPEP Success Story: Checkpoint Caribbean
Checkpoint Caribbean, LTD Eliminates Lead in Manufacturing
Checkpoint Caribbean, LTD began operations in Ponce, Puerto Rico in June 1979 and now employs 400 people in the manufacturing of electronic surveillance systems. The surveillance systems consist of a flexible antenna that resonates at a given frequency, 8.2 MHz, that is sent and received by an electronic transmitter/receiver device. These surveillance systems are sold worldwide mainly for the control of theft in retail stores. Annual production is 2.2 billion flexible antennas and 25 thousand transmitter/receiver sensors. The raw materials used to make the antenna are aluminum foil, extruded polyethylene, vinyl terpolymer paint, paper, and adhesive.
Checkpoint's NPEP Goal
Checkpoint has been an NPEP partner since March, 2006, when we set a goal to eliminate 1,960 pounds of lead by switching to the use of lead-free raw materials.
We chose to eliminate lead because there is a worldwide trend to prohibit the use of toxic metals in products that will be in direct contact with the public. The electronic surveillance systems sold by Checkpoint are in direct contact with the public.
NPEP Project Implementation
Our traditional manufacturing process involved soldering a variety of electronic components to printed circuit boards using a lead/tin solder. In order to achieve our goal, we procured lead-free electronic components, switched to a lead-free solder, and bought new equipment to handle the new solder process parameters. In December, 2006, after 18 months of tests and trials, Checkpoint had developed a lead-free electronic manufacturing process.
Hurdles Faced
There were few economic opportunities in the transition to a lead-free manufacturing process. The initial costs of research and development of the companies manufacturing lead-free electronic components, solders, and equipment put an economic burden on the project.
Waste Minimization Results
We surpassed our goal by eliminating 2,000 pounds of lead and creating a lead-free manufacturing process.