At OPHARDT, sustainability is an important part of our design and manufacturing processes. Through careful material selection, waste reduction initiatives, and investments in energy efficiency, the Ballymote facility is continuously working towards a more sustainable future. To gain a stronger understanding of these efforts, I spoke with Padraig McDonagh, our Engineering Manager, and Paul Donovan, our Purchasing Manager.
Designing for Sustainability
Sustainability is an integral part in our design philosophy, with a strong emphasis on producing long-life, high-quality products.
“We focus on making dispensers that last,” Padraig explained. “This means selecting durable materials and ensuring compatibility between new and existing products.”
OPHARDT’s ingo-man® dispensers are primarily housed in aluminium, a material that can be recycled multiple times without degrading in quality. Other metal components, such as those made from stainless steel, are also chosen for their durability and recyclability. Additionally, the largest plastic component in our IMP, IMC, and IMM range is made from recycled nylon, and we continuously seek to replace virgin plastics with post-consumer recycled (PCR) alternatives.
“Our dispenser bottles, currently made from HDPE, are being replaced with PET, which has better recyclability,” Padraig noted. “We’re also actively researching environmentally friendly alternatives to fluoropolymer plastics.”
Minimising Waste and Emissions
A key part of OPHARDTS’ sustainability strategy is waste reduction.
“Quality control and inspection procedures ensure that any process producing non-conforming products is quickly adjusted to minimise waste,” Padraig said.
The facility uses hot runner systems in the injection moulding department to eliminate plastic waste. Additionally, modern and well-maintained equipment reduces energy consumption and minimises product scrap and rework. Over the past few years, investments have been made to upgrade moulding machines, with a substantial percentage now fully electric or hybrid.
Designing for Recyclability and Reuse
The long lifespan of OPHARDT products make our dispensers a sustainable option for the market.
“Our ingo-man dispensers are designed to last, tested to over 1 million cycles, and typically perform flawlessly for more than 20 years,” Padraig highlighted.
The materials used also support recyclability. Aluminum and stainless steel, the primary components of the ingo-man range, are highly recyclable. PET, now used in dispenser bottles, is another excellent choice in terms of end-of-life processing.
Sustainable Sourcing and Renewable Energy
Sustainability in manufacturing goes beyond just materials—it extends into how they are sourced. Paul Donovan, our Purchasing Manager, provided insight into OPHARDTS’ approach to sustainable sourcing.
“We prioritise suppliers and freight forwarders that align with our sustainability values,” Paul said. “We also work with suppliers who follow recognised sustainability standards and certifications.”
At our Ballymote factory, renewable energy sources play a growing role in factory operations.
“Our facility is powered in part by photovoltaic (PV) solar panels and biomass in the form of wood pellets,” Paul noted.
In 2024, the factory’s solar panels generated 134,075 kWh of electricity, covering approximately 9% of the facility’s total energy consumption. A considerable amount when taking into account the Irish weather.
Energy Efficiency Measures
Beyond renewable energy, Ballymote has implemented various energy efficiency measures to reduce overall consumption.
“We’ve switched to LED lighting throughout the factory and use automated dimming systems to reduce unnecessary power usage,” Paul explained. “We’ve also invested in electric moulding machines, which are significantly more energy-efficient than traditional models.”
Looking Ahead
Sustainability at OPHARDT is an ongoing effort. With continuous research into better materials, investments in energy-efficient technology, and a commitment to reducing waste, the Ballymote facility is making steady progress toward greener manufacturing practices.
As Padraig summed up, “There is a Culture of producing long-life quality products.” It’s about constantly looking at what we do and asking, ‘How can we do this better?’
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