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I E S E A R C H T R I A N G L E I N S T I T U T E

RTI Project Number 94U-5573-000 Dccember 1993

Draft Final Report

WASTE REDUCTION ACTIVITIES FOR HAZARDOUS WASTES FROM PAINTING OPERATIONS

Prepared for:

Hazardous Waste Section and Pollution Prevention Program

North Carolina Department of Environment, Health, and Natural Resources

Raleigh, NC 2761 1

Prepared by:

Donna S. Womack Jesse N. Baskir

Timothy M. Hunter Zack Pekar

Sonji L. Turner Terrence K. Pierson

Research Triangle Institute Center for Environmcntal Analysis

Research Trianglc Park, NC 27709

3 S T O F F I C E B O X 1 2 1 9 4 R E S E A R C H T R I A N G L E P A R K , N O R T H C A R O L I N A 2 7 7 0 9 - 2 1 9 4

RTI Project Number 94U-5573-000

F A q P I f f3 - -

December 1993

Draft Final Report

WASTE REDUCTION ACTIVITIES FOR HAZARDOUS WASTES FROM PAINTING OPERATIONS

Prepared for:

Hazardous Waste Section and

Pollution Prevention Program North Carolina Department of Environment,

Health, and Natural Resources Raleigh, NC 2761 1

L.,

Prepared by:

Donna S. Womack Jesse N. Baskir

Timothy M. Hunter Zack Pekar

Sonji L. Turner Terrence K. Pierson

Research Triangle Institute Center for Environmental Analysis Research Triangle Park, NC 27709

Authorized by:

fLl&wLit ? u Terrence K. Pierson, Manager - Environmental Risk Analysis Depaament

L K W c.Lcu Dennis F. Naugle, Direqfor Center for Environmental Analysis

ACKNOWLEDGEMENTS

The authors would like to acknowledge all the people without whose help and cooperation this project could not have been completed. We would particularly like to thank Emil Breckling of the North Carolina Hazardous Waste Section and Terry Albrecht of the North Carolina Pollution Prevention Program for providing guidance and data. We would also like to thank all of the facilities that participated in the telephone survey and site visits and Coleen Northeim of RTI’s Pollution Prevention Program for her guidance and technical review of this document.

Table of Contents

1.0 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

1.1 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.2 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.3 Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.0 Methodology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. .

2.1 Overview of Methodology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2.2 Framework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2.3 Telephone Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.3.1 Industry Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.3.2 Telephone Survey Questionnaire Development . . . . . . . . . . . . . . . . 5 2.3.3 Telephone Survey Background Information . . . . . . . . . . . . . . . . . . 7 2.3.4 Summary of Telephone Responses . . . . . . . . . . . . . . . . . . . . . . . . 8

2.4 Sitevisits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 2.4.1 Site Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 2.4.2 Correspondence with Facility . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 2.4.3 Site Visit Questionnaire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 2.4.4 Summary of Site Visit Information . . . . . . . . . . . . . . . . . . . . . . . 40

. .

3.0 Waste Reduction Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

3.1 Options Identified by NC Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 3.2 Options Identified Through Literature Review . . . . . . . . . . . . . . . . . . . . 51

4.0 Information Dissemination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

4.1 Identification and Review of Technical Materials . . . . . . . . . . . . . . . . . . 53

4.2 Industries’ Recommendations for Disseminating Information . . . . . . . . . . 53

5.0 Conclusions and Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

APPENDIX A . Telephone Survey Questionnaire APPENDIX B . 1992 Facility Specific Waste Generation and Minimization Data APPENDIX C . Telephone Survey Response Summaries APPENDIX D . Sample Site Visit Confirmation Letter APPENDIX E . Sample Site Visit Follow-up Letter APPENDIX F . Site Visit Questionnaire APPENDIX G . Site Visit Reports APPENDIX H . Waste Reduction Bibliography

List of Tables

Table 1. Industries Included in Telephone Survey Sample . . . . . . , . . . . . . . . . . . . . . . . 6 __

Table 2. Telephone Survey - Facility Specific Waste Generation and Management Data . . 9 -

Table 3. Telephone Survey - Summary of Facility Specific Painting Operations . . . . . . . 19

Waste Reduction Activities for Hazardous Wastes from Painting Operations

1 .O INTRODUCTION

1.1 Background

In 1991, 59.4 million pounds or 56 percent of all hazardous wastes shipped off-site by North Carolina hazardous waste generators were landfilled or combusted'. As part of a waste reduction effort, the North Carolina Hazardous Waste Section (NCHWS) in conjunction with the Pollution Prevention Program (NCPPP) initiated a non-regulatory project. The objectives of the project are identified below.

1)

2)

Increase waste reduction activities through a targeting effort.

Develop a prototype methodology for targeting waste with potential for reduction.

3) Develop or augment technical materials that address the most crucial needs of the targeted generators.

Identify, evaluate, and disseminate information on waste minimization alternatives for specific waste types.

4)

To effectively and efficiently approach this project, the NCPPP and NCHWS selected source categories to be targeted under this project. In selecting the sources to be targeted, the NCPPP and NCHWS conducted an analysis to determine which source categories have the greatest potential for waste minimization and whose reduction would significantly impact the total volume of waste being landfilled and combusted. Once identified, a list of source categories was compiled and reviewed. Based on this review, painting operations were identified as the source category to be targeted under the initial phase of this project. Painting operations generate a significant portion of the total quantity of hazardous waste being landfilled or combusted. pw 4 pr

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1u oTLLbp..v\- c d+vLbuw?&\ JF- - I Combusted as used throughout this report will refer to those wastes that are reported by

industry in the North Carolina Hazardous Waste Annual Report data as being incinerated, recovered for energy, and fuel blended.

1


1.2 Purpose

To assist the NCPPP and the NCHWS with their efforts to reduce the wastes being ~~

landfilled and combusted, Research Triangle Institute (RTI) under took a multi-task project to provided technical support in identifying waste reduction options and disseminating technical information on these options to industries generating hazardous waste from painting operations. To identify waste reduction options, RTI staff conducted a telephone survey and site visits to collect detailed information on painting operations; activities generating hazardous wastes; and past, present, and future pollution prevention activities. After information was collected and reviewed, recommendations on potential waste reduction options were identified. In addition, technical materials with discussions on painting operations were reviewed to identify potential waste reduction options not currently employed by the industries. Lastly, assistance was provided in identifying useful technical materials and effective means of disseminating information.

.____

1.3 Organization

This document presents the project methodology, the information gathered, and the results from this effort. Section 2 of this document provides an overview of the methodology used to identify waste reduction options and to develop information dissemination recommendations. In addition, this section includes a discussion of the telephone survey and site visits conducted to collect facility-specific information on painting operations and on hazardous waste generated from these operations. A discussion of the results of the telephone survey and site visits is provided. Finally, this section provides recommendations for conducting similar data collection activities under future projects. Section 3 identifies waste reduction options identified by the targeted industries and identified in literature. Recommendations for disseminating waste reduction information to the target industries are discussed in Section 4. Conclusions from RTI's efforts are presented in Section 5. The material presented in the appendices include the generic telephone survey questionnaire, 1992 facility-specific waste generation and minimization data, telephone survey response summaries, sample site visit confirmation letter, generic site visit questionnaire, site visit reports, and sample site visit thank you letter.

2


2.0 METHODOLOGY@

2.1 Overview of Methodology

To identify waste reduction options for industries that generate hazardous waste from painting operations and to provide recommendations on disseminating information on these options to the industries, RTI completed various tasks. A telephone survey and numerous site visits were conducted to obtain detailed information on recurring, non-remediation, manufacturing hazardous painting wastes. An analysis of these data was conducted to identify potential waste reduction options. Additionally, technical materials on painting operations were reviewed to identify innovative waste reduction options not identified by the targeted industries. To encourage waste reduction and assist industry in reducing waste, RTI staff worked in conjunction with the NCHWS and NCPPP staffs to identify useful technical materials and effective means of disseminating information.

2.2 Framework

To support the NCPPP and the NCHWS in their efforts to reduce wastes being landfilled and incinerated, RTI under took a multi-task project to study waste generated from painting operations and to encourage waste reductions of these wastes. A three-tiered approach was used to complete this study. First, information from targeted industries on painting operations; activities generating hazardous waste; and past, present, and future pollution prevention activities was collected. Secondly, waste reduction options were identified. Lastly, recommendations for disseminating waste reduction information to targeted industries were developed.

To collect information from targeted industries on painting operations, activities generating hazardous waste, and pollution prevention activities a telephone survey and site visits were conducted. A telephone survey was conducted to develop an understanding of the industries’ painting practices and activities that are associated with hazardous waste generation, identify applicable waste reduction options, and identify ways to improve the transfer of waste reduction information to appropriate industries. Site visits were conducted to representative facilities to augment information collected during the telephone survey. For example, site visits provided specific information on paint type applied, painting techniques, application equipment, equipment cleaning, costs associated with operations and waste management, and past, present, and future pollution prevention activities.

3


Waste reduction options were identified based on information collected during the telephone survey, site visits, and from the literature. Responses to the telephone survey were ,reviewed to identify areas with the greatest potential for pollution prevention and feasible pollution prevention options. Information collected during the site visits were used to assess the feasibility of implementing specific waste reduction options. Literature on painting operations were reviewed to identify waste reduction options currently not being used by the surveyed industries.

~~~~ ~~

~ ~~ ~~

.___

\ RTI staff worked in conjunction with the NCHWS and NCPPP staffs to identify useful

technical materials and effective means of disseminating information. Technical materials relating to minimizing waste from painting operations were identified, reviewed, and a bibliography was prepared. In addition, recommendations on information dissemination provided by the facility contacts during site visits were compiled.

2.3 Telephone Survey

A telephone survey was conducted to collect site-specific information from the facilities that reported generating hazardous paint waste. Prior to conducting a survey, it was necessary to define the survey population, identify the survey sample, and develop a questionnaire.

2.3.1 Industry Selection

To define the survey population, the 1992 NC Hazardous Waste Annual Report (NCHWAR) data base was used to identify those facilities that reported generating hazardous waste from painting operations. Once identified, hazardous waste data reported by these facilities were obtained from the NCHWS. These data were sorted by their 2-digit Standard Industrial Classifications (SIC) codes. The population of facilities generating painting wastes in 1992 is defined by 31 2-digit SIC’S representing 178 facilities generating 8.8 million Ibs/yr of hazardous,waste. Of this total quantity of waste, 5.6 million Ibs/yr are combusted or landfilled. ‘5; p n Y , &. n

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Due to the time constraints, only a fraction of the total population of facilities could be contacted as part of the telephone survey. Therefore, it was determined that only those industries with the greatest potential to reduce their wastes and those industries whose waste reduction would significantly impact the total volume of waste being landfilled or combusted would be included in the telephone survey sample.

~~ ~~~~

,,.% 8: u&”w wJav%%zs. w fiM f3-

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w\Bs q-GS V - h - 7

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4


To identify the industries for participation in the telephone survey, an analysis was conducted using the 1992 NCHWAR data. From this analysis, it was determined that 7 2-digit SIC’S comprised of 118 facilities that generated hazardous paint waste would be targeted under this effort. Facilities comprising these industries generated more than 7 million pounds of hazardous painti - percent of the total quantity o painin waste generated in 1992. Of this 7 million, 4.5

illed.

waste in 1992.2 This quantity comprises more than 80

million Ibs/yr were combusted a o Table 1 identifies the 2-digit SIC’S that were identified for inclusion in the telephone survey, the number of facilities comprising each SIC, and the total quantity of hazardous paint waste generated by each SIC.

2.3.2 Telephone Survey Questionnaire Development

With assistance from the NCPPP, a generic telephone survey questionnaire was developed to collect information on each facility’s painting and coating opera t ionyhazardoue waste generation and pollution prevention activities. The generic questionnaire is presented in Appendix A. For some of the targeted industries, the generic questionnaire was modified to incorporate industry-specific terminology.

To ensure that the questionnaire would be useful in collecting the needed information, technical reference materials on targeted industries, paint types, application techniques, application equipment, and clean-up techniques were reviewed. These materials included books, videos, journals, and vendor brochures. Review of these materials, enhanced the RTI staffs’ understanding of the industries’ painting operations and the activities associated with hazardous waste generation.

To collect information on the facilities’ painting and coating operations, questions addressing the following topics were developed:

composition ( e g , wood) and configuration of products being painted; type and age of application equipment used; type of coatings or paints applied (e.g., waterborne paints); number of coats and colors of coatings applied; purpose of coatings; color changing requirements;

* Facilities comprising the 2-digit SIC 9700 generate 5 percent of the annual hazardous painting wastes. Only a small fraction of these wastes are combusted. Under guidance from the NCPPP staff, these facilities were included in the telephone survey .

5


SIC CODE INDUSTRY SECTOR

2500 Furniture and Fixtures

3000 Rubber and Miscellaneous Plastic Products

3400 Fabricated Metal Products (excluding machinery and transportation equipment)

3500 Non-electrical Machinery

3600 Electronic and Other Electrical Equipment and Components

(excluding computer equipment)

3700 Transportation Equipment

9700 National Security and International Affairs

Table 1. Industries Included in Telephone Survey Sample

NUMBER OF PAINT WASTE FACILITIES’ GENERATEDIN

1992 (LBS)

38 3,695,054

6 377,919

16 531,277

19 697,917

19 309,825

10 948,991

10 444,49 1

The numbers in this column corresponds to the number of facilities identified in the NCHWAR data base as generating hazardous waste; it does not indicate the total number of - facilities in each SIC. ~~~

6


- routine cleaning procedures; and personnel training requirements.

Responses to these questions were intended to provide a thorough understanding of why specific paint and application techniques were employed by each facility. A thorough understanding of each facility’s operations was essential in assessing the feasibility of waste reductions options.

Specific questions concerning past, present, and future pollution prevention activities were developed. The objective of these questions was two-fold: 1) to identify potential pollution waste reduction options; and 2) to determine the industries’ technical assistance needs. To identify potential waste reduction options, questions requesting information on the implementation of pollution prevention programs or any strategies to reduce painting or coating operation wastes were developed. To assist in assessing the feasibility of any identified options, questions were developed that requested the facilities to identify the benefits of implementing these programs or strategies. To determine the industries’ technical assistance needs, questions were developed that requested facilities to identify the type of assistance that they would need to implement any pollution prevention initiatives or to overcome any implementation obstacles.

2.3.3 Telephone Survey Background Information

Prior to conducting the telephone survey, 1992 hazardous waste generation data and waste minimization information were obtained from the NCHWAR data base and compiled. This information provided general information on the types of wastes being generated and identified the major barriers preventing each facility from implementing waste minimization activities. Specific data compiled included the Environmental Protection Agency (EPA) hazardous waste identification codes, physical form codes, waste quantity, and off-site shipment code associated with each painting waste that was reported. In addition, facility responses to the following waste minimization questions were compiled.

- Did this site begin or expand a source reduction activity during 1991 or 1992?

Did this site begin or expand a recyclinx activity during 1991 or 1992?

Did this site systematically investigate opportunities for source reduction or recvcling

-

- during 1991 or 1992?


Identify the factors that delayed or limited this site's ability to initiate new or additional on-site or off-site recycling activities during 1991 or 1992.

- Identify the factors that delayed or limited this site's ability to initiate new or additional source reduction activities in 1991 or 1992:

Appendix B presents compiled data for each of the surveyed facilities.

2.3.4

Using the telephone survey questionnaire and the hazardous waste data, the telephone

Summary of Telephone Survev Responses

survey was conducted. As discussed above, the telephone survey sample included 7 2-digit SIC'S comprised of 118 facilities. Of these facilities, 93 facilities provided responses to the questionnaire. Resulting in a response rate of approximately 79 percent. The 93 responding facilities generated 85 percent, or 3.9 million Ibs/yr, of the total quantity of hazardous paint

w.$' waste generated by the targeted SIC%, o e p e r c e n t of the total quantity of hazardous paint * IW z>"" waste generated in 1992. Because the questionnaire was extensive, the approximate amount P*IdT '' of time required to interview each facility was 50 minutes. In some cases, the telephone I survey questionnaire was faxed to the facility prior to the telephone interview. Also, a few facilities provided written responses to the faxed questionnaire and returned their responses by fax. Regardless of the method that was used to obtain responses, answers to all the questions were typically not obtained. Appendix C presents a summary of the telephone responses obtained from each of the 93 facilities.

+i% or-

8,8 m ~ i d

For each of the responding facilities, waste generation and management data obtained from the NCHWAR data base were compiled. These data are presented in Table 2. For each responding facility, Table 2 identifies the apportionment of the facility's waste quantity to the various waste management practices: The fraction of waste being managed off-site was calculated based on the reported quantity of waste reported as being shipped off-site and the total quantity of hazardous generated by the facility. The fraction of waste managed on-site

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~~

In some instances, the percentage of waste being managed exceeds 100 ( i s , the quantity of waste managed is greater than the total quantity of waste generated). One explanation for this - occurrence is that waste that was generated in 1991 was stored on-site until 1992. ~~ ~

8

- i I

~ Percent

Corn an IC 25: Fumitt

Code and Fi:

3069 Eaton

Corporation golf club grips 169939

'otal Paint Waste

Seneratec (Ibs)

21000

41 973 ~~~~

111464

~~~~

122760

~~~~~ ~~

286275

~~~~ ~

274805 . . .~ ~

36100

. ~

1574490

~~~~~ ~~ .

38637

Products PaintedKoated

res wooden dining & bedroom furniture

wood furniture

0.6 251 1 100 Baker :urnittire Co.

Cochrane Furniture Co.

La-Z-Boy Chair

Company (Two Plants:

Hammary Plants #14 &

#15) Progressive

Furniture Company

Thomasville Furniture (8 facilities)

Identification- Confidential

Lane Upholstery

Plant Broyhill

Furniture (7 facilities) Southern Furniture Company

~~~~~~~ ~

~. . __

0 0

1 0 251 1 96.2 3.8

2500 wooden tables 3 0 0 39.3

~~~ .

87.5

57.8

251 9

251 1

fiber board

~~~~ ~~ ~ ~ ~~~~~~

furniture

kitchen and bath cabinets .

wicker and rattan furniture

3 0

8 0 - .~

0 251 1 .. .

2500

7 0 ...

0 1 0

251 1 wood furniture 43 1 .I

251 2 wood casegoods 1 4.2

;IC 30: Rubber and Miscellaneous Plastics Products

O ' I i 44.9 1 95.1 \ 0 1 0 1 4.9

Table 2: Telephone Surveys- Facility Specific Waste Generation and Management Data -

'ercent ;torage )ff-site

0

~

Consolidated Metco

otal Paint. Waste

ienerated (Ibs)

73468

11 6051

'ercent Fuel-

Blended 3ff-site

0

i Percent Percent 1 Sludge .andfilled I Dewatering OffIite 1 OffIite

I

I 'ercent Solvent lecovery Off-site

0

'ercent icinera- ed Off-

site

63.8

-

- - ~ ~ ~ -

0

0

p-

~

89.8

Percent Energy

Recovery Off -site

0

0

0 ~ ~~ ~~~~ ~~ ~

~~~~~

0

Percent danaged On-site

36.2

SIC Code

3079

- erceni If SIC

19

- Products

PaintedEoated large plastic

moldings (e.g. truck dashboards) dashboard

components

tires

:awn Plastics 3079 31 0 0 0

301 1 41 0 0.1 0

0

nent

100 0 Bridgestonel Firestone Council

Business Furniture and

Council Craftsman

Incorporated (2 separate facilities)

$IC 34: Fabric Florida Steel

Drum Company

General Stee Drum

Corporation

Croft Metals

~~

mahogany furniture for both business

and residential use

'roducts, Except Mz

3036

!d Meta

18111

iinery and

167850

5 0 0 0 0 10.2

55 gallon steel 3412 ~ drums

3412 1 steel drums

7 shaped aluminum i pieces (storm & ' patio doors, tub 8, 1 .- shower enclosures)

I

3441

11 5766

81 628

3433 ~ commercial heating units ~. -~p-

32959 Mestek Incorporated Beta System!

Division, Velcon Filter:

Inc.

1 fuel filters and fuel 3479 I storagetanks

2861 1

Company Crane

Resistoflex . Company

ireif Brothers Corporation !iller Brewinc Company

(ale Security Inc.

Freightliner Parts

lanufacturinc Plant

Fenestra Corporation Crown Cork

and Seal Company

:uttis-Wright light System:

~~~~

~~~~~~~

ercent

Yalker Kidde erospace IIX

Engineered Control

International IC 35: None1 Asmo North

Carolina

i I Percent ~

Fuel- 1 Solvent ~ Incinera- Energy Percent ' Percent ~ Sludge pdcent blended Recovery ~ ted Off- Recovery Storage I Landfilled ~ Dewatering/ Managec 1 Products 1 PaintedCoated

plastic-lined iron piping for caustics

and acids

steel drums

- p ~ - ~- ~

cast iron & PVC

closures

fixtures for holding components onto

truck ~~~ ~ ~ chassis hollow metal doors

3490

~~~~

steel cans-(food packaging)

341 1

1 aluminum and stee

components fire suppression equipment for aircraft and

aerospace vehicles

LP gas valves and regulators

3499 ! aerospace

rical Machinery

3585 metal housings and

end-frames

otal Paint. Waste

he ra ted (Ibs)

26884

17855

12210

1 1438

11 385

10500

6889

4976

21 68

158

38451

2 1 1 0 0 1 O l o 1 ~ 0 ~ 100 I o

-~

NA NA

I

. .

Table 2: Telephone Survevs- Facili Specific Waste Generation and Management Data - - 'ercent icinera- ed Off-

site

0

-

-

erceni

0.6

- 'ercent Fuel-

,lended 3ff-site

62.9

Percent Sludge ewatering Off-site

0

otal Paint Waste

ienerated (Ibs)

7000

-~

371 1

'ercent Solvent lecovery Off-site

0

Percent Energy

Recovery Off-site

0

e N 'ercent

itorage a 37.1

Percent .andfilled Off-site

0

Percent Aanaged On-site

0

SIC Code - 3585

3545

Products Painted/Coated

steel and copper compressors

tee1 coil retractablf measuring tapes /

folding wooden rulers / nylon

measuring tapes air filters / military :abinets &furniture

mobile cranes

__

Companv Matsushita Zompressor Corporation

Cooper Industries

0.5 100 0 0 0 0 0 0

57339 8 -~

2

43.2 0 0 0 0 0 56.8 3552 Pneumafil Corporation American

Crane Corporation

0 118.1'

~~ ~

0

0 0 0

- .

0

0

0

0 3531 12775

ydraulic excavator 47500 7 0 0

0 ~~

97.8

0 0

0

3524

3586 ~

3569

leere-Hitach

steel gas pumps 2 ~

1

0 ~

0

0 -. -

0

0

0

0 0 ~

0

~~~ ~

Gilbarco - Inc. 15786

7292

~~~

21772

iir operated transfe pumps, grease

pumps, hose reels (aluminum __ & steel)

front loaders

Balcrank Products

'ME America Inc.

Outboard Marine

Corporation (OMC)

(Andrews) ionda Powe Equipment

MFG. Altec

Industries

~ -~~

-

0 0 2.2

3537 3 94.8 0 0 0 0 0 0 5.2

70 0 0 0 30 351 9 marine motor park 1242 0.2 0 0 0

3524 189150 27 0 0 0 50.1 46.9 0 0 3 steel lawn mowers

steel truck & trunk parts 3536 25600 7 0 0 0 0 104' 0 0 0

- - 'ercent icinera- ed Off-

site

1.3

-

~~ ~

0

. ~~~~~

0

pment

0

0

0

50

.~~ ~~~~

0

ercent

-

SIC Code

3519

-

Percent Fuel-

blended

-

'ercent storage Sff-site

0

'otal Paint Waste

2enerated (Ibs)

127902

67571

~ ~~

Percent Energy

Recovery Off-site

0 - ~~

0

Percent Solvent 3ecovery Off-site

0

~ -~

0

~~~~~~

0

iputer Ec

0

~~

0

~_____

0

0

-~

~ ~~~

0

Percent Sludge

iewaterins Off-site

0

Percent andfilled Off-site

0

Percent danaged On-site

97.6

Products PaintedICoated Company

;onsolidated Diesel

Corporation Outboard Marine

Corporation ( O W

~- (Burnsville) Jackson- Division of Textron

;IC 36: Electr Square D Company (Monroe)

~~~~ ~ ~~~ ~

AT&T

~~~~

:aterpillar Inc General

Electric Co. (Hickory)

identification, Confidential

diesel engines

351 9 marine engines 10 1 100

1 ~

0 0 0

______...- ~~

metal parts of iarious shapes an(

sizes er Electrical Equip1

arge custommad6 transformers

general electronic equipment. for

commercial and residential use

(equipment racks, coverings &

_ _ housings) tractors

transformers for residential and commercial use outer cabinets of

switch boards and power panels (for commercial and residential use)

~ ~ ~~

.___

3523

c and C

3612

3661

~~

3674

3612

1 ~ 100 0

0

0

~

0

0

0

0

0

16.4

~

0

0

~

6650

it and Cor

60499

1566

- ~~~

12300

15750

0

0

0

~- ~

0

0

:xcept C

100

0

_____

100

0

~

ments

22

0.5

4

5

~

2 3622 5670 14.5 85.5 0 0

Table 2: Telephone Surveys- Facility Specific Waste Generation and Management Data

3646 large high-power lamps (street &

stadiums)

3679 satellite dishes

-

ercen ,f SIC

13

-

- 'ercent Fuel-

Aended Dff-site

0

-

'ercent Storage

0

otal Paint Waste

ienerated (Ibs)

39545

22080

I

Percent Sludge

Newatering Off-site

0

0

~

0

Percent Solvent lecovery Off-site

0

Percent ncinera- ted Off-

site

28.9

Percent Energy

Recovery Off-site

43.4

~~ ~ ~~ ~~ ~

0

Percent Aanaged 0 n - s i t e

27.7

4.2

Percent .andfilled Off-site

0

SIC 1 Products Code ~ PaintedKoated

electrical control 3613 devices

telecommunication! equipment (sheet steel & aluminum)

3536 1 3621 electric motors

~ ~~~ ~~~ ~

Companv Square D Company (Asheville)

Alcatel Network System

Ohio Electric Motors

Hamilton IeachlProctor (Mount Airy) Vestinghouse

Electric - (Arden)

identification. Confidential

7 95.8 0 0

-~ ~~

82.7

0 0

7214 2 0 0 0 0 0 17.3

3630 1 0

0

0 0 100 0 0 0

-~

0

0 toasters &toaster 1 ovens 3634

iswitch units &, startc 3622 1 motors

3002 1 0 0

-

0

0 100 0 0

0 0 0 0 0 5441 2 100 0

ILCO Unican Corp.

push-button acces! 1 code locks (for 3662 1 buildings)

1238 0.4 0 0

0

100 0 0 0

0 0 0 0 Channel Master

1732

5587

0.6 100

Nestinghousc Electric

(Fayetteville)

I electrical control devices

0 0 0 107' 0 0 0 2 0

Products PaintedCoated

uninterruptible power supplies

(commercial use)

iipment

xterior of sea-going vessels (including

ferries)

truck axles

exterior painting of their building

hydro-mechanical uel control systems

(aircraft)

emanufactured air- brakes for trucks

~~~

-

Total Paint Waste

Generated (Ibs)

23200

23140

__

1100 (landfilled)

504

2000

11268

' Percent Fuel-

ercent blended i f SIC Off-site

i Percent ~ Percent 1 Percent i

Solvent ~ Incinera-/ Energy Percent Recovery ~ ted Off- I Recovery : Storage Off-site ~ site j Off-site j Off-site

I Landfilled Dewatering Off-site Off-site

Manage( On-site

Percent ~ ;zt ~ Percent

21 0 0 0 0 111. 0

2 100 0 0 0 0

~ . _ _ _

100

0 0

0

0

0

~

0

0 ~. -

0

0.1 0 0 -

0

0 0 0

0.05

0.2

12v 0 0 0 0

0 0 0 80 0 0

1 0 0 0

79.7

77 .~

0

0 0

1 1 0 0 I 107301 buses (primarily school use) 0 0

~

0 ustom made heavy duty trucks (class 207009 I 6,7 & 8) '

22 86.5 0 0 0 0

I I

Table 2: Telephone Surveys- Facility Specific Waste Generation and Management Data

Total Paint- Waste

- I I I I I I

Percent Storage Off-site

I 1 Percent 1 Percent Sludge Percent

Landfilled Dewatering Managec Off-site Off-site i On-site

I

I aircraft & aircraft

9711 ~ components 189379

9711 9674 portions of sea- going vessels (some land-based objects) -t . ._

.. equipment -. .

aircraft, aircraft components &

miscellaneous base

touch-up of chemical resistant coatings &

971 1 complete repaints of .; 1 non-combat equipment

~~

2781 7

46321

Company

Freightliner (Cleveland)

IC 97: Natior

US. Marine 3rps Air Basc :herry Point]

59 ! 0 6.3 i 19.2 0 ~ 0 , 0 1 0 1 7 4 . 5

I

12.1 0.9 10.7 45

~.

0

43 31.3 0

1 above-water I JSCG Base Fort Macon

(Atlantic Beach)

I S . Air F G Base

(Seymore Johnson) ._~

US. Marine Corps Base

LeJeune) (Camp

2

6

0 0 0

17.6

100 0

0 82.4 0 0 0

10 0 0 0 183.8' 0 0

SCG Suppoi Center

(Elizabeth City)

JS Air Force Base (Pope) JS Army Forl

Bragg

~-

;;;; ~ ;r;ft 1 10634

13628

130079

aircraft & ground- support equipment

tactical ground e ui ment

2 0 83.5 0 0 0 0

3 0 0 0 100 0 0

29 -

0 - 0 -

0 100 -

0 0 -

Company US Military Ocean Ter. (Southport)

I / l l

, I ~

i ~ ~ i I

Total Paint- I Percent Percent i Percent ~ Percent i Waste

Products Code ~ PaintedKoated (Ibs)

971 1 I truck trailers 1084 0.2 1 0 0 0 ~ 0 I2163.5.~ 0 1 0

i I SIC ~

i i I I I

~ j I I

I , I


was estimated based on the quantity of waste not shipped off-site (Le., the difference between the total generated quantity and the quantity shipped off-site).’ As seen from Table 2, the responding facilities reported that the majority of their wastes were shipped off-site for fuel blending. However, two facilities, American Crane Corporation and Freightliner Parts Manufacturing Plant reported that all of their paint wastes were sent for solvent recovery.

Table 3 provides an overview of information collected from the telephone survey summaries. These summaries are presented in Appendix C. The facilities identified in this table are grouped by 2-digit SIC codes. For each facility, the table identifies the product that is painted, type of paint applied on-site, maintenance practices (e.g., gun cleaning procedures), paint application method, sources of wastes, waste reduction techniques that have been implemented, and waste reduction techniques that will be considered in the future. The following paragraphs discuss analyses that were conducted on this information.

As seen in Table 3, a variety of products representing several substrates including wood, rubber, metal, plastic, and nylon are painted or coated. Since each substrate has specific coating requirements, a separate analysis for each substrate, excluding nylon, was conducted. Since only one facility reported painting nylon and the painting of nylon was only a fraction of the facility’s painting operation, sufficient information was not available to conduct a separate analysis for nylon.

Of the 93 facilities responding to the telephone survey, 26 (28 percent) reported coating wood. Twenty-four of these facilities are in SIC 2500; the other two facilities are in SIC 3000 and 3500. These facilities generated 29 percent of all painting waste generated in 1992. Table 2 indicates that the majority of these facilities sent their wastes off-site to be combusted. The most common types of coatings applied by these f cilities are stains,

or high-solids coatings. The majority of the facilities reported that they applied their coatings with high-volume, low-pressure (HVLP) guns and conventional guns. The major sources of

- washcoats, glazes, sealers, and lacquers. Sixteen facilities reportit T! e use of either waterborne

’ It should be noted that sufficient data were not available to apportion the quantity of waste managed on-site.

18

:ompany/ Faciiitv

Broyhill Furniture

Southern Furniture company

; 30: Rubbc

Eaton ;orporation

onsolidated Metco

Products ainted1Coated

vocd furniture

ood casegoods

- ubstrate -

wood

wood

Id MiScellaneOuS Plastics I

golf club grips

~~

large plastic moldings (e g

truck dashboards)

rubber

plastic

Paint Tvpes

most paints are high- ,lids with some 100% solids) toner / stain I ash-off I glaze I sealer 11-3 topcoats (UV)

lains / lacquers I high- solids

day / spray booths are ,cleaned every 3-4 weeks 1 (rotabng schedule)

I I

1 Maintenance Practices (types of cleaning 1

Application Methods solvents) ~ Sources of Waste

I application equipment a 1 I i spray lines are cleaned j between stain changes / applicafion equipment is 90% finishing I 10%

booths i cleaned in buckets of wash-off solvent overnight I spray booths utilize peelable

spray guns & paint

~L-. ??!!E

'during color changes, old 1 color paint is captured I

I 1 andretumedtopump ~

house for future use I spray guns are placed in ' cleaning solution each ~

spray guns a spray 1 not specified

Waste Reduction Techniques

not specified

implementing use of baffle booth filters (filters are

recycled)

Targeted Areas for %lure Waste Reductio

switching from disposable to-

f&rs / evaluating different coating

systems ( Unicarb & high-solids)

not specified

i overspray collected in a 1 water bath (accumulated spent MEK is recycled 1 I

[distillation) on-site (installed exclusive use of watei based paints (1997) 1984) / water-based paints

solids are shoveled out 1 residual from ' spray booths wiU? hand- 1 and disposed of as 0% water-borne acrylic 1 distillation of spent

MEK ~ phased in 1990 30% solvent-based heid HVLP guns ' hazardous. wst.) I

@tones (polyurethanes) I . . wpiimtion equipment . for ~~

solvent-based paint is ~ . .cleaned with MEK ~

I i

N N

iini containing toluene I pressure guns in spray rubber cement ( 4 0 % booths I rubber cement toluene 8. hexane or is applied as drops and

naphtha) I then spread manually 1 1 application equipment 1 cleaned to remove dried cement once per month

Table 3: Telephone Survey- Summary of Facility-specific Painting Operations

paint filters containin! toluene / dried rubbei

cement

Company1 Facility

:awn Plastics

~

Bridgestonel Firestone

cohol, xylene, titanium/ lioxide, MEK, toluene, utyl acetate) I lacquer nitrocellulose, xylene. waterwash spray boothsi

naphtha' isobutyl

acetate, methyl amyl

j spray guns and paper filter spray booths or

(depends on facility) I one of the facilities also

Or uses flash-off ovens

Council Business

Furniture and Council

Craftsman icorporated (

separate facilities)

:IC 34: Fabric

Florida Steel lrum Compar

~. .~

General Stee Drum

Corporation

guns cleaned daily (8. 1 before color changes) 1

with spent paper filters / spent solvent

toluene, butyl acetate) I paper filters changed as

needed and spray booths cleaned weekly

Products

interior of drum: phenolics, epoxies, epoxy-phenolics I

rterior of drum: enamel

'aintedlcoated

interior coating lines flushed with MEK/

exterior coating guns are; cleaned by running

l solvent through the lines 1 interiors are painted with

airless centrifugal intercoater I exterior- ~

air-assisted airless gun i not specified

dashboard components

tlkyd melamine baking ~

namel I interior: epoxy, epoxyphenolic.

new color used to flush lines for exterior painting

1 during color changes

spent solvent (with entrained paint)

ienoiic-epoxy, phenolic1 I

tires

used to use MEK instead of I new color to flush lines 1 not specified during color changes ~

mahogany irniture for bott business and .esidential use

1 Metal Produc

55 gallon steel drums

steel drums

-

plastic

rubber

wood

Except h

metal

metal

-

I ~ Maintenance Practices 1 (types of cleaning

Paint Types I Application Methods I solvents) ~ Sources of Waste

water wash system used/ I to collect overspray I 1 distillation bottoms

lacauer . . auns cleaned with a i from recvclina of 1 hand-held guns 8. spray1

I I 1 soyution of 30% toluene, 1 spent solvent booms I

1 paint applied with high 1 1

i with brushes

ller I stain (methylethyl -++--- ketonej - !

i I iinery and Transportation Equipment

1 1

-7-+ exterior: high-solids,


ater wash spray booths pu place 1985 I spent solven recycling instituted 1988

iluene use reduced by 30% by 1992

foam filters were tested several years ago (did not work as well as the paper

filters)

not specified

Targeted Areas for :uture Waste Reductio1

not specified

reduce toluene use by 50% by 1995

switch to HVLP guns and on-site recovery 01

spent solvents

VOC reductions (to be focused on in 1994)

Facili IC 25: FumitL

aker Fumituri co.

PaintedKaated Substrate and Fixtures

Cochrane -urniture Co.

3-Z-Boy Chai ompany (Tm

Plants Hammary

Plants #I4 a #15)

Progressive Furniture Company

fooden dining Sdroom fumituri

~~

wood fumiture

wooden tables

~~~

fiber board

wood

wood

wood

md (i.e flber

board)

I I I

Maintenance Practices 1 I

(types of cleaning i i Waste Reduction ~ Targeted Areas for Paint Tvpes I Application Methods I solvents) I Sourcesof Waste I Techniques ~ Future Waste Reductio

(30 colors) stain / washcoat / glaze /

sealer / lacquer and and color (water basei a high-solids solvent-

based) .~

stain coals / washcos /glaze /sealer 13 topcoats of lacquer

nost coatings are high solids)

glaze or filler / sealer I stain I lacquer

high-solids paints and sealers used / 90% of printing materials are waterborne 2-3 base- coals / stain, sealer or Iaint I lacquer top-ma

spray booth with HVLP guns

pajnt booths 8 spray guns

HVLP guns are used to apply stain and glaze / conventional guns are used to apply lacquers

conventional & HVLP guns are used

application equipment cleaned daily / lines

:leaned yearly / spray 3ooths cleaned daily / peelable booth coats eplaced yearly / filters

changed weekly

infrequent soaking of acquer guns / removal of peelable coat from ,ray booth every 2 yrs !moval of peelable coti rom glaze booth every 6-8 months I metal

baffles in spray booth are swept down

;pray guns are soaked wemight in a 5-gallon

bucket containing solvent

guns are soaked in solvent / spray bwths

are swept daily

io% wash-off 150% booth-cleaning

1% lacquer dust fro1 rerspray / 20% sper olvent from cleanin! if equipment & liner

not specified

'5-30% printing / 65 5% sealer 8. iacque ipplication 15% glui

switch to HVLP guns / initiated TQM / tried

reprocessing wash-off solvent (failed-solvenrs

noisture content increased

improved spray gun management / optimized nozzle size (on guns) /

switched from applying 3 oats of catalyzed finish to;

coats

HVLP guns have improved transfer efficiency /

improved spray techniques lave reduced overspray I i program has been lnibated o recycle wash-off matena

~

purchasing machinery that wi l l allow the use of a 100%

solids lacquer

not specified

not specified

not specified

coatings I switching to high-soliddsealer / converiid to a dry

N 0

I Waste Reduction Targeted Areas for Sources of Waste I Techniques l Future Waste Reduction-

I

Table 3: Telephone Surw

Company1 Facility

Thomasville Furniture (7 facilities)

dentification Confide n tia I

Lane Upholstery

Plant

Products 'aintedCoated

furniture

itchen and bat1 cabinets

~ _ _

,icker and ratta furniture

- -

wood

wocd

__

vwd (i.e ticker ar ratfan)

. Summary of Facility-specific Painting Operations

Paint Tvpes

(waterborne paints are used at 3 facilities)

equalizer I sap stain I pre-stain I touch-up I

3ody slain I washcoat I wiping slain I sealers I glazers I pad or spray stain I shade stain I

lacquer1 padding stain

solvent-based stains I catalyzed and non- catalyzed sealers &

varnishes / white and brown paint I 100%

polids paint & ink I wate & solvent-based

topwats

stain I glazes I sealers lacquers I water-based paints I acrylic topcoat:

Application Methods

HVLP, air-assisted airless &conventional

guns are use

spray guns and rollers

iVLPguns&conveyo

Maintenance Practices (types of cleaning

solvents)

vash-off solvent is used I flush lines during coloi

change

~~~~. .~~~~~

nozzle tips of main line spray booth guns

changed several times per day I solvent

circulated through lines between color changes I

roll lines cleaned between color changes

with solvent I spray bwth overspray is

craped I filters removec daily

color changes involving solvent stains, lines flushed with lacquer thinner I application

equipment is cleaned daily (equipment for

solvent-based coatings- bucket of lacquer thinnei I equipment for water- based coatings- after

each use)

I I , ~~ i - initiatingon-site 1 light wlors are applied

not specified /before dark (decreases

I 1 change effort) i to water-based coatings

I lover the next several yrs

reformulating coatings to

quipment clean-up I overspray material

into elemental

not specified

1 HVLP guns conserve painting matenal I use

polypropylene plastic that can be scraped to cover

conveyor

20% waste solvent I

(wash-off lacquer hinner) I 10% stain I 0% sealer & lacquer

Ransburg Turbobell in booths are replaced uns 12 booths: airless twice per month I paper

guns on floor & booth filters are changed daily

~ ~

Sources 01 Waste Waste Reduction i Targeted Areas for

Techniques i Future Waste Reductior

I ised to have on-site Solvent

recycling (not enough olvent used to make it cost-

effective)

eliminate use of xylene and toluene as solvent

degreasers

~ ~~ ~~~~~~~~ ~~~

switched from Varsol & 1.1 ,l-TCA solvent to water-

Products 'aintedlcoated

hollow metal loors and door

frames

Company1 Facilitv

Fenestra Corporation

;UbSllalE

metal

Paint Types

3C-based, high-solids iking enamel (multiple

coiors) not sDecified

:riping (exterior): vinyl- type, solvent-based cquer I interior: water-

based epoxy

rless, automated guns1 used on interior I air tomized guns used on

I extenor

appllcahon equipment and filters cleaned

weekly

Crown Cork and Seal Company

Pased formulation I built neu collector boxes for spray nozzles I switched from solvent-based coating to

vater-based for interior pain

tee1 cans (food packaging)

not specified metal

rsed to apply primer and top coat to actuators, now only ipply primer I looking at lesi

toxic paint and solvents (problem is strict product

specifications from Boeing)

I application equipment aluminum and tee1 aerospace components

. . cleaned daily (with pain

thinner) I booths and filters cleaned (changed

iaint booths and hand- ield air atomized guns

Curtis-Wright :light System

2-part solvent based paint & primer metal not specified

I weekly

acquer 12-component mxy I chromate-base1

primers I air-dry enamels (the paints used can contain

:hrome, lead, zinc and cadmium)

re suppression equipmen4 for aircraft and aerospace vehicles

spent paint roverspray and pain hat has exceeded it

shelf-life)

iiriess and HVLP guns havt been considered for use I trying to order paints in

smaller amounts

Walker Kidde ierospace In1

air atomized guns & paint booths metal not specified

Table 3: Telephone Surve

Application Methods

Summary of Facility-specific Painting Operations

solvents) Company1

Facility

Ingineered Control

ntemational

C 35: None1

4smo North Carolina

MatSushita 2ompressoi Corporation

Cooper Industries

~~~~

PneumaRl Corporation

repositioned filters (increased life three-fold)

Products aintedlcoated , Substrate

free water-based pain for paint currently usel

1 .P gas valves I md regulators ! metal

r filters I military cabinets & furniture

A Machinery

ietal housings nd end-frames

1 metal

~~ ~,~

metal

eel and copper metal compressors

steel coil I

leasuring tapes 1

Paint Tvpes

icrylic, solvent-based enamel

?poxy-based coatings

'ater-based containing Pb

leasuring tapes: water borne paint, iron-

,hosphate, ink, clear- coat epoxy / folding ulers: solvent-based, k, high-solids epoxy a: a clear coat / nylon

neasuring tape: white solvent-based, ink

air spray guns 8 airless 1 paint lines are purged 1 between color changes rotor disc

iir bell / manual spray Ins /touch-up brushe:

/spray booths

conveyor hangers 8 electrodeposition dip

tank

-coat dip tanks I roller!

air spray gunslsome types of solvent-based electrostatic coating/ 5

paints paint booths (1 waterfai 2 down-draft, 2 dry-filtei

not specified

dip tank is cleaned annually

rollers cleaned by dripping solvent onto

hem 8 then wiping witt mgs

for color changes, quipment is purged wit1

solvent

~ Waste Reduction i Targeted Areas for Sources of Waste Techniques Future Waste Reductio

not specified ' I not specified

booth sludge (resulting from

overspray)

oltom sludge from e :oat dip tank (66%) / cloth filters (33%)

spent solvent & solvent soaked rags (from cleaning paint

rollers)

left over paint 8 iolvent (42%) I filters & used rags (28%) I leaning sludges fron paint booths (16%) / still bottoms from solvent recovery

(14%)

Binks centrifuge sludge removd system installed

1993 (reduced booth sludge by 50%)

not specified

not specified

switching from MEK-based cleaning soluiion to methyl

propyl ketone 8 ethyl acetate solution / water-

lased paint use began 1991 1

switching to use of water-based paints fo

dip-painting the woode 1 folding rulers

spent solvent is reclaimed ' on-site and used for paint ~

2 investigating alternativ thinning and equipment I cleanina [excess is blended

spray equipment " . , i for fuel)

- ubstrate - metal

metal

~

metal

~

metal

~

metal

metal

~~

metal


solvents)

guns cleaned with a mixture of toluene and

xylene

Company/ Facilitv

American Crane

Corporation

Products ainted/Coated

nobile cranes

-~

hydraulic excavators

eel gas pumps

air operated ansfer pumps, irease pumps,

hose reels (aluminum 8

steel) ~

front loaders

~~ ~~ ~

marine motor parts

..

steel lawn mowers


Targeted Areas for uture Waste Reductio Paint Types Application Methods Sources of Waste

spent solvent (from gun-cleaning)

solvent-based paint iluene-based paint for

finish coat)

electrostatic, air- atomized spray guns / irless guns (finish-coat

not specified not specified

)eere-Hitachi urethane paint manual spray guns & down-draft paint booth

with tiber filter

2owder paint is applied in an automated spray bmth I solvent-based high-solids is applied manually with spray

guns

~

between color changes, the system is flushed

MAK solvent from ~un-flushing / solids

from cleaning

switched from Cr-based paint to urethane-based

considering solvent recovery system

between color changes, system is purged with solvent (mainly butyl

acetate)

some of the spent solvent il recycled / switched from solvent-based to powder

paint

Nwder paint (first coat) solvent-based high-

solids paint

currently looking at converting more of thf )ainting over to powds

spent solvent from system purging Gilbarco inc.

paint filters (70%) / 3ent cleaning solven

(30%)

;witched to high-solids pair (because of color changes decided not to use powder

Balcrank Products

'ME America! Inc.

~

Outboard Marine

Corporation PMC)

(Andrews)

high-solids baked enamel (6 colors)

nanual spray guns and paint booth

100th is scraped monthl: not specified

aint scraps a residuf (from floor) I spent

aper filters from pain bwth

~ ~~~~~~ .- ~~~~~~

iaste from a dip-tank for solvent-based paint with barium

main source) I spent MEK solvent from

gun-cleaning (minor source)

guns cleaned with citrus solve /paint lines

:leaned periodically witt mixture of solvent &

-~--P*lnt

manual guns & a paint 100th (two guns, one fo

each color)

$witched from MEK to citru solve

solvent-based not specified

chromium dip-tank (aluminum parts) / electrostatic paint

application with hand- held gun I Corefilm 19 (solvent-based paint with barium applied

using a dip-tank) ~.

automated 2-wheel discs / automated electrostatic guns

chromium dip-tank (aluminum parts) /

solvent-based (MEK) paint / solvent-based paint (with barium)

switched from 1 , l . l - trichloroethane to slightly

caustic cleaner for cleanins gears prior to painting

searching for corrosioi protecting coating tha

does not contain chromium

guns cleaned with MEK caustic for cleaning

gears

ionda Power Equipment

MFG.

pns flushed with methy n-amyl ketone solvent during color changes

waste filter cake (50%) / spray bwth solids (percent not

supplied)

ic-phosphate precoat low VOC paint not specified not specified

i

Table 3: Telephone Survey- Summary of Facilitv-specific Painting Operations Maintenance Practices

(types of cleaning 1 Waste Reduction Company/ Facility

tec industrie

Targeted Areas for

:onsolidated Diesel

Corooration

solvents) 1 Sourcesof Waste

I spent solvent from gun 8 line flushing

(majority of hazardous

solvent (containing Auene) is used to flush

lines between color

Outboard Marine

Corporation ( O W

(Bumsville)

i Techniques Future Waste Reductio!

switched to solvent with less1 want lo an on-sitl 1 solvent recovery systen toluene /switched to high-

solids paint

Jackson- Division of Texlron

i c 36: Electr

Square D Company (Monroe)

AT&T

changes


steel truck & trunk parts

-_____

iiesel engines

~~ ~-

narine engines

metal pans of iarious shapes

and sizes

and Other Eie

large custom- made

transformers

general electronic

equipment for :ommercial am residential use

(equipment acks, covering a housings)

waste) I i ~

- metal

~

metal

-

metal

metal

al Equip

metal

metal

-

during color changes, nes are flushed with air

Paint Types

high-solids / DuPont lmron

I xylene-paint mixture resulting from system 1

have investigated alternative phase out use &law- flushing (majority of 1 paint~appli~ation techniques ~ voc paints low VOC paint

guns & lines cleaned !

between mlor changes with solvent containing still bottoms from

MEK 1 booth filters I solvent recovery

not soecified

~

solvent recycled using I distillation / switch from high investigating anon- VOC to high-solids paint has hazardous solvent for resulted in 40% reduction in cleaning guns & lines

.-

powder paint / VOC paint

11 and Components, E

.her: urethane-base< epoxy / topcoat:

ilyester urethane (bot nats are high-solids)

high-solids E water- based

Application Methods

manual spray guns & six different booths

robots with spray guns (majority of painting) 1

hand-held guns for touch-up

hand-held electrostatic guns & paint booth

-~

not specified

pt Computer Equipm'

VLP hand-heid guns i a down-draft spray

booth

hand-held guns in a paint booth

changed weekly and once every 6 months (2

types of filters)

luns flushed with MEK 1 xylene-based solvents I paper paint booth filters changed every 6 weeks

i hazardous waste generation I I

1 -+..~

tried to flush guns with ~

safety clean (did not work- I paint sets quickly) / switched' from use of oxide cleaners and perchloroethylene for powder paint

parts cleaning (prior to 1 painting) to less toxic

cleaners

a complete switch to not specified

i .-

I !

W e

Paint Types Company1

Facility

Channel Master

I (types of cleaning Application Methods ' solvents)

lestinghousc Electric

Fayeneville)

Exide Electronics

C 37: Trans1

NC. lepartment o ransportatioi :erty Divisior

~ ~

Dana Corporation

rolyurethane powder I ater-based high-solids

ISM Corporation

-

Allied Signal Aerospace Company

3wky Moun

automated electrostatic i not specified

i powder application

Products 'aintedICoated

iatellite dishes

cardboard shield '?cycled I guns cleaned daily1 booth cleaned

twice per year

iectrical contro, devices

.~

uninterruptible mwer supplies ommercial use

ition Equipmer

?xterior of sea- going vessels icluding ferriee

truck axles

.

xteriir paintin: )f their building

no-hazardous waste generated (since

switch to water-basei paint)

hydro- nechanical fuel :ontroi System5

(aircraft)

(reduced hazardous waste generation by 125000

ibdyear)

metal

_____~

metal

_____

metal

metal

__

metal

-~

not specifiec

_.

metal ~

~

electrodeposition d ip tank not specified I

i water-based acrylic 1

! ~

~

urethane

epoxy

~~

water-based

~

not specified

~~ ~

Aladine 1200 (30% chromium)

hand-held HVLP guns in a filter paint booth

not specified

i

iigh-pressure air guns (outdoors)

iigh-pressure guns in i 3aint booth (overspray caught on cardboard

shields)

not specified

air spray gun in a filtered paint booth

Sources of Waste

not soecified

not specified

._

spent filters from the 300th I spent solvenl from gun-cleaning

guns are deaned after spent solvent (xylene each use i from gun-cleaning

exterior waste disposed of as

hazardous due to not specified

I liability concerns I.. ___ ~

I

spent filters from the paint booth

not specified


not soecified

Targeted Areas for :uture Waste Reductic

considering the use o in-mold painting

~

paint is removed from the wash-off tank (post paint application) & returned to

the paint bath

' planning for a switch t

powder paint

~ ~1 ~~ ~ ~~~~ ~ -~ ~~ ~~~

' waiting for water-base , paint that meets produ not specified

! testing longer lasting paints (require less frequent

application- reduce overall ~

amount of waste generated) I

switch from solvent-based 3aint to water-based in 19a, (no hazardous paint-waste :

generated since switch) i I

i ~ ~.

not soecified 1

specifications

not specified

~~~~~ -

not specified

~.

not specified

~~~~~ ~~~

not specified

Table 3: Telephone Surw Summary of Facility-specific Painting Operations - ubstrati - metal

I Waste Reduction Targeted Areas for

Techniques Future Waste Reductio

Aaintenance Practices (types of cleaning

solvents)

spray booths cleaned monmiy

w h)

Company/ Facilitv

lidland Brak, incorporated

Products 'ainted/Coated

emanufactured air-brakes for

trucks

Sources of Waste

lent solvent (iacquei thinner) from gun-

washing ~~~~ ~~

50% paint residue / 50% spent solvent from gun-cleaning

Application Methods

iirless &conventional juns in a water-wash

paint booth

Paint Types

high-solvent 989 phased out the use of

paint containing lead 1 not specified

?poxy powder / oxide / iikyd backed enamel / high-solids urethane

robotic spray guns (powder paint) /air- issisted airless spray guns / air-atomized

spray gun ~~ ~ ~~

,uns cleaned wilh each >lor change, otherwise ley are cleaned weekly

switched to high-solids 1 urethane (for exterior) to ~

educe VOCs and increase ~ not specified

durability I rhomas Buil

Buses uses (primarily

school use)

~ ~.

custom made eavy duty truck: (class 6,7 a 8)

- -.

hassis and cab or class 6.7 & e

trucks

Security and lntl

iircraft & aircrat components

~~~ ~

above-water portions of sea- going vessels (some land-

based objects)

metal

PPG Uniprimer (aqueous-based with some glycol ethers) / 3uPont lmron $000 (2-

part activated myanate) / lmron 6001 water-based with somE olvent) / asphalt-quake

coat (IPA, water a solvent)

ied HVLP and electrostatic aint application (rejected) I instituted block building of ucks (build series of trucks that can be painted same :oior) / eliminate chromium and lead in top coats and ,witch to water-based paint possible (see Appendix C:

waste paint / spent booth filters /spent solvent from gun-

cleaning

r-assisted airless gur I water curtain and dr

filter paint booths

EUS on ways to furtht ?dwe paint waste an'

water-use

Freightliner :Mount Holly

~~

Freightliner (Cleveland)

IC 97: Natioi

US. Marine :orps Air Ba: ,Cherry Poin

booth filters changed every 2-3 days metal

~~ -~

(see previous entry)

same painting processes as Mount

Holly facility (see previous entry)

metal

xtional,

metal

(see previous entry) (see previous entry) (see previous entry) (see previous entry)

rs 1

?pow polyamiue prime :oat / polyurethane top :oat (both paints- high-

solids a low-VOCS)

hand-heid HVLP a air- I sanding residue from 1 trying to curtail use 01 MEK in wiping aircrat down prior to paintins

~~~~~~~~~~~~~ ~~ ~~ ~

possible substitution c ,itrus-based cleaners f solvenls currently uses

to clean brushes a rollers /possible use c disposable brushes 8

rollers

assisted airless in filter 1

a water-wash sprav 1 not specified not specified stripping of aircraft / ~

solvent soaked raw 1 ' . I booths MEK, n-butyl acetate) - 1

USCG Base

(Atlantic Beach)

Fort Macon not specified spent solvent used to

clean brushes & rollers

metal

Company1 FaciliW

I.S. Air Forci is8 (Seymoi Johnson)

U S. Marine Corps Base

LeJeune) (Camp

ISCG Supp Center

Ilizabeth Cit

US Air Fora Base (Pope:


3ircraft, aircraft components & miscellaneous base equipmen

touch-up of chemical

?sistant coating & complete

epaints of non combat

equipment ~~

aircraft

ircraflg grouni support

equipment

-

ubstrati -

metal

metal

metal

metal

Paint Types

igh-solids polyurethan, containing Cr

isocyanate-acrylic (chemical agent

sistant paint) I solven based paint

low-VOC lmron paint

epoxy primer (with strontium chromate) I )p coat: high-solids. lo

VOC polyurethane

Application Methods

and-held HVLP guns ir a filter paint booth

brushes I hand-held spray guns (in paper 8

water-wash spray booths)

land-held HVLP guns 11 a filter paint bwth

land-held HVLP guns ii i hanger (a paint booth with filtration system is under construction) / two additional water-

wash spray bwths (for support equipment) arE ilso under construction

daintenance Practices (types of cleaning

solvents)

pray guns are cleaned with MEK. which is

'ecycled using on-site solvent distillation

not specified

bwth filters changed nonthly I guns cleaned

daily (MEK)

not specified

Sources of Waste

paint residue containing Cr) from le sanding of aircraft / MEK soaked rags [used to wipe down ircraft after sanding)

excess paint I used brushes (for

isocyanate paint) I residue from water- wash spray booth (separated paint)

~~

spent booth filters I solvent from gun cleaning (MEK)

paint residue from sanding

I Waste Reduction 1 Targeted Areas for

Techniques 1 Future Waste Reductio

~ base is currently switching to electrostati

paint application / looking to substitute a

less-toxic solvent forth

e filters in the booth utilize catalyst-based 'OC

extraction

ase encourages the use o water-based paint when

possible

rfsycling of bead-blast ,esidue (for use in making bath tubs) initiated 1990 I ;witched to low-VOC paint

1992

not Specified

MEK

future efforts will focu! )n reducing the amour

of thinner used

nstallation of advance paint booths with 99%

transfer efficiency I ying to find a substitui

solvent for MEK

not specified

w P

booth filters changed very infrequently (small mount of oaintina done

Table 3: Telephone Surve

'

Company/ Facilitv

US Army Fort Bragg

-~

US Military Ocean Ter. (Southport)

Products 'ainted/Coated

tactical ground equipment

truck trailers

- metal

metal

-


Paint Types

water-reducible epoxy primer / polyurethane

(isocyanate)

low VOC paint

Application Methods

:onventional hand-held guns in dry filter paint

booths

hand-held air-assisted airless guns in a paper

filter paint booth

Maintenance Practices I

at the facility) / guns - 1 are not specified

cleaned daily, with the I

spent solvent being returned to the paint

stock

Waste Reduction Targeted Areas for Techniques Future Waste Reductio1

~

will be switching to HVLP guns

not specified

he military switched to the use of low-VOC paints '

several years ago , not specified

- ubstratf -

metal

~- ~

metal

. -~

metal

~

metal

- . Maintenance Practices

(types of cleaning solvents)

Company1 Facility

Croft Metals


shaped uminum pieces storm a patio doors, tub &

shower enclosures)

Waste Reduction Targeted Areas for Techniques 1 Future Waste Reductior Paint Types Application Methods Sources of Waste

ines first purged with aii 8. then flushed with PM

acetate solvent (not photochemically

reactive) during color changes

:hromic acid &fluoride ombination primer coal 'clear polish I solvent- based polyester paint

. . lased solvent to flush lines 11 ise to send overspray back I

to manufacturer for ~

recycling, but they now no I longer accept it ~

3ansburg electrostatic rotating disk system

spent solvent and paint overspray not specified

not specified

~~~~~~

not specified

~

not SDecified

'nes flushed with solven ietween color changes filters changed every 2

days depending on ransfer efficiency topart

being coated

l e try t o m e spent solvent

v n e r . .

-e. I

Mestek Incorporated

commercial heating units

uei filters and fuel storage

tanks

alkyd (high-solids, solvent-based)

reciprocating electrostatic disk

not specified

~

:hanged order of painting to reduce color changes and hence the generatnn of

waste I solvent distillation system (20 gallons every 2

days) i

3eta Systems Division.

irelcon Filters Inc.

juns cleaned with MEK iilters in booths replacet

once a month

chromium conversion :oatings I polyurethane

r-assisted airless gun! a paint booths

not specified

?quipment used to appl! water-based paint is flushed with water /

100th filters are change1 m e every 2 days (whei

suction decreases)

:urrent process of switching to water-based paints I

kwitch to use of 55 gallon ~

drums of paint instead of ~

iallon cans (55 gallon drums'

currently using high- solvent based mating anti-rust) I switching to

water-based 2-pari epoxy (60% solids)

lastic-lined iron piping for

caustics and acids

Crane Resistoflex Company

lost paint HVLP guns. ome special paint witt r-assisted airless gun!

spent water and esidual water-based paint (from flushing)

h) w

Table 3: Telephone Survf

Company1 Facility

ireif Brothers Corporation

Mer Brewini Company

Vale Securih Inc

Freightliner Parts

Aanufacturin Plant

I I

Products 'aintediCoated

steel drums

aluminum cans (for ingested

liquids)

duminum, stee :ast iron & PV( parts from dooi

closures

steel and luminum fixture

for holding omponents ont truck chassis

ubstrati -

metal

metal

metal1 plastic

.~

metal

-


Paint Tvpes

1% of drums with black enamel, 20% with

variety of other colors

ik printing I Waterborne varnish (exten'or) I waterborne acrylic lacquer (interior)

;olvent-based lacquers (40 colors)

?-coat: PPG Uniprimer (aqueous solution with some glycol ethers) I lop-coat DuPont lmron 5000 (2-part activated

isocyanate paint)

Application Methods

pray booths with both air-atomized &air-

misted airless guns

high pressure airless uns (controlled by pad iming) in paint booths

electrostatic air guns

1 e-coat booth :electrodeposition) 12 top-coat booths (air- 3ssisted airless spray

guns)

~~


solvents)

ipplication equipment & spray booths are

cleaned daily I during :olor changes, the new :olor is pumped through (recycled) until the new color appears relatively

undiluted

guns cleaned every 12 hours with solvent I

baffles are removed to :lean off overspray I frei liquids at bottom of the pray bwth are collectel

as waste

between color changes, lines are flushed with

thinner

guns flushed with cleaner between color

changes I guns cleaned at end of shifts I filters changed and booths

cleaned once per week

Sources of Waste

not specified

not specified

not specified

not specified


Statistical Process Control program used to reduce thc

amount of paint used (quality gages to assess

paint application instead of visual inspection)

modifying system set-up (gun angles) to optimize

transfer efficiency (+40%) ! reducing VOC

concentrations in coatings use of Statistical Process

Control to optimize efficiency (see above)

not specified

. -

tried to use HVLP guns for the top-coat, but the high- solids metallic paint which was used did not perform

well in the guns I eliminate< Pb and Cr in their top-coats

switched from MEK & acetone to n-methyl

pyrollidone (reduces solven usage by 50%)

Targeted Areas for uture Waste Reductior

not specified

not specified

aqueous cleaning systems1 high-solids

'aintsl turbo application powder coatings

not SDecified


hazardous generation identified by the facilities are overspray removed from spray booths and spent solvents used to clean application equipment and to wash-off furniture.6 The waste reduction techniques that have been implemented include:

/ Switching to HVLP guns to improve transfer efficiency; Improving spray gun management and spray techniques) Total quality management (TQM) program; Recycle of spent solvent or wash-off material; Applying light colors before dark to minimize the need for flushing lines with solvent; Use of cleanable polypropylene plastic on conveyor to catch overspray; Use of baffle booth filters (Le., these filters are recycled); and Use of foam filters.

Waste reduc in techniques that will be considered or implemented in the future include:

- Use of waterborne coatings; - Use of high-solids coatings; - Recycle of liquid wastes; - Reformulation of paint to reduce hazardous air pollutant (HAP) emissions;

Use of a system that will decompose organics into elemental components; and - -

‘1$ Use of reusable filters@

#Of the waste reduction techniques that have been implemented only two techniques were abandoned by the reporting facilities. These two techniques are recycle of spent solvent or wash-off material and the use of foam filters? Specifically, Baker Furniture reported that reprocessing of solvent increased the moisture content of the solvent to an unacceptable level and Council Business Furniture and Council Craftsman Incorporated reported that they tested foam filters several years ago but they did not work as well as paper filters.

Through the use of the waste form codes reported in the 1992 NC Hazardous Waste Annual Report data base, attempts were made to identify the major sources of the hazardous waste associated with the painting of wood and the other substrates. However, several of the codes that are frequently reported are non-specific and could not be used to identify waste sources.

Wash-off material is a solvent mixture that is used to remove substandard finishes from wood products. Once these finishes are removed, the wood products are refinished. Wash-off material often time is used for equipment cleaning.

35


As seen in Table 3, only 2 of the 93 facilities responding to the telephone survey reported painting rubber. Both of these facilities are in SIC 3000. The total quantity of hazardous paint waste generated by these facilities i hazardous paint waste generated in 1992. However waste was generated by one of the two facilities. Based on data presented in Table 2, the majority of the waste generated from painting rubber was sent off-site to be combusted (i.e., blended for fuel). The paint applied by the facilities is solvent-based. The paint applicati equipment used at these facilities include /- HVLP guns, roller, and brushes. The contact at the facility generating the majority of the reported waste stated that their waste was mostly comprised of spent solvent used to remove excess paint from the rubber product. The other facility reported that the majority of its waste was spent filters and spent coating. The waste reduction techniques that have been implemented by the major generator include the use of HVLP guns and reuse of excess paint captured as part of the paint operation. Future waste reduction plans for this facility include researching a solvent recycling strategy with the paint manufacturer.

.

___

Sixty of the 93 facilities responding to the telephone survey reported painting or coating metal products. These facilities are associated with the following 2-digit SIC'S: 34, 35, 36, 37, and 97. These sixty facilities generated 47 percent of the total quantity of paint '%A

waste generated in 1992. With the exception of facilities in SIC 9700, the majority of the G ~ r w * f l oaCwb*cm, facilities painting metal sent their wastes off-site for combustion.8 Of the 60 facilities o~L,,.+,onL,

painting metal, 52 of the facilities report using solvent-based paints with a variety of binders (e.g., epoxies, phenolics, alkyds, polyesters, and urethanes), 18 facilities reported using waterborne paints, and 8 facilities reported using at least some powder coatings. Solvent- based paints are reported as being applied with the following equipment: airless centrifuge intercoater; air assisted airless guns; electrostatic disk system; airless rotor disk; brushes; roller; dip tank; and conventional spray guns. The major sources of hazardous waste associated with the application of solvent-based paints are line flushing and gun cleaning with solvent and overspray (e.g., paint booth filters used to capture overspray). Waterbome paints are applied with high pressure airless guns, electrostatic turbine disks, air assisted airless guns, and in electrostatic dip tanks. The major source of hazardous waste associated with the application of waterborne paints is equipment cleaning with solvent. Spray guns are used to apply powder coatings. The following are the majority of the waste reduction techniques that were identified by the surveyed facilities:

+= "t

~~

As discussed previously, the majority of the facilities comprising SIC 9700 did not report combusting their wastes. However, these facilities were included in the telephone survey since - the total quantity of paint waste generated by the facilities is significant.

~ ~~~

36


Concerning future waste reduction initiatives, several of the facility contacts stated that theiI facilities would be implementing or researching the implementation of the waste reduction initiatives specified above. However, one facility (Le., Outboard Marine Corporation, Burnsville) will be researching the feasibility of reusable metal filters for use in their spray paint booths.

Two of the facilities responding to the telephone survey reported that they painted plastic products. These facilities are responsible for generating 2 percent of the total quantity of paint wastes generated in 1992. Both of the facilities are SIC 3000 facilities. As seen in Table 2, the majority of the paint waste generated by these facilities are sent off-site for combustion. Based on information presented in Table 3, both water- and solvent-based paints are applied at these facilities. At one of the facilities paint is applied with HVLP guns. Both of these facilities have on-site distillation for recycling the solvent that is used to clean application equipment. Both facilities reported that the majority of their hazardous waste is distillation bottoms. The waste reduction techniques that both facilities identified as being implemented was on-site distillation of spent solvent. Additionally, one facility reported switching to waterborne paints and the other facility has installation a water wash spray booth. A future waste reduction activity reported by the facility that is currently using some waterborne paints is the complete conversion to waterborne paints.

2.4 Site Visits

Nine site visits were conducted to augment the site-specific information collected during the telephone survey. The types of information collected during the site visits included facility-specific information on painting application techniques, paint types being used, clean-up procedures, waste reduction options that are being considered or have been implemented, and technical assistance needs. The sites considered for visits were identified based on responses to the telephone surveys.

2.4.1 Site Selection

The sites that were visited were selected based on various criteria including: 1) willingness to participate in a site visit; 2) the representativeness of painting operations (e.g., the materials being painted, painting application and equipment cleaning techniques being employed, and paint types being used); 3) significant hazardous waste generation rates; and/or 4) innovative waste reduction practices being used. During the telephone survey, facilities were asked if they would be willing to participate in a site visit. Only those facilities expressing interest in a site visit were considered for site selection. To collect information on the various types of painting operations, attempts were made to select representative facilities.

38

Waste Reduction Activities for Hazardous Wastes from Painting Operations /imAa-lM. dh.4 .h!,6,* 1

Modified line ushing tesnique {e&, between colors, switched from flushing

flushing with air followed by acetate solvent); Recycle spent solvent for paint thinning and/or equipment cleaning; Changed order of painting to reduce color changes and flushing of lines; Purchase paint in 55 gallon drums rather than smaller containers (Le., d ruda re recycled); pa65 TW M P ~ ww uwa Implemented statistical process control program to reduce the amount of p a h applied (Le., gages assess paint thickness rather than depending on visual inspectiod; Adjusted gun angles to improved transfer efficiency (e.g., one facility reported 40 percent increase in transfer efficiency); Switched to HVLP guns to improve transfer efficiency; Eliminated heavy metals in paints (e.g., switched from lead- and chromium- based paints to a 2-part activated isocyanate paint and switched form chromium-based paint to urethane based paint); Improved good inventory control and house-keeping to minimize disposal of

lines with ME 9 to using paint and switched from flushing lines with xylene to

f i

off-spec paint; Repositioned paint booth filters and increased life three-fold; - \ I q ) ' Instalk centrifuge system to reduce volume of paint booth sludge; Switc Reduced solvent content of paint (e&, switched from low-solids to high-solids paint and switched from solvent-based paints to water-based paints); Switched from using solvent cleaners to aqueous based cleaners (e.g., switched from using methyl ethyl ketone to using CitruSolve to remove overspray from

rom solvent-based paint to powder coatings; 4

aint collected in wash-off tank following electrodepositon dip-tank.

Of the waste reduction initiatives identified above, the following initiatives were investigated and then abandoned for the stated reasons:

. HVLP guns did not perform well with high-solid metallic paint; On-site recovery was not economically feasible (Le., spent solvent generation

Flushing guns with Safety Clean product did not work since paint set-up too

Solvent recovery did not work with urethane and epoxy paint; Waterborne paint did not effectively cover machined metal surface (i.e., too

Considered powder coatings but portions of the painted products were plastic

.

rate was too low);

quickly; -

- -

much oil on the surface); and

and powder coating did not appear to be appropriate. -

37


From each of the targeted SIC’S, excluding 9700, approximately four facilities were identified as potential sites for visits.’ Follow-up calls were made to the selected facilities to inquire about a site visit. Of the facilities that were contacted, the following 9 facilities agreed to site visits.

SIC 2500

SIC 3000 SIC 3400 SIC 3500

SIC 3600

SIC 3700

La-Z-Boy Furniture Company (Hammery Plant # 15) Cochrane Furniture Company Eaton Corporation General Steel and Drum Corporation VME Americas, Inc. Outboard Maine Corporation (Burnsville) Caterpillar, Inc. Facility Identification is Confidential NC Department of Transportation,

Waste generation and painting operation profiles for each of these facilities are presented in Tables 2 and 3 (Section 2.3).

Even though great efforts were made to visit sites that best represented the surveyed population, time constraints and the time period over which the site visits were conducted (Le., November and December) had a significant impact on which sites were visited and the number of sites that were visited. For example, a site visit was not conducted at Freightliner Corporation. This company generates a large portion of SIC 3700 hazardous paint waste, has implemented several innovative waste reduction techniques, and was willing to participate in a site visit. However, the Corporation’s schedule was not compatible with the time period over which site visits were conducted.

2.4.2 Correspondence with Facility

Once site visits were agreed to and the site visit dates were established, correspondence with the facilities included a site visit confirmation letter and a follow-up thank you letter. The confirmation letter stated the site visit date, provided an overview of the project, and identified the type of information that was to be collected during the site visit. To express our gratitude for conducting a tour of the facility’s painting operations, a follow-up thank you letter was sent to the visited facilities along with a brochure identifying

’ Due to time constraints and the uniqueness of Federal facilities’ painting operations, it was determined that site visits would not be conducted to 9700 facilities.

39


the various services that the NCPPP has to offer. A sample site visit confirmation letter and thank you letter are presented in Appendices D and E, respectively.

2.4.3 Site Visit Ouestionnaire

Prior to conducting the site visits, the RTI staff were provided with a generic site visit questionnaire and facility-specific questions. The generic site visit questionnaire was developed by the NCPPP staff. Appendix F presents this questionnaire. In addition to this generic questionnaire, specific questions were developed based on the facilities’ telephone survey responses. The questions were developed to collect specific information relating to the research and implementation of any waste reduction practices that were identified during the telephone survey.

2.4.4 Summary of Site Visit Information

As discussed above site visits were conducted at 9 facilities. The sites that were visited painted or coated wood, rubber, and metal substrates. Since each substrate has specific coating requirements, the information collected during the site visits is discussed below and organized by substrate being coated. A site visit report for each of the nine sites is presented in Appendix G.

Two facilities that coat or paint wood were visited. These facilities were La-Z-Boy Chair Company (Hammery Plant ## 15) and Cochrane Furniture Company. Both of these facilities are in SIC 2500. As discussed in Section 2.3.4, 26 of the 93 facilities responding to the telephone survey reported coating wood. These responding facilities generated 29 percent of all painting waste generated in 1992.

La-Z-Y Boy Chair Company (SIC 2500) finishes wooden casegoods, such as tables. The finishing process consists of spray application with air-assisted guns of toner, washcoat, glaze, sealer, hand sanding, lacquer, shade staining, and two coats of lacquer. These coats are oven-dried twice, once following the glaze step and again following the final two coats of lacquer. Coatings are applied with both air-assisted and HVLP guns. HVLP is used to apply stain and glaze. The majority of this facility’s hazardous waste is generated from over spray (i.e., lacquer dust swept from spray booths and cardboard used to cover conveyor) and cleaning of application equipment and wash-off operations. Waste reduction activities that have been implemented at this facility include the following.

On-site recycling of wash-off material by a recycling service. Approximately 80 percent of the wash-off is recycled for reuse.

40


- Switched from using conventional guns to using HVLP g ns to apply stain and glaze.

by 30 percent. A The HVLP guns increased transfer efficiency and reduc&e amount of coating used&'

Concerning the transfer of waste reduction information to the applicable industries, the facility contact suggested that information be presented at required seminars, such as, DOT and Haz Mat seminars.

Cochrane Fumiture Company finishes wooden casegoods (e.g., dressers and tables). The assembled casegoods are placed on a cardboard covered conveyor system that travels through the finishing operations. The finishing process consists of spray application of high- solids stain, glaze, sealer, paint, and three coats of lacquer. The coats applied to the casegoods are oven cured three times: after the glaze step; after the first topcoat of lacquer; and after the last topcoat of lacquer. Conventional, HVLP, and airless spra guns are used to

processes. Following flatlining and rollcoating, one coat of 100 percent solids lacquer is applied and UV cured. The major source of the hazardous waste at this company are overspray (e.g., lacquer dust from spray booths, cardboard conveyor and floor covers, and booth coatings) and wash-off material used to remove inadequate finishes. Waste reduction techniques that have been implemented or investigated include the following.

apply the coatings. Dresser drawer sides and bottoms are coated using arry . atline and rollcoat &?

- Between colors, the new color is sprayed through the lines for a predetermined period of time to clean out the old color. The paint used to flush the lines is collected for reuse.

- Use of HVLP guns to apply stain was tested, but these guns did not produce an acceptable finish.

Adjusted guns to improve transfer efficiency. Specifically, the facility adjusted the tip orifice of their airless and conventional guns to the smallest tip size. As a result, they reduced the amount of product used per day by 20 gallons.

Future waste reduction activities will include switching from a 3-coat lacquer topcoat finish to a 2-coat finish. This new system will use a precatalyzed coating that will replace the conventional nitrocellulose topcoat and eliminate the need for a washcoat. Other activities include switching from wet booths to dry booths. This switch will reduce liquid waste generation. The facility contact also stated that they are investigating the use of a washable or recyclable filter. They currently use metal baffle filters that are sent off-site to be cleaned. Concerning the transfer of information on waste reduction options to industries, the facility

41


contact suggested presenting the materials at seminars and forums and distribution of material through trade association ;

~ ~ ~~~~~

One facility, the Eaton Corporation, that paints rubber was visited. As seen in Table 3 (Section 2.3.4), only 2 of the 93 facilities responding to the telephone survey reported painting rubber. The total quantity of hazardous paint waste generated by these facilities is 2 percent of the total quantity of hazardous paint waste generated in 1992. The Eaton Corporation generated 99.8 percent of the total quantity of waste generated by the two facilities. The following paragraph provides a summary of the information collected during the Eaton Corporation site visit.

) & The Eaton Corporation manufactures and paints 80 percent of the w o r l 9 golf club grips. All paints that are applied at this facility are solvent-based. The paints are applied with rollers and HVLP guns. The major sources of liquid hazardous waste are spent solvent (acetone) used to wipe excess paint from the grips and an acetone mixture used to flush lines. These wastes are sent off-site for fuel blending. The major source of olid facility is overspray removed from the spray booth. Waste reduction in

aste at the es that have ? been implemented or investigated include the following. 9-

- Switching from using conventional guns to using HVLP guns has reduced the total volume of polyurethane used by 66 percent.

Using floating plastic beads to cover acetone has reduced acetone use by 40 percent.

The facility investigated using hot foil printing, transfer painting, and screen painting. None of these techniques proved to be acceptable.

- The facility attempted on-site distillation of spent’solvent, but the recovered solvent did not consistently meet quality requirements.

The facility is currently investigating the possibility of shipping spent solvent off-site to the paint supplier to be reused in paint. However, environmental regulations are proving to be the major obstacle to this effort. Concerning waste reduction information transfer, the facility provided insight that suggested that future efforts needed to be more specific. For example, workshops on painting or coating operations need to be substrate-specific.

Six site visits were conducted to facilities that paint or coat metal products. As discussed in Section 2.3.4, sixty of the 93 facilities responding to the telephone survey reported painting or coating metal products. These facilities are associated with the following 2-digit SIC’S: 34, 35, 36, 37, and 97. These sixty facilities generated 47 percent of the total

. ~~ ~~

~~~

42


quantity of paint waste generated in 1992. The following paragraphs identify these facilities and summarize the information collected during each site visit.

General Steel and Drum Corporation (SIC 3400) manufactures and paints 55-gallon drums. The exterior of the drums are painted with a high-solids alkyd melamine baked enamel. The paint is applied with air-assisted airless guns. Both dry filters and a water curtain are used in sequence in the exterior painting spray booth to capture overspray. The interior of drums are painted with solvent-based coatings containing epoxy and/or phenolic binders to protect against chipping and chemical corrosion. These coatings are applied with air-assisted airless guns in a dry filter spray booth. The major sources of hazardous waste associated with the painting operations are color changes and spray booth maintenance. The exterior painting operations generate the greatest portion of the facility’s hazardous paint waste. Waste reduction activities that have been implemented or investigated include the - following.

. Three months ago, the facility switched from using methyl ethyl ketone (MEK) to flush lines between exterior paint color changes to running the new color through the line to flush out old color. The waste paint is collected and returned to the supplier to be reformulated into black coating. It is anticipated that this effort will reduce liquid paint waste by as much as 30 percent. MEK is still used occasionally to clean lines.

- Eliminated the use of lead and chrome containing paints. / - a J

- -f? t Good inventory control and house-keeping minimizes the dispos$ of paint that was not used before expiration da@

Due to frequency of color changes and striping of drums, powder coatings are not feasible.

Waterborne paints do not meet product specifications.

f i

-

In the future, the facility will be investigating the possibility of sending spray booth filters through their drying ovens to cure residual paint. The facility is very interested in receiving information (e.g., fact sheets and case studies) on feasible waste reduction opportunities. They feel that videos would be especially useful for line operators who do not have time to read reports. Also, the videos can be shown to several individuals at one time and lead to follow-up discussions. The facility expressed interest in the NCPPP conducting an on-site waste reduction assessment. A

VME Corporation (SIC 3500) paints and touch-up parts of heavy construction equipment. Both a primer coat and topcoat are applidl with airless spray guns. The primer

43


is a modified alkyd solventborne coating and the topcoat is a modified alkyd solventborne enamel. Touch-up paint is applied with air atomized spray guns, brushes or aerosol cans. Paint lines are cleaned with solvent that is reused for paint thinning. CitruSolv is used to clean overspray from the tires. The majority of the facility’s hazardous solid wastes are generated during spray booth cleaning (e.g., spent filters and paint solids removed from walls and floors). The majority of the facility’s liquid hazardous waste is generated from line and gun cleaning. The waste reduction activities that have been investigated or implemented include the following.

~ ~ ~~~~~~

. In 1992, changed paint cleaning practices. Now, the solvent that is used to clean the lines is reused as paint thinner. This effort has decreased solvent waste generation by 50 percent.

- Good inventory control and housekeeping minimizes the amount of paint that is

The facility eliminated the use of chromium and lead containing paints.

discarded as off-spec.

-

Implementation of a cost accounting system encouraged a switch from MEK to CitruSolv for cleaning overspray from tires. The CitruSolv is applied to rags and the rags are used to wipe down the tires. Typically, the used rags do not contain enough solvent to classify them as hazardous.

The facility no longer offers custom product colors. Only two colors are available. Thus, allowing a separate paint line for the application of each color.

- The facility implemented a TQM program that encourages employees to seek solutions to problems.

In the future, the facility will be investigating electrostatic and HVLP systems.

Outboard Maine Corporation, Burnsville (SIC 3500) manufactures and paints outboard motor parts. The parts are manually painted with an electrostatic spray (air atomized spray gun) and then passed through a drying oven. Occasionally, touch-up paint is applied with aerosol cans. Four types of paints are applied at the facility: 2-component high-solids epoxy; electrostatic primer; acrylic paint; and silicon paint. The major portion of the facility’s solid

MEK used in gun and line cleaning. The following identifies the waste reduction activities that have been implemented or investigated.

hazardous paint waste is spent spray booth filters. The major source of liquid waste is spent . ~~~

~~~~~~

44


The facility switched from using corrosion preventing chrome containing paint to a 2- component high-solids epoxy. The epoxy consists of a paint component and a catalyst component that are mixed in a 4 to 1 ratio. Due to the higher solids content of the epoxy, the switch has reduced the amount of paint being applied. Additionally, VOC emissions have been reduced.

- In the past, the 2-component epoxy was prepared on a continuous basis using automated measuring equipment. However, the system did not consistently and accurately mix the paint. The facility switched to a batch system where 5-10 gallons of painted are mixed in an agitated pressure pot.

- Several years ago, the facility attempted to conduct on-site solvent recycling but the

Approximately 2 years ago, the facility tried to reduce MEK use by blending the MEK

resulting solvent was not pure enough and caused many problems.

- with alcohol. However, the mixture was not effective in cleaning.

Four years ago, the facility switched to electrostatic guns. Prior to the switch, they investigated HVLP, airless, and air-assisted airless guns. These guns did not function properly with the high-solids paint.

- They have investigated powder coatings but determined that the irregular contours and deep recesses of the parts would not be sufficiently covered with the powder.

The Corporation has issued a pollution prevention plan to its facilities entitled Toxic Substance and Hazardous Waste Reduction. This plan outlines the Corporation’s waste reduction hierarchy, identifies its commitment to waste reduction, and encourages each facility to form a toxic reduction team to investigate waste reduction options.

In the future the facility will be investigating the use of metal filters in the spray booth. Currently, a prototype filter is being designed. Concerning technical assistance from the State, the facility contact stated that they would like information on the ways that other facilities set-up spray booths and if any other facilities are using reusable filters. Also, the facility would like information (Le., not from a vendor) on the use of dry filters verses a water curtain and on the use of electrostatic coating operations ( e g , design of racks and ways to improve coverage). The facility contact stated that NCPPP had conducted a thorough on- site waste audit at the facility, however, the information that was presented in the report was overwhelming. The audit results may have been more meaningful if the facility had first prioritized their waste streams and then identified a few waste streams to be focused on during the audit. To improve the transfer of technology to the industries, the facility contact

45


suggested that information be compiled into a report and then the information should be outlined in a presentation.

. ~ ~~~~~~

Caterpillar, Inc. (SIC 3600) assembles and paints industrial tractors. This facility is only three years old and waste minimization was a key consideration in the design of this plant. The facility is currently at 50 percent of its operating capacity; the facility should be at full capacity by 1994. The paint used at this facility is a 2-component isocyanate catalyzed polyurethane. The paint is applied in a spray booth with air-assisted airless spray guns under electrostatic conditions. Guns and lines are cleaned with an acetone mixture. Overspray is captured in a water wash pit. The hazardous waste generated by this facility is 50 percent water wash solids and 50 percent spent solvent. The following identifies the waste reduction options that have been investigated by this facility.

The facility considered using powder coatings but they were not practical. The tractors contain volatile fluids that would limit the curing temperature of the paint.

- The facility tried using a citrus-based product to flush lines but it was not effective in removing urethanes.

The quantity of spent solvent is not significant enough to justify on-site recycling.

The facility contact expressed frustration over current regulations concerning solvent-based paints. Specifically, the facility would like to switch to a lower VOC paint but current regulations prevent this switch. The lower VOC paint has a higher concentration of the regulated branch chain solvent than the paint that is currently being used.

Facility A, identification is confidential (SIC 3600). paints the metal housings of high powered lights for streets, stadiums, and other special applications. Ninety percent of parts are painted with an electrostatic coating (e-coating) system. The remaining parts are painted with a low gloss enamel applied manually in a spray paint booth with air-assisted airless spray guns or powder coating applied automatically in a spray booth. E-coating is conducting in 2 separate dip tanks designated for two different colors of paint. The dip tank is cleaned annually to remove non-hazardous sludge that is shipped off-site for solidification and landfilling. Spent spray booth filters are disposed of as non-hazardous waste. Paint wastes comprise only a small portion of the facility’s hazardous waste. The hazardous paint waste generated from this facility is approximately 65 percent spent MEK used to clean guns and

Waste reduction options to be investigated in the future include switching to lower VOC coatings and the replacement of the air spray booth system with a powder system. The facility contact stated that they would like to receive information on the time, costs, and benefits associated with switching to a new system.

flush lines, 30 percent spray booth solids, and 5 percent quality control samples of e-coating. . ~~~~

~~~~

46


~

NC Department of Transportation, Ferry Division (SIC 3700) at Manns Habour is responsible for the operation and maintenance of 30 ferries. Painting of the ferry hull, deck, and the interior of the ferry is conducted when needed. 2-part epoxy paints and an antifoulant coating is applied to the hull below the water line and only an epoxy paint is applied above the water line. The coatings are only applied if visual inspections reveal substantial deterioration. The deck and the interior of the ferries are painted with an epoxy and colored enamel. Coatings are typically applied with hand held airless spray guns; touch-up paint is applied with brushes. The application equipment is cleaned with a petroleum based solvent. The majority of the facility’s hazardous waste is spent solvent. The following identifies the waste reduction activities that have been implemented or are being investigated.

Currently, the facility is switching to a new coating system to be applied to the ferry hulls. The new system like the old system will be comprised of epoxy paint and antifoulant, but the system will provide longer lasting coatings.

In the past, ferries were automatically stripped to the bare metal and repainted. Now, the ferries are visually inspected and stripped to the bare metal if substantial deterioration of all coatings is observed.

The facility attempted on-site recycling but the recycled solvent was not effective in cleaning equipment.

The facility has considered water-based cleaners and uses a citrus-based cleaner for some cleaning applications. Their major concern over these cleaners is that they may corrode the application equipment.

WASTE REDUCTION OPTIONS

This section identifies feasible waste reduction options currently employed by industries, being investigated by industries, and options not identified by industries. Information collected during the telephone survey and site visits were used to identify those options that have been implemented or are being investigated. To ensure that all potential waste reduction options have been considered, a literature search was conducted to identify those options not identified by the targeted industries.

47


3.1

During the telephone survey and site visits, facility contacts were asked to identify the

Options Identified by NC Industries

.~~ ~ ~~~~~~

waste reduction activities that have been implemented or are under investigation. As seen in Sections 2.3.4 and 2.4.4, the facility contacts identified numerous waste reduction options many of which were specific to each facility’s painting operations and would not be appropriate for use by other facilities. Rather than identifying all waste reduction options specified by the facility contacts (see Sections 2.3.4 and 2.4.4), this section focuses on waste reduction options that be could he implemented by several facilities. Specifically, only those waste reduction options that can be implemented to reduce waste generation from the major sources of waste. For each substrate painted by the targeted industries, waste reduction options that have been successfully implemented and that will be considered in the future are identified. In some cases, it was determined that a waste reduction technique employed by a facility painting a specific substrate may be applicable to a facility painting different substrate. In these instances, the waste reduction option is identified for both substrates. Additional information on the identified waste reduction options can be found in Sections 2.3.4 and 2.4.4 and in Appendices C and G.

The facilities that were identified during the telephone as painting wood generated approximately 29 percent of all the hazardous paint waste generated in 1992. The of majority of this waste is sent off-site to be combusted. The major portion of this waste stream is comprised of overspray removed from spray booths and spent solvents used to clean coating application equipment and used to wash-off substandard finishes on furniture. To reduce wastes from these sources, the following waste reduction techniques have been successfully implemented:

- Switching to HVLP guns to improve transfer efficiency. Specifically, one facility switched from using conventional guns to using HVLP guns to apply stain and glaze. The HVLP guns increased transfer efficiency and reduce the amount of coating used by 30 percent.

- Improving spray gun management and spray techniques reduce overspray;

Implementation of a total quality management (TQM) program;

- Applying light colors before dark to minimize the need for line flushing with solvent; and

48


- Between colors, the new color is sprayed through the lines and collected for a predetermined period of time to clean out the old color. The collected coating is blended with other coatings and reused.

- Using reusable materials to catch overspray (e.g., cleanable polypropylene plastic on conveyors and metal baffle filters).

On-site recycling of wash-off material by a recycling service. Approximately 80 percent of one facility’s wash-off material is recycled for reuse.

Additional waste reduction techniques that will be considered or implemented in the future include:

Use of waterborne coatings; - Use of high-solids coatings; - Switching from a 3-coat lacquer topcoat finish to a 2-coat finish through the

use of a precatalyzed coating; Switching from wet booths to dry booths; and Investigating the use of a washable or recyclable filter (Le., other than the metal baffle filter currently used).

Two facilities out of the targeted industries that were contacted during the telephone survey painted rubber products. These facilities generated 2 percent of the total quantity of hazardous paint waste generated in 1992. The majority of the waste generated by these facilities is spent solvent and overspray removed from spray booths. The waste reduction techniques that have been successfully implemented include:

Switching from using conventional guns to using HVLP guns to improve transfer efficiency;

. Capturing and reusing excess paint that drips from rollers;

Waste reduction options that will be investigated in the future include researching a solvent recycling strategy in which the spent solvent is sent to the paint manufacturer and reused in paint. Possible waste reduction options that were identified by facilities painting a different substrate include the use of CitruSolv to remove solvent-based paint from rubber products and the use of reusable filters in spray booths.

During the telephone surveys, it was determined that 60 of the 93 facilities responding to the survey painted metal products. These facilities generated 47 percent of the total quantity of the hazardous paint waste generated in 1992. The types of paint applied by these

49


facilities include solvent-based, water-based, and powder. The major source of hazardous waste associated with the application of solvent-based paint is line flushing and gun cleaning with solvent and overspray removal from spray booths. The major component of the hazardous waste streams generated from the applicatioii of waterborne paints is spent solvent used to clean application equipment. Very little, if any, hazardous waste is generated from the application of powder coatings. The following waste reduction techniques were identified by RTI staff as those techniques with the greatest potential to reduce spent solvent and overspray waste from painting of metal:

~~ ~

~ ~~~~~~~~~

Modified line flushing technique (e.& between colors, switched from flushing lines with MEK to using paint and switched from flushing lines with xylene to flushing with air followed by acetate solvent); Recycle spent solvent for paint thinning and/or equipment cleaning; Changed order of painting to reduce color changes and flushing of lines; Purchase paint in 55 gallon drums rather than smaller containers ( i t . , drum are recycled); Implemented statistical process control program to reduce the amount of paint applied (i.e., gages assess paint thickness rather than depending on visual inspection; Repositioned paint booth filters and increased life three-fold; Installed centrifuge system to reduce volume of paint booth sludge; Switch from solvent-based paint to powder coatings; Reduced solvent content of paint (e.g., switched from low-solids to high-solids paint and switched from solvent-based paints to water-based paints); Switched from using solvent cleaners to aqueous based cleaners (e.g., switched from using methyl ethyl ketone to using CitruSolve to remove overspray from tires); Adjusted gun angles to improved transfer efficiency (e&, one facility reported 40 percent increase in transfer efficiency); Switched to HVLP guns to improve transfer efficiency; Implementation of a cost accounting system; Implementation of a TQM program; and Reduced the number of product colors ( i t . , reduced the number of color changes).

Additional waste reduction techniques that are currently being investigated arc the use of reusable metal filters and the possibility of sending spray booth filters through drying ovens to cure residual paint (i.c., making the filters non-hazardous).

~

Only two facilities contacted during the telephone survey painted plastic products. These facilities generated two percent of the total quantity of hazardous paint waste generated in 1992. Solvent is used at these sites to clean equipment that is used to apply solvent based paints. Both of the facilities reported that the majority of their hazardous waste is comprised

~

50


of distillation bottoms from on-site solvent recovery. A waste reduction technique that is being used at one facility is switching from solvent-based paints to water based paints. By 1997, waterborne paints will be used exclusively.

3.2

To identify waste reduction options that have not been identified through the telephone survey or site visits, RTI staff conducted a literature search and reviewed materials relating to painting operations. As a result of this effort, the following waste reduction techniques were identified.

Options Identified Through Literature Review

Inorganic Coatings: Zinc Silicate Water-based zinc silicates protect steel from corrosion through a combination of two processes: 1) zinc acting as a sacrificial anode in the corrosion process and 2) the establishment of a barrier coating that protects the steel substrate from corrosive elements. According to one vendor, this coating has no VOCs, is not a fire hazard and does not generate a toxic waste. Recent developments in the coating curing process have enhanced the ease of application for this coating. One vendor stated that use of zinc silicate coatings in combination with passing a low level electric signal through the substrate can provide long- term anti-fouling protection for metal substrates in marine environments.

References: "Long Term Corrosion Protection with Single-Coat High-Ratio Zinc Silicate" by Puke Schaffer, Jr., Inorganic Coating, Inc. Abstract from the Pollution Prevention Conference on Low- and No-VOC Coating Technologies sponsored by the U.S. Environmental Protection Agency, May 25-27, 1993.

"Two Surprises from Inorganic Zinc-Rich Silicate Coating: A Reactive Semi- Conductor Approach to Surface Protection" by C. William Anderson, Marine Environmental Research. Abstract from the Pollution Prevention Conference on Low- and No-VOC Coating Technologies sponsored by the U S . Environmental Protection Agency, May 25-27, 1993.

"Inorganic Chemistry as an Option for Formulating High Solids, Low and Zero-VOC Architectural and Industrial Maintenance Coatings" by Christine Stanley and Raymond E. Foscante, Ameron Protective Coatings Division. Abstract from the Pollution Prevention Conference on Low- and No-VOC Coating Technologies sponsored by the U S . Environmental Protection Agency, May 25-27, 1993.

51


Supercritical Fluid Spray Application This technology uses a supercritical fluid, usually carbon dioxide, to replace a significant portion of the organic solvent used in traditional coating formulations. Since carbon dioxide can be brought to supercritical conditions at 88" F and 1070 psi, the system does not require exotic equipment as compared with airless spray application. Use of this system can reduce solvent use by as much as 80 percent.

Reference (for apolication to plastic substrates):

. ~~

~~~ ~~~~~~~

"Supercritical Fluid Spray Application of Low-Pollution Coatings for Plastic Substrates" by Wayne P. Miller, Union Carbide Corporation and Tom Morrison, Red Spot Paint & Varnish Co., Inc. Abstract from the Pollution Prevention Conference on Low- and No-VOC Coating Technologies sponsored by the U.S. Environmental Protection

Agency, May 25-27, 1993.

Lower Volatility Solvent Replacements for MEK in Paint Equipment Cleaning According to the vendor, a "hybrid chemistry" approach to solvent formulation that combines advantages of aqueous, semi-aqueous and hydrocarbon cleaning systems has been used to develop replacements for solvents. The vendor is marketing one product as a less volatile, higher flashpoint replacement for MEK that can be used for cleaning application equipment (e.g. paint guns, paint lines, paint pots, etc.).

Reference: "Low Volatility Surface Preparation: A Hybrid Approach" by Joseph A. Lucas, Inland Technology, Inc. Abstract from the Pollution Prevention Conference on Low- and No- VOC Coating Technologies sponsored by the US . Environmental Protection Agency, May 25-27, 1993.

Paint Line Cleaning Systems Facilities sometimes clear paint from paint lines between color changes, during shift changes, and at the end of the day for shut down. Solvent flushing of the lines is a common technique. To clean paint lines more efficiently using less solvent, one vendor has developed a system that generates sustained turbulent flow in the paint line. This turbulence provides a more efficient cleaning action that will clean paint lines faster and use 50 - 70 percent less solvent than the traditional pulsed line cleaning systems.

52


Reference: "In Living Color: A National Waste Reduction Teleconference for Industrial Painting

v - 0perations"sponsored by the University of Tennessee Center for Industrial Services and the Tennessee Department of Environment and Conservation, October 8, 1991, pp. 120-125.

4.0 INFORMATION DISSEMINATION

To encourage and assist industry in reducing their wastes, RTI staff worked in conjunction with the NCHWS and NCPPP staffs to identify useful technical materials, to identify effective means of disseminating information, and to assist with the transfer of information to appropriate industries. As part of this effort, RTI staff identified and reviewed technical materials relating to reducing waste generation from painting operations. Additionally, technology transfer recommendations provided by facility contacts were compiled.

4.1 Identification and Review of Technical Materials

RTI's Pollution Program reference repository was searched to identify technical materials that discuss techniques for reducing painting wastes. Once identified these materials were reviewed and a bibliography was prepared. For each reference, the bibliography identifies the waste reduction topic discussed in the reference and reference type (e.g., fact sheet, journal article). This bibliography is presented in Appendix H. When a facility or industry needs information on a specific waste reduction topic, this bibliography will serve as a useful tool for identifying technical materials addressing the topic of concern.

4.2

During site visits, facility contacts were asked to identify ways of transferring

Industries' Recommendations for Disseminating Information

materials on waste reduction options to appropriate facilities. Recommendations provided by the facility contacts are summarized below.

. Fact sheets and case studies on successful waste reduction opportunities would be useful.

53


Videos would be especially useful for line operators who do not have time to read reports. Also, the videos can be shown to several individuals at one time and lead to follow-up discussions.

Information should be substrate specific.

Present information at required seminars, such as, DOT and Hazardous Materials (Haz Mat) seminars.

Present material at seminars and forums.

. ~~~~ ~~~~~~~

Distribute materials through trade associations.

CONCLUSIONS AND RECOMMENDATIONS

Results of this study indicate that the majority of the total quantity of hazardous paint wastes being combusted is comprised of spent solvent used to clean application equipment and overspray removed from spray booths." Information collected and summarized in this document identifies numerous facilities that have successfully implemented waste reduction activities or are investigating techniques that could significantly reduce their wastes. Techniques that have been implemented to reduce spent solvent wastes include solvent substitution, switching to paints with lower solvent content, and recycling. The techniques that have been implemented to reduced overspray wastes include reusable filters, use of HVLP guns, improving application techniques through better training, improving spray booth set-up (e.g., adjusting angles of guns), and switching to paints that contain lower solvent content.

To encourage and assist industries in reducing their wastes, it is recommended that information collected and presented in this document be used to identify facilities that have significantly reduced their wastes or are investigating innovative techniques that could significantly reduce hazardous paint wastes. The facilities that have successfully implemented techniques should be contacted to develop case studies. Once developed, these case studies could be presented at substrate-specific workshops and seminars. In addition to providing

~

lo Initially, this study was to include landfilled and combusted wastes. However, analysis

landfilled in 1992. This quantity comprises 0.02 percent of the total quantity of hazardous paint waste combusted and landfilled in 1992. Therefore, the scope of this study was narrowed to focus on combusted wastes.

of the 1992 NCHWAR data revealed that only 1100 pounds of hazardous paint waste was ~~~~

54


opportunities for presenting these case studies, the seminars and workshops would provide opportunities for panel discussions of implemented activities and of techniques that are being investigated. Also, these workshops and seminars would provide a means for eliminating misconceptions over the type of coatings that are appropriate for particular substrates. For example, the misconception that powder coatings are not appropriate for coating plastic.

Based on project experience, several recommendations can be made to help the NCHWS and NCPPP in conducting similar studies.

The time frame under which site visits are to be conducted should be long enough to accommodate unavoidable conflicts that industries may have. For example, the months of November and December defined the time frame under which this study’s site visits were conducted. During these months, industries shut down for holidays and are busy completing end of the year projects. As a consequence, facilities that were willing to conduct tours of their operations could not visited

Because the telephone survey was extensive, answers to all the questions were not obtained, and if obtained, they were not always adequate. In addition, some of the survey questions were not specific to the scope of this study. If similar surveys are conducted in the future, it is recommended that the questionnaire be limited to fewer more focused questions.

In conducting the telephone surveys, specific RTI personnel were assigned to each of the targeted industries. This staffing plan allowed the assigned personnel to become familiar with each industry’s painting operations. Thus, allowing the telephone interviews to be conducted efficiently. It is recommended that a similar staffing plan be employed in conducting future surveys.

In summary, this study provides information that can be used to encourage and assist industries in reducing the quantity of hazardous paint wastes being generated and incinerated. This document identifies numerous waste reduction techniques that are being implemented or are being investigated by industries. Also identified are techniques discusses in literature but not being employed by the surveyed industries. Recommendations from visited facilities indicate that an effective way to educate industry about successful waste reduction techniques is through substrate-specific workshops and seminars. During these workshops and seminars, industries would be provided with opportunities to exchange information concerning implemented techniques and discuss potential reduction techniques under investigation.

55

Appendix A

Telephone Survey Questionnaire

A - 1

Painting Operations Telephone Survey

Date: Name of Company: EPA Facility ID Number(s): Name of Original Contact: Phone No.: Name of Questionnaire Respondent: Phone No.:

NoteslQuestionslConcerns from review of Hazardous Waste Data:

1.

2.

3.

What is the job title of the questionnaire respondent?

Approximately how many people are currently employed at each facility? How many people are involved in painting or coating operations?

Provide background information on facility painting and coating operations.

a) Briefly describe primary painting and coating operations at each facility?

A - 2

b) If not identified in response to part (a) above, identify the following:

Products or product parts that are painted or coated -

Material being painted or coated (e.g., wood, metal, etc.) -

Product configuration (e.g., case goods, flat line, etc.)

Number of coats applied -

c) If not identified in response to part (a) above, what type of paints are applied at your facility(ies) (e.g., stains, lacquers, paints, etc.)? Also what type of liquid or powder painting or coating formulations used at the facility (e&, high solids and water borne)?

d) If not identified in response to part (a) above, are multiple colors applied at each facility? If so, how many colors?

e) If multiple colors are used at a facility, briefly describing color change procedures including cleaning requirements and frequency of changes.

A - 3

0 If not identified in response to part (a) above, identify the age of the following painting and coating equipment used:

Application equipment -

Spray booth -

Filters -

Gun Washers -

Other (specify) -

g) Briefly describe any routine cleaning of equipment?

Application equipment -

Spray booth

Filters -

Gun Washers -

Other (specify) -

A - 4

h) What purpose does the paint or coat serve (e.g., appearance, protection, etc.,)? Identify any performance standards that are required?

i) Are there any training requirements for painting or coating operators? If so, briefly describe.

j) Approximately, what fraction of the total quantity of hazardous painting wastes reported in 1992 were generated from each of the painting or coating operations.

I 4. Provide information on pollution prevention activities related to painting or coating

operations.

a) Briefly describe any pollution prevention programs including TQM or EQM strategies directed at reducing painting or coating operation wastes that have been implemented at your facility(ies) in recent years.

b) Is there a waste management cost account strategy in place at your facility(ies)? If so, briefly describe.

c) What have been the benefits of implementing these programs or strategies?

A - 5

d) If NCPPP has provided assistance to this company, how has this assistance helped or not helped in implementing these programs?

e) Which of the following motives have had the greatest influence on the implementation pollution prevention technologies or strategies at your company? (Please check).

-

- Reducing waste management costs

- Reducing process operating costs

- Limiting future liability

- Public relations

- Other. Please specify.

Achieving compliance with environmental regulations

f) If achieving compliance with environmental regulations was checked above, identify the specific regulations of concem?

5. Provide information on future plans for implementing pollution prevention activities targeted at painting or coating operations.

a) Does your company have any pollution prevention initiatives planned for the near future? If so, what are these plans and when are they scheduled to be initiated?

A - 6

b) If future plans are in place, what type of implementation assistance would be helpful to your company?

~~ ~~

c) If no future plans are in place, what are the obstacles to investigating and implementing additional pollution prevention programs at the facility(ies) (e.g., costs, concern over product quality, lack of management support, etc.)?

-~

d) If no future plans are in place, exactly what would be needed to overcome obstacles and to get the company to investigate and implement future waste reduction programs?

6. If the facility was selected for a site visit to gather additional information, would they be willing to participate?

A - 7

Appendix B

1992 Facility-Specific Waste Generation and Minimization Data

SIC2500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 2

SIC3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 4 3

SIC 3400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 4 9

SIC 3500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 6 7

SIC 3600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 103

SIC 3700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 122

SIC9700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 1 3 0

B - 1

Facility ID Number: NCD003448453 Facility Name: Hammary Plant #14 Facility SIC Code: 2500 Waste Codes Listed:

Total Code Definition - D001D035F003 Ignitable. MEK, spent non-hal.solv. 45,930 lbs/vr - D001F003F005 Ignitable, spent non-ha1 soh . 43,779 lbs&

Waste Form: B203 - Non-halogenated solvent Waste Handling: M061 Fuel blending Source Reduction: None specified NCPPP involvement: None Comments: None

Did this site begin or expand a source reduction activity during 1991 or 1992? Yes

Did this site begin or expand a recvcling activity during 1991 or 1992? Yes

Did this site systematically investigate opportunities for source reduction or recycling during 1991 or 1992? Yes

The following factors delayed or limited this site’s ability to initiate new or additional on-site or off-site recvclinK activities during 1991 or 1992:

Lack of technical information on recycling techniques applicable to this site’s specific production processes

Concern that product quality may decline as a result of recycling Permitting burdens inhibit recycling

The following factors delayed or limited this site’s ability to initiate new or additional reduction activities in 1991 or 1992:

Concern that product quality may decline as a result of source reduction

B - 2

Facility ID Number: NCD003220969 Facility Name: Hickory White Company Facility SIC Code: 251 1 Waste Codes Listed:

Code Definition F003F005 Spent non-hal. solvents

Total 33,314 Ibs/yr.

Waste Form: B211 - Paint thinner or petroleum distillates. Waste Handling: M021 - Fractionatiotddistillation Source Reduction: None specified. NCPPP involvement: None. Comments:

Did this site begin or expand a source reduction activity during 1991 or 1992? No.

Did this site begin or expand a recvcling activity during 1991 or 1992? No.

Did this site systematically investigate opportunities for source reduction or recvcling during 199 1 or 1992? No.

Plant is planned to close in early part of 1993.

The following factors delayed or limited this site’s ability to initiate new or additional on-site or off-site recvcling activities during 1991 or 1992:

Other (specify): See comments above.



B - 3

Facility ID Number: NCD048401087 Facility Name: Facility SIC Code: 25 11 Waste Codes Listed:

Hooker Furniture - Pleasant Garden

Code Definition Total DO0 1 Ignitable 0 Ibs/yr

Waste Form: B409 - Other nonhalogenated organic solids Waste Handling: None specified. Source Reduction: W12W73: Began to Segregate hazardous waste from non-hazardous

~~~

waste; and Substituted coating materials used.

NCPPP involvement: None. Comments: None.


Did this site begin or expand a recycling activity during 1991 or 1992? No.

Did this site systematically investigate opportunities for source reduction or recycling during 1991 or 1992? Yes.

The following factors delayed or limited this site's ability to initiate new or additional on-site or off-site recycling activities during 1991 or 1992:

None Specified.

The following factors delayed or limited this site's ability to initiate new or additional reduction activities in 1991 or 1992:

Concern that product quality may decline as a result of source reduction Technical limitations of production processes

B - 4

Facility ID Number: NCD058830050 Facility Name: Facility SIC Code: 25 11 Waste Codes Listed:

F003F005 Spent non-hal. solvents 82,188 Ibs/yr.

Waste Form: B211 - Paint thinner or petroleum distillates Waste Handling: Source Reduction: None specified. NCPPP involvement: None. Comments: None.

National Mt. Airy Furniture

Code Definition Total

M023 - Solvent extraction



Did this site systematically investigate opportunities for source reduction or recycling during 199 1 or 1992? No.

The following factors delayed or limited this site’s ability to initiate new or additional on-site or off-site recycling activities during 1991 or 1992:

None specified.


None specified.

B - 5

Facility ID Number: NCD003233228 Facility Name: Stoneville Furniture Facility SIC Code: 2500 Waste Codes Listed:

D001F003F005 Ignitable, spent non-hal. solv. 13,537 Ibs/yr

Waste Form: B219 Other organic liquids Waste Handling: M05 1 Energy recovery - liquids Source Reduction:

Code Definition _Total

W 13W 14W54W74: Improved maintenance scheduling, record keeping or procedures; Changed production schedule to minimize equipment and feedstock changeovers; Instituted better controls on operating conditions (e.g., flow rate, temperature, pressure, residence time); and Improved application techniques.

NCPPP involvement: I’m not sure about this company. Comments: None.


Did this site begin or expand a recvcling activity during 1991 or 1992? No

Did this site systematically investigate opportunities for source reduction or recvcling during 1991 or 1992? Yes


None specified


None specified.

B - 6

Facility ID Number: NCD003 159084 Facility Name: Hammary Plant #I5 Facility SIC Code: 2500 Waste Codes Listed:

Code Definition Total DOOIF003F005 Ignitable, spent non-hal. soh . 7,203 Ibs/yr DOOlD035F003 Ignitable,MEK,spt non-ha1 s o h 14,552 Ibi/yr

Waste Form: B203 Non-halogenated solvent Waste Handling: M061 Fuel blending Source Reduction:

NCPPP involvement: None. Comments: ,None.

Waste #1 - W 13 - Improved maintenance scheduling, recordkeeping,or procedures.

Did this site begin or expand a source reduction activity during 1991 or 1992? yes

Did this site begin or expand a recycling activity during 1991 or 1992? No

Did this site systematically investigate opportunities for source reduction or recyclingduring 1991 or 1992? Yes


Lack of technical information on recycling techniques applicable to this site’s specific

Concern that product quality may decline as a result of recycling production processes


Lack of technical information on source reduction techniques applicable to this site’s

Concern that product quality may decline as a result of source reduction specific production processes

B - 7

Facility ID Number: NCD0534883.59 Facility Name: Hooker Furniture Corp. Facility SIC Code: 2500 Waste Codes Listed:

Code Definition Total DO01 F003F005 Ignitable, spent non-hal. solv. 18,489 Ibs/yr

Waste Form: B3 10 - Spent solid filters or adsorbents Waste Handling: Source Reduction: None specified. NCPPP involvement: Site visit 9/93. Comments: None.

M061 - Fuel Blending


Did this site begin or expand a recvclinq activity during 1991 or 1992? No.

Did this site systematically investigate opportunities for source reduction or recycling during 199 1 or 1992? Yes.



Technical limitations of production processes inhibit shipments off site for recycling Technical limitations of production processes inhibit on-site recycling Permitting burdens inhibit recycling Unable to identify a marketplace for recyclable materials Recycling previously implemented - additional recycling does not appear to be technically

production processes

feasible

The following factors delayed or limited this site’s ability to initiate new or additional source reduction activities in 1991 or 1992:

Lack of technical information on source reduction techniques applicable to this site’s specific production processes

Technical limitations of production processes Permitting burdens

B - 8

Facility ID Number: NCD079049409 Facility Name: Lane Upholstery Plant Facility SIC Code: 2500 Waste Codes Listed:

Code Definition DO0 1 Ignitable

Waste Form: B319 - other waste inorganic solids Waste Handling: M061 - Fuel blending Source Reduction: None specified. NCPPP involvement: None. Comments: None.

Total 36,100 Ibs/yr

Did this site begin or expand a source reduction activity during 1991 or 1992? Yes.


Did this site systematically investigate opportunities for source reduction or recyclinR during 1991 or 1992? Yes.



Concern that product quality may decline as a result of recycling Lack of permitted off-site recycling facilities





B - 9

Facility ID Number: NCD062568035 Facility Name: Singer Furniture Co. Facility SIC Code: 25 11 Waste Codes Listed: - Code Definition Total

D001F003F005 Ignitable, spent non-hal. soh . 175,312 Ibslyr.

Waste Form: B209 - Organic paint, ink, lacquer, or varnish Waste Handling: M02 1 - Fractionation/distillation Source Reduction: None specified. NCPPP involvement: None. Comments: None.


Did this site begin or expand a recvcling activity during 1991 or 1992? Yes.

Did this site systematically investigate opportunities for source reduction or recvcling during 1991 or 1992? Yes.

The following factors delayed or limited this site’s ability to initiate new or additional on-site or off-site recvclincg activities during 1991 or 1992:

Concern that product quality may decline as a result of recycling Technical limitations of production processes inhibit shipments off site for recycling Recycling previously implemented - additional recycling does not appear to be

economically feasible


Insufficient capital to install new source reduction equipment or implement new source

Concern that product quality may decline as a result of source reduction Technical limitations of production processes Source reduction previously implemented - additional source reduction does not appear

reduction practices

to be economically feasible

B - 10

Facility ID Number: NCD003445939 Facility Name: Baker Furniture Co. (Andrews) Facility SIC Code: 25 1 1 Waste Codes Listed:

Code Definition Total DO01 ignitable waste 21000 Ibs/year

Waste Form: B403- solid resins or polymerized organics Waste Handling: M059- energy recovery (type unknown) Source Reduction: W99- specified in comments (portable


Did this site begin or expand a recycling activity during 1991 or 1992? yes

Did this site systematically investigate opportunities for source reduction or recycling during 1991 or 1992? no

distillation unit)



Recycling not economically feasible: cost savings in waste management or production

Concern that product quality may decline as a result of recycling Permitting burdens inhibit recycling Unable to identify a marketplace for recyclable materials Recycling previously implemented - additional recycling does not appear to be

Recycling previously implemented - additional recycling does not appear to be feasible


will not cover the capital investment


due to permitting requirements



Source reduction not economically feasible: cost savings in waste management or

Concern that product quality may decline as a result of source reduction Technical limitations of production processes Permitting burdens

specific production processes

production will not cover the capital investment

B - 11

Facility ID Number: NCD000277293 Facility Name: Broyhill Furniture (Conover) Facility SIC Code: 25 1 1 Waste Codes Listed:

Code Definition Total DO01 ignitable waste 73941 lbs/year F003, F005 nonspecific sources 340675 Ibstyear

.- Waste Form: waste #1: B409- non-halogenated organic solids, waste #2: B203- non- halogenated solvent Waste Handling: M061- fuel blending Source Reduction: DO01 waste: W02- began off-site recycling in 1991

Did this site begin or expand a source reduction activity during 1991 or 1992? no


Did this site systematically investigate opportunities for source reduction or recvcling during 199 1 or 1992? yes



Financial liability provisions inhibit shipments off site for recycling Technical limitations of production processes inhibit shipments off site for recycling Technical limitations of production processes inhibit on-site recycling Unable to identify a marketplace for recyclable materials Recycling previously implemented - additional recycling does not appear to be technically


f e a s i b 1 e



Source reduction not economically feasible: cost savings in waste management or reduction practices

production will not cover the capital investment Technical limitations of production processes . ~~ ~~~

Permitting burdens ~ ~ ~~~~

Source reduction previously implemented - additional source reduction does not appear to be technically feasible

B - 12

Facility ID Number: NCD083682583 Facility Name: Broyhill Furniture (Newton) Facility SIC Code: 25 11 Waste Codes Listed:

Code Definition Total DO0 1 ignitable waste 7 1795 Ibs/year F003, F005 nonspecific sources 69008 Ibdyear

Waste Form: waste #1: B409- non-halogenated organic solids, waste #2: B203- non- halogenated solvent Waste Handling: M06 I - fuel blending Source Reduction: W02- off-site recycling began during 1991, W52- layout or piping



Did this site systematically investigate opportunities for source reduction or recycling during 1991 or 1992? yes


modified equipment,




feasible



Permitting burdens Source reduction previously implemented - additional source reduction does not appear

Source reduction previously implemented - additional source reduction does not appear


to be technically feasible


B - 13

Facility ID Number: NCD083682229 Facility Name: Broyhill Furniture (Rutherfordton) Facility SIC Code: 251 1 Waste Codes Listed:

. ~~~ ~

Total - Code Definition DO01 ignitable waste 61485 Ibs/year F003, F005 non-specified sources

~ ~~~~

83001 Ibs/year

Waste Form: waste #I : B409- non-halogenated organic solids, waste #2: B203- non- halogenated solvent Waste Handling: M061- fuel blending Source Reduction: W52- modified equipment, layout, or piping

Did this site begin or expand a source reduction activity during 1991 or 1992? yes Did this site begin or expand a recycling activity during 1991 or 1992? no Did this site systematically investigate opportunities for source reduction or recvcling during 199 1 or 1992? yes The following factors delayed or limited this site’s ability to initiate new or additional on-site OI

off-site recyclinK activities during 1991 or 1992:



Recycling previously implemented - additional recycling does not appear to be


feasible





Technical limitations of production processes Permitting burdens ~


reduction practices


~~ ~


B - 14

Facility ID Number: NCD003 154903 Facility Name: Cochrane Furniture Co. (Lincolnton) Facility SIC Code: 25 1 I Waste Codes Listed:

Code Definition Total DO0 1 ignitable waste 7653 Ibs/year F003, F005 nonspecific sources DO0 1 ignitable waste 34320 Ibslyear

included in above

Waste Form: waste # I : B203- non-halogenated solvent, waste #2: B409- non-halogenated organic solids Waste Handling: waste #1: M051- energy recovery (liquids), waste #2: M053- energy recovery (solids) Source Reduction: waste #2: W 11- began to segregate types of hazardous waste to make them more amenable to recycling



Did this site systematically investigate opportunities for source reduction or recycling during 199 1 or 1992? yes

The following factors delayed or limited this site’s ability to initiate new or additional on-site or off-site recvclinx activities during 1991 or 1992:

none




reduction practices

B - 15

Facility ID Number: NCD980840177 Facility Name: Hickory Chair Co. (Conover) Facility SIC Code: 251 1 Waste Codes Listed:

~~

Code Definition Total DO0 1 ignitable waste 3 1750 Ibs/year F003, F005 nonspecific sources 17975 Ibs/year

Waste Form: 17500 Ibs of DOOl waste: B601- still bottoms of halogenated (e.g. chlorinated) solvents or other organic liquids, 13900 Ibs of DOOl waste: B403- solid resins or

polymerized organics, 350 Ibs of DOOl waste: B101- aqueous waste with low solids, F003 and F005 waste: B211- paint thinner or petroleum distillates Waste Handling: M061- fuel blending Source Reduction: F003 and F005 wastes: W42- substituted raw substituted coating materials used





m a t e r i a l s , W 7 3 -

Concern that product quality may decline as a result of recycling Technical limitations of production processes inhibit shipments off site for recycling

The following factors delayed or limited this site’s ability to initiate new or additional ~ource reduction activities in 1991 or 1992:


B - 16

Facility ID Number: NCD986171130 Facility Name: Herman Miller (Sanford) Facility SIC Code: 25 I 1 Waste Codes Listed:

Code Definition Total F003 nonspecific source 32000 Ibs/year

Waste Form: B310- spent solid filters or adsorbents Waste Handling: M141- transfer facility storage, waste was TDR activity Source Reduction:

shipped off site with no on-site


Did this site begin or expand a recvcling activity during 1991 or 1992? no

Did this site systematically investigate opportunities for source reduction or recycling during 199 1 or 1992? no


Insufficient capital to install new recycling equipment or implement new recycling practice


Insufficient capital to install new source reduction equipment or implement new source reduction practices

B - 17

Facility ID Number: NCD049769144 Facility Name: Hickory White Company (Hickory) Facility SIC Code: 251 I Waste Codes Listed:

Code Definition Total DO01 ignitable waste 25447 Ibslyear F003, F005 nonspecific sources included in above

Waste Form: B209- organic paint, ink, lacquer or varnish

Waste Handling: M061- fuel blending Source Reduction:


Did this site begin or expand a recycling activity during 1991 or 1992? no



B604- organic paint or ink sludge

Insufficient capital to install new recycling equipment or implement new recycling

Lack of technical information on recycling techniques applicable to this site’s specific practice







reduction practices



B - 18

Facility ID Number: NCD066303728 Facility Name: Lea Industries Inc (Waynesville) Facility SIC Code: 25 11 Waste Codes Listed:

Code Definition F005 nonspecific sources

Waste Form: B319- inorganic solids Waste Handling: M061- fuel blending Source Reduction:

Total 64200 lbdyear







Concern that product quality may decline as a result of recycling Technical limitations of production processes inhibit on-site recycling Lack of permitted off-site recycling facilities Unable to identify a marketplace for recyclable materials Recycling previously implemented - additional recycling does not appear to be technically





feasible



The following factors delayed or limited this site’s ability to initiate new or additional reduction activities in 1991 or 1992: \



Technical limitations of production processes



B - 19





to be economically feasible ~~

to be feasible due to permitting requirements .~

B - 20

Facility ID Number: NCD003233 1 I I Facility Name: Marsh Furniture Co. (High Point) Facility SIC Code: 25 11 Waste Codes Listed:

Code Definition Total DO0 1 ignitable waste 274805 Ibs/year F003, F005 nonspecific sources included in above

Waste Form: B209- organic paint, ink, lacquer or varnish Waste Handling: M061- fuel blending Source Reduction:






Concern that product quality may decline as a result of recycling Technical limitations of production processes inhibit on-site recycling Lack of permitted off-site recycling facilities





B - 21

I

Facility ID Number: NCD072012354 Facility Name: Singer Furniture Company (Washin Chocowinity) Facility SIC Code: 25 11 Waste Codes Listed:

~ ~~~ ~~ ~

Code Definition Total DO0 1 ignitable waste 166932 Ibslyear F003, F005 nonspecific source

~~~~~~

included in above

____ Waste Form: 106566 Ibs: B209- organic paint, ink, lacquer or halogenated organic solids Waste Handling: M061- fuel blending Source Reduction: W 11- began to segregate types of hazardous waste to make them more amenable to recycling



Did this site systematically investigate opportunities for source reduction or recvcling during 199 1 or 1992? no

vanish, 60366 Ibs: B409- non-



Concern that product quality may decline as a result of recycling practice



B - 22

Facility ID Number: NCD062568035 Facility Name: Singer Furniture (Lenoir) Facility SIC Code: 25 11 Waste Codes Listed:

Code Definition Total DO0 1 ignitable waste 149121 Ibs/year

Waste Form: B409- non-halogenated organic solids Waste Handling: M053- energy recovery (solids) Source Reduction: W02- began off-site recycling in 1991





Concern that product quality may decline as a result of recycling Technical limitations of production processes inhibit shipments off site for recycling Recycling previously implemented - additional recycling does not appear to be





reduction practices


B - 23

Facility ID Number: NCD0032197 14 Facility Name: Thomasville Furniture (Winston Salem) Facility SIC Code: 25 11 Waste Codes Listed:

Code Definition Total DO0 1 ignitable waste 38182 Ibdyear

Waste Form: B409- non-halogenated organic solids Waste Handling: M061- fuel blending Source Reduction:



Did this site systematically investigate opportunities for source reduction or recvclinq during 1991 or 1992? no

The following factors delayed or limited this site’s ability to initiate new or additional on-site or off-site recvclinq activities during 1991 or 1992:

none



B - 24

Facility ID Number: NCD044440642 Facility Name: Hickory Chair Company (Hickory) Facility SIC Code: 2512 Waste Codes Listed:


Waste Form: B310- spent solid filters or adsorbents Waste Handling: M05 1- energy recovery (liquids) Source Reduction: W11- began to separate types of hazardous waste to make them more amenable to recycling, W 13- improved maintenance scheduling, record keeping or procedures






Financial liability provisions inhibit shipments off site for recycling Lack of permitted off-site recycling facilities Unable to identify a marketplace for recyclable materials





B - 25

Facility ID Number: NCD081427023 Facility Name: Southern Furniture Company (Claremont) Facility SIC Code:2512 Waste Codes Listed:

Definition Total DO0 1 ignitable waste 38637 lbstyear F003, F005 nonspecific sources included in above

Waste Form: B602- still bottoms of non-halogenated liquids or Waste Handling: M042- incineration-sludges Source Reduction:



Did this site systematically investigate opportunities for source reduction or recyclinf: during 199 1 or 1992? no


other organic liquids



Recycling not economically feasible: cost savings in waste management or production will not cover the capital investment

Permitting burdens inhibit recycling Lack of permitted off-site recycling facilities Unable to identify a marketplace for recyclable materials


Concern that product quality may decline as a result of source reduction Permitting burdens Source reduction previously implemented - additional source reduction does not appear




to be economically feasible ~

to be feasible due to permitting requirements

B - 26

Facility ID Number: NCDE981472905 Facility Name: Progressive Furniture (Claremont) Facility SIC Code: 2519 Waste Codes Listed:

Q& Definition Total F003, F005 nonspecific sources 122760 Ibslyear

Waste Form: B20 1- concentrated solvent water solution Waste Handling: M061- fuel blending Source Reduction: W72- modified spray systems or equipment, W73- substituted coating materials used, W74- improved



Did this site systematically investigate opportunities for source reduction or recycling during or 1992? yes

The following factors delayed or limited this site’s ability to initiate new or additional on-s off-site recycling activities during 1991 or 1992:

application techniques

99 1

5 or


Concern that product quality may decline as a result of recycling will not cover the capital investment




Concem that product quality may decline as a result of source reduction Technical limitations of production processes Source reduction previously implemented - additional source reduction does not appear


reduction practices




B - 27

Facility ID Number: NCD991278466 Facility Name: Broyhill Furniture (Lenoir) Facility SIC Code: 25 1 1 Waste Codes Listed:

Code Definition Total DO01 ignitable waste 250745 Ibs/year F003, F005 nonspecific sources 194855 Ibs/year

Waste Form: waste #1: B409- non-halogenated organic solids, waste #2: B203- non- halogenated solvent Waste Handling: M061- fuel blending Source Reduction: DO01 waste: W02- began off-site recycling in 1991, W52- equipment, layout or piping





m o d i f i e d




feasible




Technical limitations of production processes Permitting burdens Source reduction previously implemented - additional source reduction does not appear

reduction practices

production will not cover the capital investment ~


B - 28

Facility ID Number: NCD991278342 Facility Name: Broyhill Furniture (Lenoir) Facility SIC Code: 251 1 Waste Codes Listed:

Code Definition Total DO01 ignitable waste 48675 Ibslyear F003, F005 nonspecific sources 59279 Ibslyear

Waste Form: waste #I : B409- non-halogenated organic solids, waste #2: B203- non- halogenated solvent Waste Handling: M061- fuel blending Source Reduction: DO01 waste: W02- began off-site recycling in 1991, W52- equipment, layout or piping



Did this site systematically investigate opportunities for source reduction or recvclina during 199 1 or 1992? yes


m o d i f i e d




feasible





reduction practices



B - 29

Facility ID Number: NCD003162336 Facility Name: Broyhill Furniture (Lenoir) Facility SIC Code: 25 11 Waste Codes Listed:

Total . ~~ ~

Code Definition DOOl ignitable waste 138941 Ibs/year F003, F005 nonspecific sources 182090 Ibs/year ~~ ~~~

Waste Form: waste #I: B409- non-halogenated organic solids, waste #2: B203- non- halogenated solvent Waste Handling: M061- fuel blending Source Reduction: DOOl waste: W02- began off-site recycling in 1991, W52- equipment, layout or piping


Did this site begin or expand a recycling, activity during 1991 or 1992? yes

Did this site systematically investigate opportunities for source reduction or recvcline, during 199 1 or 1992? yes


__

m o d i f i e d




f e a s i b I e



Source reduction not economically feasible: cost savings in waste management or reduction practices

production will not cover the capital investment . ~~~

Technical limitations of production processes ~ ~~



B - 30

Facility ID Number: NCD003217536 Facility Name: Hickory White Co. (Hickory) Facility SIC Code: 25 11 Waste Codes Listed:

Code Definition Total DO02 corrosive waste 14689 lbs/year DO01 ignitable waste 46297 lbdyear F002, F003 nonspecific sources i n c l u d e d i n 4 6 2 9 7

Ibs above

Waste Form: waste #I: B403- solid resins or polymerized organics, halogenated solvent Waste Handling: M061- fuel blending Source Reduction:

waste #2: B203- non-




The following factors delayed or limited this site’s ability to initiate new or additional on-site or off-site recyclinr: activities during 1991 or 1992:

Insufficient capital to install new recycling equipment or implement ncw recycling practice





Concern that product quality may decline as a result of source reduction Source reduction previously implemented - additional source reduction does not appear



reduction practices






B - 31

Facility ID Number: NCD981024730 Facility Name: Burns Aerospace Corporation (Winston Salem) Facility SIC Code: 2531 Waste Codes Listed:

Code Definition DO0 1 ignitable waste

Total 5280 Ibdyear

DO35 methyl ethyl ketone contained in above F003 nonspecific sources contained in above

Waste Form: B209- organic paint, ink, lacquer or varnish Waste Handling: M061- fuel blending Source Reduction: Did this site begin or expand a source reduction activity during 1991 or 1992? yes Did this site begin or expand a recvcling activity during 1991 or 1992? yes Did this site systematically investigate opportunities for source reduction or recycling during 1991 or 1992? yes The following factors delayed or limited this site’s ability to initiate new or additional on-site or off-site recycling activities during 1991 or 1992:

Insufficient capital to install new recycling equipment or implement new


Technical limitations of production processes inhibit on-site recycling Recycling previously implemented - additional recycling does not appear to be technically


recycling practices


feasible








reduction practices


to be technically feasible . ~ ~ ~ . .

~ ~~



B - 32

Facility ID Number: NCD09 1254532 Facility Name: A.G. Industries Inc. (Forest City) Facility SIC Code: 2541 Waste Codes Listed:

Code Definition Total DO0 1 ignitable waste 30201 Ibs/year F003, F005 nonspecific sources (note: waste#2 is also classified as D001)

2328 1 Ibs/year

Waste Form: waste #1: B409- non-halogenated organic solids

206381bs: B211- paint thinner or petroleum Waste Handling: M061- fuel blending Source Reduction: waste #2: W42- substituted raw materials, W73- materials used

waste #2: 2643 Ibs: B409- non-halogenated organic s o l i d s , distillates

substituted coating



Did this site systematically investigate opportunities for source reduction or recvcling during 1991 or 1992? yes


none




B - 33

Facility ID Number: NCD052548153 Facility Name: Robersonville Product (Robersonville) Facility SIC Code: 2541 Waste Codes Listed:

Code Definition rotal DO0 1 ignitable waste 181244 Ibs/year F003, F005 nonspecific sources included in above

Waste Form: 42081 Ibs: B409- non-halogenated organic solids, 139163 Ibs: B604- organic paint or ink sludge Waste Handling: M05 1- energy recovery (liquids) Source Reduction:

-






Technical limitations of production processes inhibit on- site recycling production processes



B - 34

Facility ID Number: NCD083682468 Facility Name: Broyhill Furniture (Taylorsville) Facility SIC Code: 2599 Waste Codes Listed:

Code Definition F003, F005 nonspecific sources

Total 3493 Ibslyear

DO0 1 ignitable waste 5665 Ibslyear

Waste Form: waste #I- B409- halogenated organic solvents

Waste Handling: M141- transfer facility storage, waste was shipped off site with no on-site TDR activity Source Reduction: W02- off-site recycling began during 1991

waste #2- B203- non-halogenated solvents

W52- modified equipment, layout or piping

Did this site begin or expand a source reduction activity during 1991 or 1992? yes Did this site begin or expand a recycling activity during 1991 or 1992? yes Did this site systematically investigate opportunities for source reduction or recycling during 1991 or 1992? yes The following factors delayed or limited this site’s ability to initiate new or additional on-site or off-site recycling activities during 1991 or 1992:




feasible





reduction practices



B - 35

Facility ID Number: NCD054290770 Facility Name: Thomasville Furniture (Lenoir) Facility SIC Code: 25 11 Waste Codes Listed:

Code Definition Total DO01 ignitable waste 72781 Ibs/year



Did this site begin or expand a recvclinx activity during 1991 or 1992? no

Did this site systematically investigate opportunities for source reduction or recvclinc: during 199 1 or 1992? no


none



B - 36

Facility ID Number: NCD0445 16862 Facility Name: Thomasville Furniture (Thomasville) Facility SIC Code: 25 11 Waste Codes Listed:

Code Definition Total DO0 I ignitable waste 606 1 Ibs/year






none



B - 37

Facility ID Number: NCD0445 17043 Facility Name: Thomasville Fumiture (Thomasville) Facility SIC Code: 25 11 Waste Codes Listed:

Code Definition DO0 1 ignitable waste


Total 22900 lbslyear

Did this site begin or expand a source reduction activity -xing 1991 or


’ no

Did this site systematically investigate opportunities for source reduction or recvclina during 1991 or 1992? no


none



B - 38

Facility ID Number: NCD000828863 Facility Name: Thomasville Furniture (Thomasville) Facility SIC Code: 25 I 1 Waste Codes Listed:

Code Definition Total DO01 ignitable waste 18638 lbs/year




Did this site systematically investigate opportunities for source reduction or recyclinR during 1991 or 1992? no


none



B - 39

Facility ID Number: NCD044517167 Facility Name: Thomasville Furniture (Thomasville) Facility SIC Code: 25 11 Waste Codes Listed:

Code Definition Total DO0 1 ignitable waste 18638 Ibdyear



Did this site begin or expand a recyclinR activity during 1991 or 1992? no

Did this site systematically investigate opportunities for source reduction or recvcling during 1991 or 1992? no


none



B - 40

Facility ID Number: NCD0032 196 15 Facility Name: Thomasville Furniture (Thomasville) Facility SIC Code: 251 1 Waste Codes Listed:







none



B - 41

Facility ID Number: NCD003 159894 Facility Name: Thomasville Furniture (West Jefferson) Facility SIC Code: 25 11 Waste Codes Listed:

Ql& Definition Total DO01 ignitable waste 62386 lbs/year




Did this site systematically investigate opportunities for source reduction or recvclin,: during 1991 or 1992? no


none


none

B - 42

Facility ID Number: NCD51331999 Facility Name: Consolidated Metco Facility SIC Code: 3079 Waste Codes Listed:

Code Definition F003,FOOS Spent non-hal. solvents FOO3,FOOS Spent non-hal. solvents F003,F005 Spent non-hal. solvents

- Total 24,255 Ibs/vr 40,545 Ibs/yr 8,668 Ibs/yr

Waste Form: B409 Other non-halogenated Waste Handling: M043 Incineration - Solids Source Reduction: None NCPPP involvement: None Comments:




The following factors delayed or limited this site’s ability to initiate new or additional on-site or off-site recvcling activities during 1991 or 1992

Reduction of hazardous waste will reduce recycling.

Other (specify):


B - 43

Facility ID Number: NCD980559645 Facility Name: Council Business Fur. Facility SIC Code: 3036 Waste Codes Listed:

Code Definition Total DO0 1 Ignitable waste 8511 Ibs/yr

Waste Form: B310 Spent solid filters or adsorbents Waste Handling: Incineration - Solids Source Reduction: None NCPPP involvement: None Comments: None

Did this site begin or expand a source reduction activity during 1991 or 1992?


Did this site systematically investigate opportunities for source reduction or recycling during 199 1 or 1992? Yes

No





B - 44

Facility ID Number: NCD067 178707 Facility Name: Fawn Plastics Company Facility SIC Code: 3079 Waste Codes Listed:

F003,F002,D001 Spent non-hal & ha1 soh . 1 16,05 1 Ibs/yr

Waste Form: B211 Paint thinner or petroleum distillates Waste Handling: M061 Fuel blending Source Reduction:


Improved maintenance scheduling, record keeping, or procedure; instituted procedures to ensure that materails do not stay in inventory beyond shelf- life; began to test outdated material - continue to use if still effective; instituted clearinghouse to exchange materails that would otherwise be discarded.

NCPPP involvement: None Comments:

Did this site begin or expand a source reduction activity during 1991 or 1992? Yes Did this site begin or expand a recvcling activity during 1991 or 1992? Yes Did this site systematically investigate opportunities for source reduction or recycling during 199 1 or 1992? Yes

Major goals for 93/94 vast improvements for our plant in source reduction and recycling.

The following factors delayed or limited this site’s ability to initiate new or additional on-site or off-site recvcling, activities during 1991 or 1992:

None







Other (specify):

reduction practices





B - 45

Facility ID Number: NCD067191262 Facility Name: BridgestoneXrestone Facility SIC Code: 301 1 Waste Codes Listed:

Definition Total DO0 1 Ignitable Waste 410 Ibs/yr

Waste Form: B209 Adhesive/Expoxies Waste Handling: MI41 Transfer facility storage Source Reduction: none NCPPP involvement: Comments: None.


Did this site begin or expand a recvcling activity during 1991 or 1992? yes

Did this site systematically investigate opportunities for source reduction or recvclinq during 1991 or 1992? yes




Concern that product quality may decline as a result of recycling Technical limitations of production processes inhibit on-site recycling Unable to identify a marketplace for recyclable materials

On-site waste reduction assessment with report.



Concem that product quality may decline as a result of source reduction Technical limitations of production processes

B - 46

Facility ID Number: NCD067422758 Facility Name: Council Craftsmen Inc. Facility SIC Code: 3036 Waste Codes Listed

Q.& Definition Total DO0 1 Ignitable Waste 9600 Ibslyr

Waste Form: B310 Spent solid filters or adsorbent Waste Handling: Incineration - Solids Source Reduction: None NCPPP involvement: None Comments: None

Did this site begin or expand a source reduction activity during 1991 or 1992? No







B - 47

Facility ID Number: Facility Name: Facility SIC Code: Waste Codes Listed:

Code F003, DO01

Waste Form: B203 Waste Handling: Source Reduction:

NCD045923059 Eaton Corp. Molded Pro. 3069

Definition Total Spent non-hal. Soh., Ignitable

Non-halogenated Solvent M061 Fuel Blending None

169,939 Ibs/yr




The following factors delayed or limited this site’s ability to initiate new or additional on-site or off-site recvclin,: activities during 1991 or 1992:

Concern that product quality may decline as a result of recycling Technical limitations of production processes inhibit on-site recycling Recycling previously implemented - additional recycling does not appear to be technically












B - 48

Facility ID Number: NCD981021413 Facility Name: Accudyne, Inc. Facility SIC Code: Waste Codes Listed:

347 1 Electroplating, Plating, Polishing, Anodizing and Coloring

Code Definition Total DO0 1 Ignitable Waste 0

Waste Form: B209 Organic Paint, Ink, Lacquer or Varnish Waste Handling: M041 Incineration - Liquids Source Reduction:



Did this site systematically investigate opportunities for source reduction or recycling, during 199 1 or 1992? No


None


Source reduction not economically feasible: cost savings in waste management or production will not cover the capital investment

B - 49

Facility ID Number: Facility Name: Crane Resistoflex Company Facility SIC Code Waste Codes Listed:

NCD 982 091 092

3494 Valves and Pipe Fittings, Not Elsewhere Classified

Code Definition Total DO01 Ignitable Waste 7,010 DO01 Ignitable Waste 8,080 F003 Spent non-halog. solvents F005 Spent non-halog. solvents 11,794

Waste Form: B209 Organic Paint, Ink, Lacquer or Varnish B209 Organic Paint, Ink, Lacquer or Varnish B209 Organic Paint, Ink, Lacquer or Varnish

M043 Incineration - Solids M043 Incineration - Solids M061 Fuel Blending

Waste Handling:

Source Reduction:


Did this site begin or expand a recvclinx activity during 1991 or 1992? Yes

Did this site systematically investigate opportunities for source reduction or rccvcling during 1991 or 1992? Yes


None


None

Other:

NCPPP Report, 3/90; On-site visit 6/89

B - 50

Facility ID Number: NCD 021 389 358 Facility Name: Crown Cork & Seal Co. Facility SIC Code: 341 1 Metal Cans Waste Codes Listed:

Code Definition F003 Spent non-halog. solvents F005 Spent non-halog. solvents 6,889

Waste Form: B209 Organic pain, ink, lacquer or varnish Waste Handling: M029 Solvents recovery, type unknown Source Reduction:



Did this site systematically investigate opportunities for source reduction or recvcling during 1991 or 1992? No


None





B - 51

Facility ID Number: Facility Name: Engineered Control International Facility SIC Code: Waste Codes Listed:

NCD 991 302 498

3494 Valves and Pipe Fittings, Not Elsewhere Classified

Code Definition Total F003 Spent non-halog. solvents F005 Spent non-halog. solvents 158

Waste Form: B211 Paint Thinner or Petroleum Distillates Waste Handling: [Blank] Source Reduction:



Did this site systematically investigate opportunities for source reduction or recvclinq during 1991 or 1992? Yes



Unable to identify a marketplace for recyclable materials Recycling previously implemented - additional recycling does not appear to be








Other: NCPPP On-site, 10/90

B - 52

Facility ID Number: NCD 003 170 784 Facility Name: Florida Steel Drum Company Facility SIC Code: 3412 Metal Shipping Barrels, Drums Kegs and Pails Waste Codes Listed:

Code Definition Total DO01 Ignitable waste 4 1,400 F003 Spent non-halog. solvents F005 Spent non-haolg. solvents DO0 1 Ignitable waste DO35 Methyl ethyl Ketone 126,450

Waste Form: B209 Organic paint, ink, lacquer or varnish B604 Organic paint or ink sludge

Waste Handling: M051 Energy recovery - liquids M053 Energy recovery - solids

Source Reduction:



Did this site systematically investigate opportunities for source reduction or recvcling during 199 1 or 1992? Yes


None


None

B - 53

Facility ID Number: NCD 095 463 88 1 Facility Name: General Steel Drum Corporation Facility SIC Code: 3412 Metal Shipping Barrels, Drums, Kegs and Pails Waste Codes Listed:

Code DO01 DO07 DO08 DO0 1 DO07 DO08 DO0 1 DO07 DO08

Definition Total Ignitable Waste Chromium Waste Lead Waste 44,570 Ignitable Waste Chromium Waste Lead Waste 2,788 Ignitable Waste Chromium Waste Lead Waste 68,408

Waste Form: B409 Other Non-Halogenated Organic Solids B209 Organic Paint, Ink, Lacquer or Varnish B209 Organic Paint, Ink, Lacquer or Varnish

Waste Handling: M061 Fuel Blending

Source Reduction: W72/W74 Modified Spray Systems or EquipmentIImproved Application Techniques [BLANK] W52/W54 Modified Equipment Layout or Pipinghstituted Better Controls on Operating

Conditions


Did this site begin or expand a recycling, activity during 1991 or 1992? Yes


The following factors delayed or limited this site’s ability to initiate new or additional on-site or off-site recycling, activities during 1991 or 1992:




Concern that product quality may decline as a result of recycling Technical limitations of production processes inhibit on-site recycling

practice


will not cover the capital investment ~

B - 54

Unable to identify a marketplace for recyclable materials Recycling previously implemented - additional recycling does not appear to be technically







Facility ID Number: NCD 075 575 191 Facility Name: Mestek Incorporated Facility SIC Code: 3433 Heating Equipment, Except Electric and Warm Air Furnaces Waste Codes Listed:

Code Definition Total F003 Spent non-halog. solvents 24,191 F003 Spent non-halog. solvents 8,768

Waste Form: B319 Other waste inorganic solids

Waste Handling: M043 Incineration - solids M061 Fuels blending

Source Reduction:



Did this site systematically investigate opportunities for source reduction or recvclinR during 199 I or 1992? Yes


None

B203 Non-halogenated solvent



NCPPP On-site: 3/93

B - 56

Facility ID Number: NCD 000 616 516 Facility Name: Yale Security, Inc. Facility SIC Code: 3449 Miscellaneous Structural Metal Work Waste Codes Listed:

Code Definition Total DO0 1 Ignitable Waste DO35 Methyl Ethyl Ketone 11,438

Waste Form: B211 Paint thinner or petroleum distillates Waste Handling: M041 Incineration Source Reduction:

Did this site begin or expand a source reduction activity during 1991 or 1992? YES

Did this site begin or expand a recyclinx activity during 1991 or 1992? No



None


None

B - 57

Facility ID Number: NCD 061 786 000 Facility Name: Beta Systems Division, Velcon Filters Inc. Facility SIC Code: 3479 Coating, Engraving and Aliied Services Not Elsewhere Classified Waste Codes Listed:

Code Definition Total DO0 1 Ignitable Waste F003 Spent non-halog. solvents F005 Spent non-halog. solvents 15.01 1 DO01 Ignitable Waste F003 Spent non-halog. solvents F005 Spent non-halog. solvents 13,600

Waste Form:

Waste Handling: M053 Energy recovery - solids Source Reduction:

B2I 1 Paint thinner or petroleum distillates B602 Still bottoms of non-haolgenated solvents or other organic liquids







Technical limitations of production processes inhibit on-site recycling Unable to identify a marketplace for recyclable materials






Concem that product quality may decline as a result of source reduction Technical limitations of production processes

~

-

B - 58

Facility ID Number: NCD 067 200 949 Facility Name: Croft Metals Inc. of NC Facility SIC Code: 3441 Fabricated Structural Metal Waste Codes Listed:

Code Definition F003 Spent non-halog. solvents F005 Spent non-halog. solvents 46,928 DO01 Ignitable Waste F003 Spent non-halog. solvents F005 Spent non-halog. solvents 19,300 DO0 1 Ignitable Waste F003 Spent non-halog. solvents 15,400

Waste Form: B203 Non-halogenated solvent B310 Spent solid filters or adsorbents B604 Organic paint or ink sludge

Waste Handling: M061 Fuels blending Source Reduction:






Unable to identify a marketplace for recyclable materials Recycling previously implemented - additional recycling does not appear to be technically



feasible




Source reduction previously implemented - additional source reduction does not appear specific production processes


B - 59

Source reduction previously implemented - additional source reduction does not appear to be economically feasible

Other: NCPP On-Site, V88, 6/89, 6/93

B - 60

Facility ID Number: NCD 098 770 746 Facility Name: Curtis-Wright Flight Systems Facility SIC Code: 3499 Fabricated Metal Products Not Elsewhere Classified Waste Codes Listed:

Code Definition Total DO0 1 Ignitable Waste F003 Spent non-halog. solvents F005 Spent non-halog. solvents 4,712 F005 Spent non-halog. solvents 264

Waste Form: B209 Organic Paint, Ink, Lacquer or Varnish

Waste Handling: M061 Fuel Blending B409 Other non-Halogenated Organic Solids

M141 Transfer Facility Storage, waste was shipped off site with no on-site TDR activity

Source Reduction:


Did this site begin or expand a recycling activity during 1991 or 1992? Yes


The following factors delayed or limited this site’s ability to initiate new or additional on-site or off-site recwling activities during 1991 or 1992:

Unable to identify a marketplace for recyclable materials


None

B - 61

Facility ID Number: NCD 085 075 745 Facility Name: Facility SIC Code: 3442 Metal Doors, Sash, Frames, Molding and Trim Waste Codes Listed:

Fenestra COT. Harrisburg Division

- Code Definition Total DO0 1 Ignitable Waste F003 Spent non-halog. solvents F005 Spent non-halog. solvents 1,000 DO0 1 Ignitable Waste 9,500

Waste Form: B319 Other waste inorganic solids

Waste Handling: M061 Fuel Blending Source Reduction:

B209 Organic paint, ink, lacquer or varnish





None




reduction practices

B - 62

Facility ID Number: NCD 091 245 431 Facility Name: Freightliner Parts Manufacturing Plant Facility SIC Code: 3490 Miscellaneous Fabricated Metal Products Waste Codes Listed:

Code Definition Total DO0 1 Ignitable Waste 2,475 F005 Spent non-halog. solvents 8,910

Waste Form: B403 Solid Resins or Polymerized Organics B203 Non-halogenated solvent

Waste Handling: M061 Fuel Blending Source Reduction: [BLANK]

W59 Modified StrippingKleaning Equipment




The following factors delayed or limited this site's ability to initiate new or additional on-site or off-site recycling activities during 1991 or 1992:




The following factors delayed or limited this site's ability to initiate new or additional reduction activities in 1991 or 1992:


Source reduction previously implemented - additional source reduction does not appear to he technically feasible

to he economically feasible

Other: [From "NC Leaders" report]: Converted wet paint booth operations to baffled dry filtered booth, to enable dry cleanup of paint overspray. (1989)

B - 63

Facility ID Number: NCD 981 922 362 Facility Name: Greif Brothers Corporation Facility SIC Code: 3412 Metal Shipping Barrels, Drums, Kegs and Pails Waste Codes Listed:

Definition Total F003 Spent non-halog. solvents 7,525 DO01 Ignitable Waste 10,300

Waste Form: B209 Organic Paint, Ink, Lacquer or Varnish

Waste Handling: M053 Energy Recovery - Solids

Source Reduction: W 13AV 14 Improved Maintenance Scheduling, Record-keeping or ProceduresKhanged Production Schedule to Minimize Equipment and Feedstock Changeovers W 13 Improved Maintenance Scheduling, Record-keeping or

B209 Organic Paint, Ink, Lacquer or Varnish M05 1 Energy Recovery - Liquids

Procedures






Technical limitations of production processes inhibit on-site recycling Lack of permitted off-site recycling facilities Unable to identify a marketplace for recyclable materials




B - 64

Facility ID Number: NCD 089 914 31 1 Facility Name: Miller Brewing Company Container Division Facility SIC Code: 341 I Metal Cans Waste Codes Listed:

Code Definition Total F003 Spent non-halog. solvents 1,850 F002 Spent halog. solvents F003 Spent non-halog. solvents 10,360

Waste Form: B209 Organic Paint, Ink, Lacquer or Varnish B209 Organic Paint, Ink, Lacquer or Varnish

MI41 Transfer Facility Storage, waste was shipped off site with no on-site TDR activity MI41 Transfer Facility Storage, waste was shipped off site with no

Waste Handling:

on-site TDR activity Source Reduction:





Recycling previously implemented - additional recycling does not appear to be technically feasible



B - 65

Facility ID Number: NCD 033 999 764 Facility Name: Walter Kidde Aerospace, Inc. Facility SIC Code: 3479 Coating Engraving and Allied Services, Not Elsewhere Classified Waste Codes Listed:

Code Definition Total DO07 Chromium Waste DO08 Lead Waste 1,334 DO01 Ignitable Waste F003 Spent non-halog. solvents F005 Spent non-haolg. solvents 834

Waste Form: B209 Organic paint, ink, lacquer or varnish

Waste Handling:

Source Reduction:


Did this site begin or expand a recwling activity during 1991 or 1992? Yes



B211 Paint thinner or petroleum distillates MI41 Transfer facility storage, waste was shipped off-site with no on-site TDR activity



Technical limitations of production processes inhibit on-site recycling










B - 66

Facility ID Number: NCD980841753 Facility Name: ALTEC INDUSTRIES Facility SIC Code: 3536 Contact’s name: LARRY TOWNSEND Telephone number: (919) 528-2535

Waste Codes Listed: Definition Total (Ibs)

F003 spent non-halogenated solvent 25600 F005 spent non-halogentaed solvent

Waste Form: paint thinner or petroleum distillates Waste Handling: transfer facility storage

Did this site begin or expand a source reduction activity during 1991 or 1992? - yes

Did this site begin or expand a recycling activity during 1991 or 1992? - yes

Did this site systematically investigate opportunities for source reduction or recycling during 1991 or 1992? - yes




Permitting burdens inhibit recycling Recycling previously implemented - additional recycling does not appear to be


practice



Insufficient capital to install new source reduction equipment or implement new

Concern that product quality may decline as a result of source reduction source reduction practices

B - 67

Facility ID Number: NCD980846877 Facility Name: THE AMERICAN CRANE CORP Facility SIC Code: 3531 Contact’s name: DONALD DUNLAP (facility manager) Telephone number: (919) 395-8500

Waste Codes Listed: Code Definition Total (Ibsl F003 spent non-halogenated solvents 12775 F005 spent non-halogenated solvents

Waste Form: paint thinner or petroleum distillates Waste Handling: solvents recovery - thin film evaporation

Did this site begin or expand a source reduction activity during 1991 or 1992? - no

Did this site begin or expand a recycling activity during 1991 or 1992? - no

Did this site systematically investigate opportunities for source reduction or recvcling during 199 1 or 1992? - n o



Recycling previously implemented - additional recycling does not appear to be will not cover the capital investment




Source reduction previously implemented - additional source reduction does not appear production will not cover the capital investment


B - 68

Facility ID Number: NCD982134181 Facility Name: ASMO NORTH CAROLINA INC. Facility SIC Code: 3585 Contact’s name: DANNY YOUNT Telephone number: (704) 878 - 8571

Waste Codes Listed: Code Definition DO05 barium

Total (Ibs) 31124

Waste Form: organic paint or ink sludge Waste Handling: sludge treatment - sludge dewatering



Did this site systematically investigate opportunities for source reduction or recyclinx during 199 1 or 1992? - y e s



Concern that product quality may decline as a result of recycling Recycling previously implemented - additional recycling does not appear to be technically



feasible




B - 69

Facility ID Number: NCD982134181 Facility Name: ASMO NORTH CAROLINA INC. Facility SIC Code: 3585 Contact’s name: DANNY YOUNT Telephone number: (704) 878 - 8571

Waste Codes Listed: Code Definition DO05 barium

Waste Form: non-halogenated solvent Waste Handling: transfer facility storage

Total (Ibsl 7327



Did this site systematically investigate opportunities for source reduction or recvcling, during 199 1 or 1992? - y e s






f e a s i b 1 e




B - 70

Facility ID Number: NCD062548995 Facility Name: BALCRANK PRODUCTS Facility SIC Code: 3569 Contact’s name: MITCHAEL STOUT (environmental manager) Telephone number: (704) 645-426 1

Waste Codes Listed: Code Definition DO0 1 ignitable

Total (Ibs) 5963

Waste Form: spent solid filters or adsorbants Waste Handling: incineration - solids



Did this site systematically investigate opportunities for source reduction or recycling during 199 1 or 1992? -yes



Technical limitations of production processes inhibit on-site recycling Recycling previously implemented - additional recycling does not appear to be





Technical limitations of production processes Source reduction previously implemented - additional source reduction does not appear



B - 71

Facility ID Number: NCD062548995 Facility Name: BALCRANK PRODUCTS Facility SIC Code: 3569 Contact’s name: MITCHAEL STOUT (environmental manager) Telephone number: (704) 645-4261

Waste Codes Listed: Code Definition Total (lbs) F005 spent non-halogenated solvent 1329 F003 soent non-halogenated solvent DO0 1 ignitable DO22 chloroform

Waste Form: paint thinner or petroleum distillates Waste Handling: incineration - liquids



Did this site systematically investigate opportunities for source reduction or recycling during 1991 or 1992? - y e s



Technical limitations of production processes inhibit on-site recycling Recycling previously implemented - additional recycling does not appear to be







~


B - 12

Facility ID Number: NCD056463573 Facility Name: CONSOLIDATED DIESEL COMP. Facility SIC Code: 3519 Contact’s name: CLIFTON SMITH (environmental engineer) Telephone number: (919) 437-661 1

Waste Codes Listed: Code Definition Total (Ibs) DO01 ignitable waste 378 F005 spent non-halogenated solvents

Waste Form: paint thinner or petroleum distillates Waste Handling: fuel blending



Did this site systematically investigate opportunities for source reduction or recvcling during 1991 or 1992? -yes


none listed



B - 73

Facility ID Number: NCD0.56463573 Facility Name: CONSOLIDATED DIESEL COMP. Facility SIC Code: 3519 Contact’s name: CLIFTON SMITH (environmental engineer) Telephone number: (919) 437-661 1

Waste Codes Listed: Code Definition Total (Ibsl DO0 1 ignitable waste 125924 F005 spent non-halogenated solvents

note: 23849 Ibs treated in-site, solvents recovery (fractionatioddistillation)

Waste Form: paint thinner or petroleum distillates Waste Handling: fuel blending





none listed



B - 74

Facility ID Number: NCD056463573 Facility Name: CONSOLIDATED DIESEL COMP. Facility SIC Code: 3519 Contact’s name: CLIFTON SMITH (environmental engineer) Telephone number: (919) 437-661 1

Waste Codes Listed: Q& Definition Total (lbsl DO0 1 ignitable waste 1600 F005 spent non-halogenated solvents

Waste Form: soil contaminated with organics Waste Handling: incineration - solids



Did this site systematically investigate opportunities for source reduction or recvcline, during 199 1 or 1992? - yes


none listed



B - 75

Facility ID Number: NCD042892067 Facility Name: COOPER INDUSTRIES INC Facility SIC Code: 3545 Contact’s name: MATT CATON Telephone number: (919) 362-751 1

Waste Codes Listed: Code Definition Total (Ibs] F005 spent non-halogenated solvent 3711 DO0 1 ignitable F003 spent non-halogenated solvent

Waste Form: organic paint or ink sludge Waste Handling: fuel blending



Did this site systematically investigate opportunities for source reduction or recvcling during 199 1 or 1992? - y e s



Financial liability provisions inhibit shipments off site for recycling Unable to identify a marketplace for recyclable materials






B - 76

Facility ID Number: NCD982122210 Facility Name: DEERE - HITACHI Facility SIC Code: 3524 Contact’s name: JOE KOERNER Telephone number: (919) 966-8123

Waste Codes Listed: - Code Definition DO07 chromium DO08 lead DO0 1 ignitable F003 spent non-halogenated solvents

Waste Form: organic paint, ink, lacquer, or varnish Waste Handling: energy recovery - sludges

Total (Ibs) 47500




The following factors delayed or limited this site’s ability to initiate new or additional on-site or off-site recycling activities during 199 1 or 1992:

Financial liability provisions inhibit shipments off site for recycling Technical limitations of production processes inhibit shipments off site for recycling Technical limitations of production processes inhibit on-site recycling Lack of permitted off-site recycling facilities



B - 77

Facility ID Number: NCD003 154804 Facility Name: DUFF-NORTON CO. Facility SIC Code: 3569 Contact’s name: PAUL BARNHARDT Telephone number: (704) 588-05 10

Waste Codes Listed: Code Definition DO0 1 ignitable F003 spent non-halogenated solvent

Waste Form: organic paint, ink, lacquer or varnish Waste Handling: energy recovery - liquids

Total (Ibs) 26036



Did this site systematically investigate opportunities for source reduction or recycling during 199 1 or 1992? - yes







B - 78

Facility ID Number: NCD003 154804 Facility Name: DUFF-NORTON CO. Facility SIC Code: 3569 Contact’s name: PAUL BARNHARDT Telephone number: (704) 588-0510

Waste Codes Listed: Definition

DO0 1 ignitable DO07 chromium

Total (Ibs) 13400

Waste Form: other non-halogenated organic solids Waste Handling: fuel blending










B - 79

Facility ID Number: NCD089989917 Facility Name: EMERSON ELECTRIC COMP. Facility SIC Code: 3553 Contact’s name: LONNIE OWENE Telephone number: (704) 837-5 101

Waste Codes Listed: Code Definition Total (lbs) DO01 ignitable 400 F003 spent non-halogenated solvent F005 spent non-halogenated solvent

Waste Form: organic paint or ink sludge Waste Handling:



Did this site systematically investigate opportunities for source reduction or recvcling during 199 1 or 1992? -yes



Technical limitations of production processes inhibit on-site recycling Unable to identify a marketplace for recyclable materials Recycling previously implemented - additional recycling does not appear to be








to be technically feasible ~


B - 80

Facility ID Number: NCDOO1115245 Facility Name: GILBARCO INC. Facility SIC Code: 3586 Contact’s name: ED FAIRES Telephone number: (919) 547-5554

Waste Codes Listed: Code Definition Total (lbs) F003 spent non-halogenated solvent 15786 F005 spent non-halogenated solvent

Waste Form: organic paint, ink, lacquer or varnish Waste Handling: energy recovery - sludges



Did this site systematically investigate opportunities for source reduction or recvclinR during 199 1 or 1992? - y e s




Concern that product quality may decline as a result of recycling Requirements to manifest wastes inhibit shipments off site for recycling Financial liability provisions inhibit shipments off site for recycling Technical limitations of production processes inhibit shipments off site for recycling Technical limitations of production processes inhibit on-site recycling Permitting burdens inhibit recycling Unable to identify a marketplace for recyclable materials Recycling previously implemented - additional recycling does not appear to be technically



Other (specify):

practice


feasible



B - 81




Concern that product quality may decline as a result of source reduction Technical limitations of production processes Permitting burdens Source reduction previously implemented - additional source reduction does not appear



Other (specify):

reduction practices

production will not cover the capital investment ~




€3 - 82

Facility ID Number: NCD980840466 Facility Name: HONDA POWER EQUIPMENT MFG. Facility SIC Code: 3524 Contact’s name: RICHARD HOPKINS Telephone number: (919) 578-5300

Waste Codes Listed: Code Definition Total (Ibs) DO0 1 ignitable 94750 F003 spent non-halogenated solvent

Waste Form: organic paint, ink, lacquer, or varnish Waste Handling: energy recovery -type unknown



Did this site systematically investigate opportunities for source reduction or recycling during 199 1 or 1992? - y e s




practice




reduction practices


B - 83

Facility ID Number: NCD980840466 Facility Name: HONDA POWER EQUIPMENT MFG. Facility SIC Code: 3524 Contact’s name: RICHARD HOPKINS Telephone number: (919) 578-5300

Waste Codes Listed: Code Definition Total (Ibs) F019 wastewater treatment sludges 94400

from the chemical conversion coating of aluminum

Waste Form: spent solid filters or adsorbants Waste Handling: transfer facility storage







practice




reduction practices


B - 84

Facility ID Number: NCD041414772 Facility Name: INGERSOLL RAND PORTABLE COMPRE Facility SIC Code: 3563 Contact’s name: CHARLIE WHALEY (environmental administrator) Telephone number: (704) 634-6728


DO0 1 ignitable 5500 F003 spent non-halogenated solvent F005 spent non-halogenated solvent

Waste Form: organic paint or ink sludge Waste Handling: incineration - liquids

Did this site begin or expand a source reduction activity during 1991 or 1992? -






Technical limitations of production processes inhibit shipments off site for recycling Technical limitations of production processes inhibit on-site recycling Unable to identify a marketplace for recyclable materials Recycling previously implemented - additional recycling does not appear to be technically





feasible





B - 85



DO01 ignitable 3900 F003 spent non-halogenated solvent F005 spent non-halogenated solvent

Waste Form: organic paint or ink sludge Waste Handling: incineration - solids



Did this site systematically investigate opportunities for source reduction or recwling during 1991 or 1992? -yes









feasible



Source reduction previously implemented - additional source reduction does not appear specific production processes ~

to be economically feasible -

B - 86


Waste Codes Listed: Code Definition Total (Ibs) DO0 1 ignitable 13340 F003 spent non-halogenated solvent F005 spent non-halogenated solvent

Waste Form: paint thinner or petroleum distillates Waste Handling: solvents recovery - type unknown



Did this site systematically investigate opportunities for source reduction or recvcling during 1991 or 1992? - y e s








feasible






B - 87

Facility ID Number: NCD000822247 Facility Name: JACOBSEN - DIVISION OF TEXTRON Facility SIC Code: 3523 Contact’s name: ASTOR AZARCON Telephone number: (704) 588-5 120

Waste Codes Listed: Code Definition DO0 1 ignitable Do3 5 methyl ethyl ketone

Waste Form: other non-halogenated organic solids Waste Handling: fuel blending

Total Ilbs) 6650










Source reduction previously implemented - additional source reduction does not appear reduction practices


B - 88

Facility ID Number: NCD986185.585 Facility Name: MATSUSHITA COMPRESSOR CORP. Facility SIC Code: 3585 Contact’s name: STAN C FAIRES Telephone number: (704) 644-6700

Waste Codes Listed: Code Definition DO08 lead

Total (Ibs) 4400

Waste Form: other aqueous waste with low dissolved solids Waste Handling: fuel blending



Did this site systematically investigate opportunities for source reduction or recvcling during 199 1 or 1992? - yes





B - 89

Facility ID Number: NCD986185585 Facility Name: MATSUSHITA COMPRESSOR CORP. Facility SIC Code: 3585 Contact’s name: STAN C FAIRES Telephone number: (704) 644-6700

Waste Codes Listed: Code Definition DO08 lead

Total (Ibs) 2600

Waste Form: spent solid filters or adsorbants Waste Handling: transfer facility storage



Did this site systematically investigate opportunities for source reduction or recwling during 1991 or 1992? -yes





B - 90

Facility ID Number: NCD101773992 Facility Name: OUTBOARD MARINE CORP (OMC) - BURNSVILLE Facility SIC Code: 3519 Contact’s name: BERNICE WILSON Telephone number: (704) 682-213 1

Waste Codes Listed: Code Definition Total (Ibs) DO0 1 ignitable waste 63902 DO07 chromium F003 spent non-halogenated solvents F005 spent non-halogentaed solvents

Waste Form: spent solid filters or adsorbents Waste Handling: fuel blending








practice




Lack of technical information on source reduction techniques applicable to this site’s reduction practices


B - 91

Facility ID Number: NCD101773992 Facility Name: OUTBOARD MARINE CORP (OMC) - BURNSVILLE Facility SIC Code: 3519 Contact’s name: BERNICE WILSON Telephone number: (704) 682-2 13 1

Waste Codes Listed: Code Definition Total (Ibsl DO0 1 ignitable waste 3669 DO35 methyl ethyl ketone F003 spent non-halogenated solvents F005 spent non-halogentaed solvents

Waste Form: non-halogenated solvent Waste Handling: fuel blending



Did this site systematically investigate opportunities for source reduction or recvcling, during 1991 or 1992? - y e s





practice




Lack of technical information on source reduction techniques applicable to this site’s reduction practices


B - 92

Facility ID Number: NCD98 1003 197 Facility Name: OUTBOARD MARINE CORP (OMC) - ANDREWS Facility SIC Code: 35 19 Contact’s name: RICK WELCH (maintainence supervisor) Telephone number: (704) 837-53 1 1

Waste Codes Listed: Code Definition Total (Ibs) DO0 1 ignitable waste 1242 DO07 chromium DO35 methyl ethyl ketone F005 spent non-halogenated solvents

Waste Form: paint thinner or petroleum distillates Waste Handling: incineration - liquids





none listed




B - 93

Facility ID Number: NCD003 156940 Facility Name: PNEUMAFIL CORP Facility SIC Code: 3552 Contact’s name: LARRY BEARDEN (process engineer) Telephone number: (704) 399-7441

Waste Codes Listed: Code Definition Total (Ibs) DO0 1 ignitable 31192 F003 spent non-halogenated solvent F005 spent non-halogenated solvent

note: 16972 Ibs were treated onsite by solvents recovery - fractionation/distillation

Waste Form: organic paint, ink, lacquer or varnish Waste Handling: feu1 blending









Recycling ‘previously implemented - additional recycling does not appear to be

practice



f e a s i b 1 e


B - 94







reduction practices





B - 95

Facility ID Number: NCD003 1.56940 Facility Name: PNEUMAFIL CORP Facility SIC Code: 3552 Contact’s name: LARRY BEARDEN (process engineer) Telephone number: (704) 399-7441

Waste Codes Listed: Code Definition DO07 chromium

Total (Ibs) 16.514

Waste Form: organic paint or ink sludge Waste Handling: feu1 blending



Did this site systematically investigate opportunities for source reduction or recyclinx during 1991 or 1992? - yes







practice



feasible


E - 96







reduction practices





B - 97

Facility ID Number: NCD003 156940 Facility Name: PNEUMAFIL CORP Facility SIC Code: 3552 Contact’s name: LARRY BEARDEN (process engineer) Telephone number: (704) 399-7441


Total (Ihs) 9633

Waste Form: spent solid filters or adsorbants Waste Handling: feu1 blending



Did this site systematically investigate opportunities for source reduction or recycling during 1991 or 1992? -yes






feasible Recycling previously implemented - additional recycling does not appear to be


practice



B - 98







reduction practices





B - 99

Facility ID Number: NCD079068607 Facility Name: VME AMERICAS, INC. Facility SIC Code: 3537 Contact’s name: MIKE FRANKLIN (manager of employment) Telephone number: (704) 684-3 121

Waste Codes Listed: Code Definition Total (Ibs) DO01 ignitable 8495 DO07 chromium F003 spent non-halogenated solvent F005 spent non-halogenated solvent

Waste Form: organic paint, ink, lacquer, or varnish Waste Handling: fuel blending



Did this site systematically investigate opportunities for source reduction or recvclinq during 1991 or 1992? - y e s





Concern that product quality may decline as a result of source reduction reduction practices

B - 100

Facility ID Number: NCD079068607 Facility Name: VME AMERICAS, INC. Facility SIC Code: 3537 Contact’s name: MIKE FRANKLIN (manager of employment) Telephone number: (704) 684-3 121


Total (Ibs) 13277

Waste Form: spent solid filters or adsorbants Waste Handling: fuel blending



Did this site systematically investigate opportunities for source reduction or recvcling during 199 1 or 1992? - yes





Concern that product quality may decline as a result of source reduction reduction practices

B - 101

Facility ID Number: NCD079054680 Facility Name: WESTINGHOUSE ELECTRIC CORP. Facility SIC Code: 35 11 Contact’s name: R.H. Carpenter Telephone number: (704) 55 1-5 149

Waste Codes Listed: DO01 Code Definition Total (Ibs] DO01 ignitable waste 5600

Waste Form: organic paint, ink,lacquer, or vamish Waste Handling: fuel blending

Did this site begin or expand a source reduction activity during 1991 or

Did this site begin or expand a recycling activity during 1991 or 1992?

992? -yes





practice

The following factors delayed ar limited this site’s ability to initiate new or additional source reduction activities in 1991 or 1992:


B - 102

Facility ID Number: NCD003 195963 Facility Name: Facility SIC Code: 3612 Waste Codes Listed:

Code Definition Total DOOl,D018,D035 ignitable,benzene,MEK 6,638 Ibs/yr

Waste Form: B203 Non-halogenated solvent Waste Handling: M029 Solvents recovery - type unknown Source Reduction: None NCPPP involvement: None Comments: None

ABB Power T & D Co.



Did this site systematically investigate opportunities for source reduction or recvcling during 1991 or 1992? yes



Concern that product quality may decline as a result of recycling Technical limitations of production processes inhibit shipments off site for recycling





B - 103

Facility ID Number: NCD986194330 Facility Name: AT&T Facility SIC Code: 3661 Waste Codes Listed:

D001F003F005 Ignitable, non-hal. solvents 1,388 Ibs/yr DO0 1 DO03 Ignitable, reactive 60 Ibs/yr DO0 1 Ignitable 120 Ibs/yr

Waste Form: Wastes #I and #2 - B209 - Organic paint, ink, lacquer, or varnish. Waste #3 - BOO1 - Lab packs of old chemicals only.

Waste Handling:

Source Reduction: NCPPP involvement: None. Comments: Did this site begin or expand a source reduction activity during 1991 or 1992? Yes. Did this site begin or expand a recycling activity during 1991 or 1992? Yes. Did this site systematically investigate opportunities for source reduction or recycling during 199 1 or 1992? Yes.



MI41 - Transfer facility storage, waste shipped off-site with no on-site TDR activity. Waste #1 - W02 - Off-site recycling began during 1991.

New facility in 1992; Source reduction and recycling.



Concern that product quality may decline as a result of recycling Requirements to manifest wastes inhibit shipments off site for recycling Financial liability provisions inhibit shipments off site for recycling Technical limitations of production processes inhibit shipments off site for recycling Technical limitations of production processes inhibit on-site recycling Unable to identify a marketplace for recyclable materials Other (specify): See comments above.

practice




Technical limitations of production processes Other (specify): See comments above.

reduction practices ~~~~

-

B - 104

Facility ID Number: NCD980844898 Facility Name: Channel Master Facility SIC Code: 3679 Waste Codes Listed:

Code Definition Total F005 spent non-ha1 solvents 1,732 lbslyr

Waste Form: B209 - Organic paint, ink, lacquer, or varnish. Waste Handling: Source Reduction: None specified. NCPPP involvement: None. Comments: None.

M061 - Fuel blending







Permitting burdens inhibit recycling




to he technically feasible

B - 105

Facility ID Number: NCD986187029 Facility Name: Exide Electronics Facility SIC Code: 3629 Waste Codes Listed:

Code Definition F005F003 Spent non-hal. solvents

Total 23,200 ibs/yr

~~ ~

Waste Form: B211 - Paint thinner or petroleum distillates. Waste Handling:

Source Reduction: None specified. NCPPP involvement: None. Comments:




MI41 - Transfer facility storage, waste was shipped off site with no on-site TDR activity.

~

On-site recovery still approved for purchase, implementation set for 5/1/93.


None specified


None specified.

B - 106

Facility ID Number: NCD057037194 Facility Name: General Electric, Mebane Facility SIC Code: 3622 Waste Codes Listed

F003F005D001 Spent non-ha1 solv., ignitable 820 Ibslyr F003F005D035 Spent non-hal solv., MEK 4,650 lbslyr

Waste Form: Waste #I - B204 - HaUnon-hal. solvent mixture Waste #2 - B409 - Other non-hal. organic solids

Waste Handling: Waste #I - M061 - Fuel blending Waste #2 - M141 - Transfer fac. storage, waste was shipped off-site with no on-site TDR activity.

Source Reduction: None specified. NCPPP involvement: Prepared report but no on-site visit; sent misc. info. Comments:


Plating line upgraded in 1992 to accept recycling equipment installed in 1993. Source waste reduction achieved through process simplification.






Technical limitations of production processes inhibit on-site recycling Permitting burdens inhibit recycling




B - 107

Facility ID Number: NCD003229358 Facility Name: Facility SIC Code: 3634 Waste Codes Listed:

D001F003F005 Ignitable, spent non-hal. solv. 3,630 lbslyr

Waste Form: B209 - Organic paint, ink, lacquer, or varnish Waste Handling: M053 - Energy recovery - solids Source Reduction: None specified. NCPPP involvement: None. Comments: None.

Hamilton BeacMProctor, Mount Airy




Did this site systematically investigate opportunities for source reduction or recvclinr: during 1991 or 1992? Yes.



Recycling not economically feasible: cost savings in waste management or production production processes






B - 108

Facility ID Number: NCD045646924 Facility Name: ILCO Unican Corp. Facility SIC Code: 3662 Waste Codes Listed:

Code Definition Total F003D001 Spent non-hal. solv., ignitable 1,238 Ibs/yr


M051 - Energy recovery - liquids.






Technical limitations of production processes inhibit shipments off site for recycling Technical limitations of production processes inhibit on-site recycling Permitting burdens inhibit recycling Lack of permitted off-site recycling facilities Recycling previously implemented - additional recycling does not appear to be technically


feasible





B - 109

Facility ID Number: NCD089904536 Facility Name: Smith A 0 Corporation Facility SIC Code: 3622 Waste Codes Listed:

D001D035F003 Ignitable, MEK, spnt non-ha1 soh . 40,396 Ibs/yr

Waste Form: B211 - Paint thinner or petroleum distillates. Waste Handling: Source Reduction: None specified. NCPPP involvement: None. Comments: None.


M051 - Energy recovery - liquids








B - 110

Facility ID Number: NCD00395 1878 Facility Name: Facility SIC Code: 3613 Waste Codes Listed:

F003F005 Spent non-hal. soh . 22,385 Ibs/yr F003F005D001 Spent non-hal. solv, ignitable 17,160 lbs/yr

Waste Form: waste #1 - B209 - Organic paint, ink, lacquer, or varnish Waste #2 - B203 - Non-hal. solvent

Waste Handling:

Source Reduction: None specified. NCPPP involvement: Sent information, misc. Comments:

Square D Comp., Asheville


#1 - M041 - Incineration - liquids #2 - M051 - Energy recovery -liquids

Failure of engineering contractor to install.

Did this site begin or expand a source reduction activity during 991 or 2? les.


Did this site systematically investigate opportunities for source reduction or recyclinK during 1991 or 1992? Yes.


None specified.



B - 111

Facility ID Number: NCD046135992 Facility Name: Westinghouse Electric, Fayetteville Facility SIC Code: 3622 Waste Codes Listed:

D001D007D008 Ignitable, chromium, lead 3,336 Ibs/yr F003F005 Spent non-hal. solvents 2,251 Ibs/yr

Waste Form: Waste #I - B211 - Paint thinner or petroleum distillates. Waste #2 - B409 - Other non-halogenated organic solids.

Waste Handling:

Source Reduction: None specified. NCPPP involvement: None. Comments: None.

Code Definition Total ~

-~

-

M141 -Transfer facility storage, waste was shipped off site with no on-site TDR activity.



Did this site systematically investigate opportunities for source reduction or recycling during 1991 or 1992? No.







B - 112

Facility ID Number: NCD005002894 Facility Name: Alcatel Network System Facility SIC Code: 3613 Waste Codes Listed:

F003F005DO 18 Spent non-hal. soh., Benzene 22,080 lbs/yr




Did this site begin or expand a source reduction activity during 1991 or 1992? No,

Did this site begin or expand a recvclin,: activity during 1991 or 1992? No,

Did this site systematically investigate opportunities for source reduction or recvclin,: during 1991 or 1992? Yes.


None specified.



B - 113

Facility ID Number: NCD086330412 Facility Name: Caterpillar, Inc. Facility SIC Code: 3674 Waste Codes Listed:

F003F005 Spent non-hal. soh. 12,300 lbs/yr

Waste Form: B209 - Organic paint, ink, lacquer, or varnish Waste Handling: Source Reduction: None specified. NCPPP involvement: None. Comments:


M061 - Fuel blending.

This is a new paint start-up for 1992. Waste minimization activities will begin when a baseline is established.



Did this site systematically investigate opportunities for source reduction or recvcling during 199 1 or 1992? No.


None specified


None specified.

B - 114

Facility ID Number: NCD097721849 Facility Name: Exide electronics, Raleigh Facility SIC Code: 3674 Waste Codes Listed:

Code Definition F005 Spent non-hal. solv. F00.5 Spent non-hal. solv.

Waste Form: B203 - Non-halogenated solvent. Waste Handling: Source Reduction: None specified. NCPPP involvement: None. Comments: None.


Total 29,000 Ibs/yr 13,400 Ibs/yr


Did this site begin or expand a recyclinx activity during 1991 or 1992? Yes.



None specified.


None specified.

B - 115

Facility ID Number: NCD079044426 Facility Name: GE Lighting Systems Facility SIC Code: 3646 Waste Codes Listed:

Code Definition - Total F005D001 Spent non-hal. soh., ignitable 5,441 Ibslyr

Waste Form: B203 - Non-halogenated solvent. Waste Handling: Source Reduction: None specified. NCPPP involvement: None. Comments: None.





M061 - Fuel blending.

Technical limitations of production processes inhibit on-site recycling Recycling previously implemented - additional recycling does not appear to be technically






B - 116

Facility ID Number: NCD003237948 Facility Name: General Electric Facility SIC Code: 3612 Waste Codes Listed:

code Definition Total F005,F003,D001 Spent non-hal. soh., ignitable 15,750 Ibs/yr

Waste Form: B604 Organic paint or ink sludge Waste Handling: M041 Incineration - liquids Source Reduction: None NCPPP involvement: None Comments:


Did this site begin or expand a recycling activity during 1991 or 1992? Yes.

Did this site systematically investigate opportunities for source reduction or recycling during or 1992? Yes.

99

The following factors delayed or limited this site’s ability to initiate new or additional on-site or off-site recvclinr: activities during 1991 or 1992:

None specified.


None specified.

€3 - 117

Facility ID Number: NCD002594273 Facility Name: Hamilton BeacMProctor, Clinton Facility SIC Code: 3634 Waste Codes Listed:

code Definition Total D001F003F005 Ignitable, spent non-hal. soh . 2,635 lbslyr

Waste Form: B209 - Organic paint, ink, lacquer, or varnish Waste Handling: Source Reduction: None specified. NCPPP involvement: None. Comments:


This process was in the process of closing, shutting down. As of June 1, 1993, the facility will he officially closed.



Did this site systematically investigate opportunities for source reduction or recvcling, during 199 1 or 1992? No.


None specified.


None specified.

B - 118

Facility ID Number: NCD097362321 Facility Name: Ohio Electric Motors Facility SIC Code: 3621 Waste Codes Listed:

Code Definition Total F003F005D001 Spent non-hal. solv., ignitable 5,968 Ibslyr - F003F005D001 Spent non-hal. solv., ignitable 1,246 Ihsjyr

Waste Form: Waste #I - B409 - Other non-hal. org. solids Waste #2 - B219 - Other organic liquids

Waste Handling: Waste #I - M042 - Ininceration - sludges Waste #2 - M124 - Phase separation (e.g., emulsion breaking,filtration) only.

Source Reduction: None. NCPPP involvement: Sent miscellaneous information. Comments: None.


Did this site begin or expand a recycling activity during 1991 or 1992’7 No.



None specified.




B - 119

Facility ID Number: NCD101773000 Facility Name: Square D Company, Monroe Facility SIC Code: 3612 Waste Codes Listed:

DO0 1 F005 Ignitable, spt. non-bal. soh . 19,116 Ibs/yr F005D035F006 Non-ha1 soh , MEK, Electro. plat. 37,500 lbs/yr DOOlD007D035 Ignitable, chromium, MEK 3,883 lbs/yr DO01 Ignitable 9,500 lbs/yr

Waste Form: Wastes #1 and #3 - B602 - Still bottoms of non-halogenated solvents or other organic liquids. Wastes #2 and #4 - B209 - Organic paint, ink, lacquer, or varnish


Waste Handling: Source Reduction: None specified. NCPPP involvement: None. Comments: None.


Did this site begin or expand a source reduction activity during 1991 or 1992? yes.

Did this site begin or expand a recycling activity during 1991 or 1992? yes.

Did this site systematically investigate opportunities for source reduction or recycling during 199 1 or 1992? yes.


Technical limitations of production processes inhibit shipments off site for recycling Technical limitations of production processes inhibit on-site recycling




B - 120

Facility ID Number: NCD093338598 Facility Name: Westinghouse Electric, Arden Facility SIC Code: 3622 Waste Codes Listed

DOOlD008F003 Ignitable, Lead, spnt non-hal. solv. 3,002 Ibs/yr

Waste Form: B203 - Non-halogenated solvent Waste Handling:





M141 - Transfer facility storage, waste was shipped off site with no on-site TDR activity.

Did this site systematically investigate opportunities for source reduction or recvcling during 199 1 or 1992? Yes.



Unable to identify a marketplace for recyclable materials production processes



B - 121

Facility ID Number: NCDO18652339 Facility Name: Freightliner Corporation (Cleveland) Facility SIC Code: 3714 Waste Codes Listed:


Waste Form: B211- paint thinner or petroleum distillates Waste Handling: 444647 lbs M02 1- fractionatioddistiilation

Source Reduction: 115654 Ibs M041- incineration (liquids)








Other (specify):

practice





Technical limitations of production processes production will not cover the capital investment

B - 122

Facility ID Number: NCD98 1920580 Facility Name: N.C. Department of Transportation (Ferry Division) (Mans Harbor) Facility SIC Code: 3731 Waste Codes Listed:

Code Definition Total F002, F005 nonspecific source DO0 1 ignitable waste included in above

23001 Ibs/year

Waste Form: B202- halogenated solvent. (chlorinated) Waste Handling: M061- fuel blending Source Reduction:



Did this site systematically investigate opportunities for source reduction or rec~clinx during 1991 or 1992? yes



Recycling not economically feasible: cost savings in waste management or production practice






Concern that product quality may decline as a result of source reduction Technical limitations of production processes Permitting burdens Source reduction previously implemented - additional source reduction does not appear

reduction practices




B - 123

Facility ID Number: NCD091245498 Facility Name: Daimler Benz (Freightliner Corporation) (Mt. Holly) Facility SIC Code: 3700 Waste Codes Listed:

Code Definition Total F003, F005 nonspecific sources DO01 ignitable waste contained in above

207009 Ibs/year

Waste Form: B209- organic paint, ink, lacquer or varnish Waste Handling: M061- fuel blending Source Reduction:


Did this site begin or expand a recvclinr: activity during 1991 or 1992? no



Insufficient capital to install new recycling equipment or practice Lack of permitted off-site recycling facilities Recycling previously implemented - additional recycling does not appear to be technically



implement new recycling

feasible





Concem that product quality may decline as a result of source reduction Technical limitations of production processes Permitting burdens Source reduction previously implemented - additional source reduction does not appear

Other (specify):


~


-

B - 124

Facility ID Number: NCD131416182 Facility Name: Midland Brake Inc. (Marion) Facility SIC Code: 3714 Waste Codes Listed:

Code Definition Total DO08 Lead I1268 Ibs/year

Waste Form: B604 - organic paint and ink sludge Waste Handling: M141 - transfer facility storage, waste was shipped off-site with no on-site TDR activity. Source Reduction:




The following factors delayed or limited this site’s ability to initiate new or additional on-site or off-site recvclinr: activities during 1991 or 1992:

Recycling not economically feasible: Cost savings in waste management or production will not

Recycling previously implemented - additonal recycling does not appear to be technically cover the capital investment.

f e a s i b 1 e.



Technical limitations of production processes Source Reduction previously implemented - additonal source reduction does not appear


to be technically feasible.

B - 125

Facility ID Number: NCD000623 165 Facility Name: IBM Corp. (Charlotte) Facility SIC Code: 3773 Waste Codes Listed: - Code Definition DO01 ,DO07 Ignitiable/Chromium

Total 504 Ibs/year

Waste Form: B209 - organic paint, ink, lacquer, or varnish Waste Handling: M061 - fuel blending Source Reduction:




The following factors delayed or limited this site’s ability to initiate new or additional on-site or off-site recyclinK activities during 1991 or 1992:

Recycling not economically feasible: Cost savings in waste management or production will not cover the capital investment.


Concern that product quality may decline as a result of source reduction.

B - 126

Facility ID Number: NCD0912585 17 Facility Name: Dana COT. Sicer Heavy Axle Division (Morgantown) Facility SIC Code: 3714 Waste Codes Listed:

Code Definition Total DO07 Chromium I100 Ibs/year

Waste Form: B310 - spent solid filters or adsorbents Waste Handling: M132 - Landfill Source Reduction: Wll/W13/W81 (respectively: beban to sergregate types of hazardous waste to make them more amenable to recycling/improved maintenance scheduling, recordkeeping, or procedures/changed product specifications)





None.


Lack of technical information on source reduction techniques applicable to this site’s specific production processes.

Technical limitations of production processes.

B - 127

Facility ID Number: NCD980838478 Facility Name: Allied Signal Aerospace Co. (Rocky Mount) Facility SIC Code: 3721 Waste Codes Listed:

Definition Total DO07 Chromium 2000 Ibs/year ove

~ ~~~ ~~

Waste Form: B310 - Spent solid filters or adsorbents Waste Handling: M141 - Transfer facility storage, waste was shipped off-site with no on-site TDR activitiy. Source Reduction:





~



Concern that production quality may decline as a result of recycling. Permitting burdens inhibit recycling.

practice





Concern that product quality may decline as a result of source reduction Permitting burdens Source reduction previously implemented - additional source reduction does not appear


reduction practices


to be econnomically feasible .~ ~

to be feasible due to permitting requirements.

-

I3 - 128

Facility ID Number: NCD003233970 Facility Name: Thomas Built Buses (Highpoint) Facility SIC Code: 3713 Waste Codes Listed:

Code Definition - Total F003,F005,D001,D007 spent non-hal. solv./ignitable/chromium 107301 Ibs/year ove

Waste Form: B209 - organic paint, ink, lacquer, or varnish Waste Handling: M051 - energy recovery, liquids Source Reduction:



Did this site systematically investigate opportunities for source reduction or recvclin,: during 1991 or 1992? yes




Technical limitations of production processes inhibit on-site recycling Lack of permitted off-site recycling facilities Unable to identify a market place for recyclable materials

The following factors delayed or limited this site’s ability to initiate new or additional source_ reduction activities in 1991 or 1992:





reduction practices




B - 129

Facility ID Number: NC8210020121 Facility Name: Facility SIC Code: 971 1 Waste Codes Listed:

Wastes comprised of D001, D006,D007, D008, D035, F002, F003, F005

Waste Form: metal scale, filings, or scraps / organic paint, ink, lacquer, or varnishhalogenated and nonhalogenated solvent mixture / paint thinner or petroleum distillates

Waste Handling: MI41 - Transfer facility storage, waste was shipped off site with no on-site TDR activity.

Source Reduction: None specified. NCPPP involvement: Prepared report but no site visit. Comments: None.





US Army Ft. Bragg Air

Code Total 130,079 Ibs/yr

~~~ ~

~

None specified.


None specified.

B - 130


F005D008D007 Spent non-hal. solv., chrom., lead 8,883 Ibs/yr D001F003F005 Ignitable, spent non-hal. soh . 1,75 1 Ibdyr

Waste Form: B209 - Organic paint, ink, lacquer, or varnish Waste Handling:




Did this site systematically investigate opportunities for source reduction or recvclinq during 199 1 or 1992? Yes.


USCG Support Center Elizabeth City

- Code Definition Total

Waste #1 - M049 - Incineration - type unknown Waste #2 - M029 - Solvent recovery

Technical limitations of production processes inhibit on-site recycling



B - 131


US Marine Corps Base Camp LeJeune

Code Total Wastes comprised of D001, D005,D006, D007, D008,

D03.5, F002, F003, F00.5, Other organic halogenated solids / other non-halogenated organic solids / halogenated solvent / organic paint, ink, lacquer, or varnish / paint thinner or petroleum distillates / other organic liquids. M141 - Transfer facility storage,waste was shipped off site with no on-site TDR activity.

46,321 Ibs/yr ~

Waste Form: ~

Waste Handling:


Did this site begin or expand a source reduction activity during 1991 or 1992? Yes,




None specified.


None specified.

B - 132

Facility ID Number: NC697 1590009 Facility Name: Facility SIC Code: 971 1 Waste Codes Listed:

US Military Ocean Ter Southport

Code Definition F003F005 spent non-hal. solv.

Total 1084 Ibs/yr

Waste Form: BlOl - Aqueous waste with low solvents.

Waste Handling:


MI41 - Transfer facility storage, waste was shipped off site with no on-site TDR activity.

Did this site begin or expand a source reduction activity during 1991. or 1992? No.



The following factors delayed or limited this site’s ability to initiate new or additional on-site or off-site recyclin,: activities during 1991 or 1992:

Permitting burdens inhibit recycling Unable to identify a marketplace for recyclable materials Recycling previously implemented - additional recycling does not appear to be technically

feasible


Source reduction not economically feasible: cost savings in waste management or production will not cover the capital investment

B - 133


US Air Force Base Seymore Johnson

Code Definition Total DOO1,F003,F005 Ignitable, spent non-halo. solv. 27,817 lbs/yr

Waste Form: Waste Handling: Source Reduction: None specified. NCPPP involvement: None. Comments: None.

B209 - Organic paint, ink, lacquer, or varnish M051 - Energy recovery - liquids


Did this site begin or expand a recvclinn activity during 1991 or 1992? No.

Did this site systematically investigate opportunities for source reduction or recwling during 1991 or 1992? No.


none specified.



B - 134


DO0 1 DO08 Ignitable, lead 3,914 Ibs/yr DO0 1 Ignitable 5,160 Ibs/yr

Waste Form: B209 - Organic paint, ink, lacquer, or varnish Waste Handling:


USCG Base Fort Macon Atlantic Beach

- Code Definition Total

M141 - Transfer facility storage, waste was sent off site with no on-site TDR activity.





None specified.


None specified.

B - 135


Wastes comprised of: DO01 ,D006,D007,D008,

Waste Form:

Waste Handling: Source Reduction: None. NCPPP involvement: None. Comments: None.

Did this site begin or expand a source reduction activity during 1991 or 1992? Yes,

Did this site begin or expand a recyclinx activity during 1991 or 1992? Yes.

US Marine Corps Air S Cherry Point

Code Total . ~~~

DO35 ,F003 ,F005 189,379 lbs/yr Organic paint, ink, lacquer, or varnish / paint thinner or petroleum distillates / other halogenated orgainc solids. off-site storage: ineration; energy recovery; or fuel blending.

. ~~~~ ~

~

Did this site systematically investigate opportunities for source reduction or recycling during 199 1 or 1992? No.





Concern that product quality may decline as a result of recycling Technical limitations of production processes inhibit on-site recycling Lack of permitted off-site recycling facilities Unable to identify a marketplace for recyclable materials Recycling previously implemented - additional recycling does not appear to be technically


practice



feasible



Lack of technical information on source reduction techniques applicable to this site’s specific production processes -

~

B - 136




B - 137


US Marine Corps Air S Jacksonville

Code Total Wastes comorised of: DO0 1 ,D005,D006,D007,

~~

DO08 ,DO3 5 ,F003 ,F005 Halogenated solvent / organic paint, lacquer, or varinish / paint thinner or petroleum distillates / other halogenated organic solids / other non- halogenated organic solids. MI41 - Trasfer faciltiy storage, waste was shipped off site with no on-site TDR activity.

10,883 lbs/yr Waste Form:

~

Waste Handling:

Source Reduction: None. NCPPP involvement: None. Comments: None.

No responses to the source reduction section.

B - 138

Facility ID Number: NCD98 1856396 Facility Name: Facility SIC Code: 971 1 Waste Codes Listed:

NCNG - C.T. Bowers CE Raleigh

Code Total Wastes comprised of D001, F003, FOOS 4,992 Ibslyr

Waste Form:

Waste Handling:


Organic paint, ink, or lacquer I paint thinner or petroleum distillates I other non-halogenated orgainc solids. M141 - Transfer facility storage, waste was shipped offsite with no on-site TDR activity.





Recycling previously implemented - additional recycling does not appear to be technically feasible






B - 139


US Air Force Base - P. Pope Air Force

Code Total Wastes comprised of: DO01 ,D007,D008,F003,F005 13,628 Ibs/yr

~~

Waste Form: Organic paint, ink, or lacquer / other halogenated organic solids / aqueous wastes with low solvents.

Waste Handling: M141 -Transfer facility storage, waste was shipped off site with no on-site TDR activity.

Source Reduction: None specified. NCPPP involvement: Workshop / tour of autoshop. Comments: None.

~


Did this site begin or expand a recvcline, activity during 1991 or 1992? Yes.






B - 140

Appendix C

Telephone Survey Response Summaries

c - 1

j

2-Digit SIC Code: 25 Number of facilities contacted: 38 (20 companies) Number of facilities responding: 24 (10 companies) Quantity of paint waste generated by SIC 25: 3,695,054 Ibdyr Quantity of paint waste combusted: 3,352,572 Ibdyr Quantity of paint waste landfilled: 0 Ibs/yr ~~~~~~

- Baker Furniture Co.: This company generates 0.6 percent of this SIC’S hazardous paint waste (all of their waste is sent to energy recovery). This company applies stain, washcoat, glaze, sealer, lacquer, and hand color to wood dining and bedroom furniture. The coatings that are applied are high-solids solvent-based and some are water-based. As many as 30 colors of coatings are available. The application equipment is cleaned daily and lines are flushed once a year. The spray booths are cleaned daily and the peelable booth coaters are replaced annually. Filters are changed weekly. Approximately 50 percent of their hazardous waste results from wash-off; the remaining 50 percent of hazardous waste is generated by booth cleaning. Concerning pollution prevention, the company stated that they use HVLP spray guns. Also, they initiated a TQM program 11/1/93, They tried reprocessing wash-off solvent but each time they reprocessed the solvent the solvent’s moisture content increased, This increase in moisture caused deterioration of the furniture. They would be willing to participate in a site visit.

Cochrane Furniture Co.: This company generates approximately 1 percent of this SIC’S hazardous paint waste (their wastes are sent to energy recovery). At this company, the following coatings are applied to wood furniture: two stain coats, washcoat, glaze, sealer, and three topcoats of lacquer. Sometimes they shade stain or splatter between coats of lacquer. The majority of their coatings are high-solids. Routine cleaning includes infrequent soaking of lacquer spray guns and removal of peelable coater from lacquer spray booth every two years and from glaze booth every 6 to 8 months. Also, the metal baffles used in the spray booths are swept down. The hazardous waste generated are comprised of 80 percent lacquer dust resulting from overspray and 20 percent waste solvent resulting from the cleaning of equipment and lines. Concerning pollution prevention, they have improved spray gun management and optimized nozzle size. They also have switched from applying 3 coats of catalyzed finish to applying 2 coats. NCPPP has sent miscellaneous information to this company. They would be willing to participate in a site visit.

La-Z-Boy Chair Company (Hammay Plants #14 and 15): This company (2 facilities) generates 3 percent of this SIC’S hazardous paint waste (all of their waste is sent to fuel blending). At this’company, wood tables are finished as follows: 1) glaze or filler is applied to give depth and color; 2) sealers are applied; 3) sanded by hand; 4) shaded or highlighted with stain; 5) lacquered; 6) sanded by hand; and 7) placed in an oven. Steps 5-7 are repeated

. ~~ ~

~~ ~

several times and then the table is cooled in an air-cooled oven. HVLP guns are used to apply stain and glaze; HVLP guns have helped to reduce the amount of coating being used. Conventional guns are used to apply lacquers. Guns are soaked overnight in 1 gallon of

- ~

c - 2

solvent in a 5-gallon bucket. Future pollution prevention plans include ensuring that proper application techniques are used with spray equipment and initiating a program to recycle wash-off material. This company is willing to participate in a site visit.

Progressive Furniture Company: This company generated 3 percent of this SIC’s hazardous paint waste (their wastes are sent to fuel blending). Fiberboard is finished at this company. Specifically, fiberboard is filled, sanded, 2 or 3 basecoats are applied, stain and sealer or paint is applied, and lacquer top coat is applied. High-solids paints and sealers are used by this company. 90 percent of printing materials are waterborne. They use conventional and HVLP spray guns to apply coatings. To clean guns, the guns are soaked in solvent. The spray booths are swept daily to remove settlement. Their hazardous wastes are generated from the following operations: 25-30 percent is from printing; 30 percent from sealer and lacquer application; and 5 percent from gluing. Pollution prevention plans include ksearching the possibility of switching from solvent-based to water-based coatings, switching sealers to a high-solids system, and converting to a dry system using foil and paper. Additionally, they are currently buying machinery that will allow them to use 100 percent solids lacquer. They would be will to participate in a site visit.

Thomasville Furniture: This company (8 facilities but 1 facility has been sold) generated approximately 8 percent of this SIC’s hazardous paint waste (all of their waste is sent to fuel blending). At the various facilities, the finishing operations may include applying the following coatings: equalizer; sap stain; pre-stain; touch-up; body stain; washcoat; wiping stain; sealers; glazers; pad or spray stain; shade stain; lacquer; and padding stain. Waterborne paints are used at three of the facilities; stains and lacquers are used at all the facilities. To minimize the effort required in changing colors, they apply light colors before dark colors. If a light color is applied after a dark color, wash-off solvent is used to flush the lines until the color change is obvious. Coatings are applied with HVLP, air assisted airless, and conventional guns. Future pollution prevention plans include initiating an on-site recovery program for waste liquids and switching to water-based coatings over the next several years. NCPPP conducted an on-site waste reduction assessment at the Thomasville Furniture Plant in Thomasville. They would be willing to participate in a site visit.

Robersonville Products Company: This company generated 5 percent of this SIC’s hazardous paint waste (all of their wastes are sent to energy recovery). This facility closed in March of 1993.

Company Identification is ‘Confidential: This company generates approximately 7 percent of this SIC’s hazardous paint waste (all of their wastes are sent to fuel blending). Kitchen and bath cabinets are finished at this facility. The types of coatings used on-site include solvent- based stains, catalyzed and non-catalyzed sealers and varnishes, white and brown paint, 100 percent solids paint and ink, and water- and solvent-based topcoats. Coatings are applied with both spray guns and rollers. Their hazardous waste is generated from equipment clean- up and overspray materials. On main lines of spray booths, nozzle tips may be changed several times daily and solvent may be circulated through lines between colors. Roll lines are

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cleaned between colors with solvent. In spray booths overspray is scrapped. Waste thinner is added to overspray to prevent solidification of waste; liquid waste is easier to dispose of than solid waste. Filters are removed daily. Future pollution prevention activities include reformulating coatings to reduce HAP’S, investigating waste-based stains and sealers and high-solids paint, and researching a system that will breakdown VOC’s into elemental components. This facility is willing to participate in a site visit as long as it is not regulatory.

The Lane Upholstery Plant: This company (1 facility) generated 1 percent of this SIC’S hazardous paint waste (all of their waste is sent to fuel blending). The facility’s finishing operations apply stains, glazes, sealers, and lacquers to wicker and rattan furniture. Additionally, they apply water-based paints and acrylic topcoats. For color changes with solvent stains, lines are flushed with lacquer thinner. Application equipment is cleaned daily. Equipment used to apply solvent-based coatings are cleaned in buckets of lacquer thinner. Equipment used to apply water-based coatings are cleaned in water after each use. This facility’s hazardous waste is comprised of the following: 20 percent waste solvents (Le., wash-off, lacquer thinner); 10 percent stains; and 70 percent sealer and lacquer. They have switched to HVLP guns to conserve coating materials. Also, use a polypropylene plastic that can be scrapped to cover the conveyer in lieu of cardboard. This facility would be willing to participate in a site visit.

Broyhill Fumiture: This company (7 facilities) generates 43 percent of this SIC’s hazardous paint waste (the majority of their waste is sent to fuel blending). At this company wood furniture is assembled, sanded, and coated. Coatings applied included toner, stain, wash-off, glaze, sealer, and 1 to 3 topcoats. The finish may or may not be distressed. To achieve the distressed look, the finish is cowtailed andor stain splattered before topcoat is applied. The type of coatings applied are high-solids, some 100 percent solids, UV topcoats, and experimenting with waterborne systems. Application equipment and spray lines are cleaned between stain changes. Application equipment is cleaned in buckets of solvent overnight. Spray booths have peelable coaters and are swept daily. 90 percent of this company’s hazardous waste results from finishing. The remaining 10 percent is generated from wash-off. Future pollution prevention plans include switching from disposable filters to reusable filters and evaluating different types of coating systems ( e g , Unicarb and high-solids). The respondent did not have the authority to approve a site visit, but he said that it probably would not be approved.

Southern Furniture Company: This company (1 facility) generated 1 percent of this SIC’S hazardous paint waste (all of their wastes are sent to incineration). This facility finishes wood casegoods. The types of coatings applied include stains, lacquers, and high-solids. When colors are changed, the old color is captured and returned to the pump house for future use. Spray guns are placed in cleaning solution each day. Spray booths are cleaned every 3 ~ ~~ ~~

to 4 weeks on a rotating schedule. Concerning pollution prevention, they are trying and using ~~~

baffle booth filters. These filters are sent out to be cleaned. The contact person did not have the authority to approve a site visit.

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(’%bigit SIC Code: 30 Number of facilities contacted: 6 Number of facilities responding: 6 Quantity of paint waste generated by SIC 30: 377,979 Ibs/yr Quantity of paint combusted: 353,314 Ibdyr Quantity of paint waste landfilled: 0 Ibs/yr

Eaton Corporation: Largest generator of hazardous paint waste in this SIC (44.9 percent - all blended for fuel). Manufacture golf club grips. Paint is applied to the grips using rollers. Residual paint drips back onto the rollers. HVLP guns are used to paint labels onto the grips. They switched to HVLP guns approximately 2.5 years ago to minimize waste. The major source of hazardous waste at this facility is the spent solvents used to clean off the excess paint sprayed onto the grip when the labels are being applied. Also, the guns are cleaned at the facility at least 3 times per day. Visit is possible.

Consolidated Metco: This facility generates 19 percent of this SIC’s hazardous paint waste (wastes are sent to solid incineration). This facility produces large pieces of plastic molding (e.g. , dashboards for large trucks). Painting occurs in spray booths where HVLP guns are used by hand. 70 percent of the applied paint is water-borne acrylic latex and 30 percent is solvent based ketones (polyurethanes). Three years ago they switched to water-based paints. Their goal is to switch completely over to water-based paints by 1997. Overspray is collected in a water bath. Accumulated solids in the water bath are shoveled out and disposed of as non-hazardous wastes. Solvent-based paints are cleaned from the guns and equipment using methyl ethyl ketone. The spent MEK is distilled to recover the solvent. The residual is treated as hazardous waste. Solvent recovery was instituted in 1984. Visit is possible.

Fawn plastics: Second largest generator of hazardous paint waste in this SIC (31 percent). All of their wastes are blended for fuel. The painting operations that generate the majority of this facility’s hazardous waste application of paint to interior dashboard components. There are four lines that apply lacquer. In a few of the lines, a water-wash system is used to catch overspray. The water is treated and recycled and residual paint sludge is classified as noo- hazardous. Hazardous waste is generated in the cleaning of the application guns and equipment with a solution of 30 percent toluene and 70 percent MEK or acetone. This spent solution is distilled to recover the solvent and the distillation bottoms are classified as hazardous waste. The process of recycling MEWacetone and toluene was implemented in 1988. The water-wash system was installed in 1985. A site visit is possible.

BridgestoneFirestone: This facility generates only 0.1 percent of this SIC’S hazardous paint waste. At this site, tires are manufactured. There are 2 painting/coating operations at this facility. One operation applies paint to tires that have been damaged during manufacturing and then repaired. Paint containing toluene is applied in spray booths with high pressured guns. Paint filters contaminated with toluene are classified as hazardous waste. The other operation is part of the manufacturing process. Rubber cement comprised of <10 percent

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toluene and hexane or naphtha is applied to make pieces of the tire stick together before they are fused. The rubber cement is applied using a drip process. The drops are spread manually onto the pieces using brushes. The majority of the excess rubber cement is captured and reused. Once a month the application equipment is cleaned to remove dried cement. This dried waste cement is considered hazardous. Pollution prevention efforts included at this facility include reducing toluene use by 30 percent by 1992 and by 50 percent by 1995. NCPPP conducted on-site waste reduction assessment with report. A site visit is possible.

Council Business Furniture and Council Craftsmen Inc.: This company (2 facilities) generates 5 percent of this SIC’S hazardous paint waste (all of their waste is sent to incineration). This company manufactures mahogany furniture for both business and residential use. The coating operations are identical at both facilities except for the booths that arc used and the use of flash ovens. The Council Business facility is an older facility and uses water-wash spray booths. The residual water is shipped off-site for use in fuel blending. Council Craftsmen facility is a newer facility that uses paper-filter spray booths. The paper filters are changed as needed and the spray booths are cleaned weekly. The spent paper filters are shipped off-site as hazardous waste. Also, flash ovens are used at the Council Craftsmen facility and not at the Council Business facility. As mention above, the aspects of the finishing coating operations at the two facilities are identical with the exception of the spray booths and use of the flash ovens. Finishing operations are comprised of three distinct steps: the application of filler to fill the wood grain; the application of stain; and the application of lacquer. In spray booths, conventional spray guns are used to apply the filler, stain, and lacquer. The guns used to apply these coatings are cleaned daily with a solvent containing MEK, toluene, and butyl acetate. Spent solvent is sent off-site for recycling. No information on the contents of the filler were available. The stain contains methyvethyl alcohol, xylene, titanium dioxide, MEK, toluene, and butyl acetate. The lacquer that is applied contains nitrocellulose, xylene, naphtha, isobutyl alcohol, butyYisobuty1 acetate, and methyl amyl ketone (MAK). Color changes for stain and filler are accomplished by cleaning guns and spray booths. Typically, color changes only occur once every two weeks. The facilities are considering a switch to HVLP guns and on-site recovery of solvents. Several years ago, they tested foam filters in their spray booths. However, they did not work as well as the paper filters. A site visit to either facility is possible.

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2-Digit SIC Code: 34 Number of facilities contacted: 16 Number of facilities responding: 16 Quantity of A21 waste generated by SIC 34: 531,277 Ibs/yr Quantity of paint combusted: Quantity of paint waste landfilled: 0 Ibs/yr

Florida Steel Drum Company: This company generated approximately 32 percent of this SIC’S hazardous paint waste (they send both liquid and solid waste to energy recovery). At this facility they manufacture and paint 55 gallon steel drums. The interior of the drum and the end parts are coated to protect the drum from the product which will be put into it. There are seven different materials that are used to coat the interior of the drum and the end parts. Coatings include phenolics, epoxies, and epoxy-phenolics. The exterior of the drum is painted with an enamel. The end parts and the exterior of the drum are coated with air- assisted airless guns, while the interior shell is painted with an airless centrifugal intercoater. The interior coating booth lines are flushed with MEK. The facility reuses the MEK as many times as possible. The exterior coating application equipment is cleaned by running solvent through the manifold to the gun and sprayed out. The sprayed out material is not captured. They are planning on reducing VOC emissions in 1994. A site visit is possible with approval from management.

General Steel Drum Corporation: This facility generates approximately 22 percent of this SIC’s hazardous paint waste (all of their wastes are sent to fuel blending). Steel drums are painted at this facility. The exterior is painted with a high-solids alkyd melamine baking enamel. The interior can be painted with 5 different types of coatings: epoxy, epoxyphenolic, phenolic-epoxy, and phenolic materials. All application guns are air-assisted airless. When changing exterior paint colors, they used to use MEK to flush lines. Due to environmental concern, they now flush lines with the new color for a few seconds. The spent paint is sent back to the manufacturer for recycle into a low grade coating. The methodology used to change interior paint colors is the same as that for exterior paints, but the flushed material is disposed of as hazardous waste. They would be willing to participate in a site visit.

Croft Metals: This facility is responsible for approximately 15 percent of this SIC’s hazardous paint waste (all of their wastes are sent to fuel blending). This facility paints aluminum shapes for storm doors, patio doors, and tub and shower enclosures. Pretreatment prior to painting consists of 5 stages: 1) alkaline cleaning; 2) rinsing; 3) chromic acid/fluoride combination (primer coat); 4) rinse; and 5 ) clear (polish) rinse. A solvent-based polyester paint is applied with a Ransburg electrostatic rotating disk system to the aluminum parts. When changing colors, they used to flush lines with xylene. They now have switched to a PM acetate solvent that is not photochemically reactive and is 4 times as expensive as the xylene. Now the paint line is purged with air and then flushed with the solvent. The spent solvent and paint overspray are collected in drums and classified as hazardous waste.

446,649 Ibs/yr

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They used to send overspray back to the paint manufacturer for recycling, but they no longer accept the paint waste. NCPPP has been somewhat helpful, but many things suggested were already being done or already looked at. They would be willing to participate in site visit.

Mestek Incorporated: This facility generates 6 percent of this SIC’S hazardous paint waste ( all of their wastes are sent to incineration or fuel blending). They manufacture and paint

solvent-based) paint. The paint is applied with a reciprocating electrostatic disk. Between color changes, the lines are flushed with solvent. They try to recycle solvents for use as paint thinner. Filters are changed once every two days, depending on the transfer efficiency of the parts being coated. NCPPP conducted an on-site waste reduction assessment and provided a report. The facility said that they have not been able to do all the things recommended by NCPPP. They are not interested in participating in a site visit.

Beta Systems Division, Velcon Filters Inc.: This facility generates 5 percent of this SIC’S hazardous paint wastes (all of their wastes are sent to energy recovery - solids). This facility manufactures fuel filters and fuel storage tanks for the government. The storage containers receive a chromium conversion coating and are then painted. Air assisted guns are used to apply a polyurethane paint developed to meet government specifications. Guns are cleaned with MEK. Filters are cleaned about once a month. No pollution prevention activities have been implemented in the past year, but previously they did change the order of their painting to reduce color changes and paint waste generation. Also, they have a solvent distillation system in which they recycle a 20 gallon batch of solvent every 2 days. A site visit may be possible with the appropriate approval.

Crane Resistoflex Company: This company generates 5 percent of the waste from this SIC (their waste are sent to incineration and fuel blending). This facility manufactures plastic- lined iron piping systems for caustics and acids. The pipes are currently painted with a high- solvent based coating to protect against flash rusting. However, they are switching to a waste-based 2 part epoxy that is about 60 percent solids. The majority of the paint is applied with HVLP guns. When special coatings are applied, an airless gun is used. Generally the red oxide primer is used, but occasionally the color is changed to white zinc oxide. For color changes with the water-based paint, the lines will be flushed with water and then with solvent. The flushed material will be shipped off-site for disposal as hazardous waste. Filters are changed when the booth loses suction (about once every 2 days). They have switched from using 1 gallon paint cans to using 55 drums that can be recycled. NCPPP did conduct an on-site waste reduction assessment and provided a report. The facility reported that their assistance was helpful. However, they did respond that it is hard to get painters to change their practices. They would be willing to participate in a site visit.

Greif Brothers Corporation: This facility generates 3 percent of this SIC’S hazardous paint waste (they send all of their wastes to energy recovery). This facility manufactures steel drums that are coated. Both air atomized and air-assisted airless guns are used to apply the enamel coatings. The purpose of the coatings is mostly for appearance. Approximately, 80

commercial heating units at this facility. The parts are coated with an alkyd (high-solids, ~ ~~~~ ~~~

~

. ~~~

-

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percent of the drums are coated with black enamel. When a color change does occur, the there is no flushing with any additional solvents or solutions. Pumping of the new paint color begins and the old paint color remaining in the lines is captured and reused. When the new color appears, the recycle process ceases. Small bleeding of the new color into the old color is not a problem. The application equipment and spray booths are cleaned daily. A Statistical Process Control program has been used to reduce the amount of paint used. Specifically, they now use quality gauges rather than visual inspection of the drums to determine acceptability. The contact person would need to check with the division manager for permission for a site visit.

Miller Brewing Company: This company generates 2 percent of this SIC’s hazardous paint waste (their waste is shipped off-site for transfer facility storage). At their facility, aluminum cans are decorated with ink printing, a waterborne varnish is applied to the exterior, and the interior is coated with a waterborne acrylic lacquer. High pressure airless spray guns are used to apply the coatings. Due to the high costs of the coatings, the amount sprayed is tightly controlled by pad timing. Scraps from spray booth filter boxes are sent off-site for fuel blending. Each gun is cleaned every 12 hours with a solvent in the coating itself. Baffle plates are removed to clean off the overspray. Additionally, some free liquids at the bottom of the spray booth are collected as waste. Statistical Process Control is used to optimize process efficiency. Specific waste reduction activities include modifying system set-up and gun angles to optimize transfer efficiency (reduced waste by 40 %). Also, reducing VOC content of coatings. Potential liability if coating is faulty. Cannot afford to make a mistake since the containers hold beverages for consumer consumption. They probably would not be willing to participate in a site visit.

Yale Security, Inc.: This facility generates 2 percent of this SIC’s hazardous paint waste (their waste is incinerated). At this facility aluminum, steel, cast iron, and PVC parts from door closures and installation hardware are painted. Electrostatic air guns are used to apply lacquers (is., solvent-based) to the parts. Forty colors are applied at the facility. Between each color, the lines are flushed with paint thinner. Future waste reduction activities include investigating aqueous cleaning systems, high-solids and turbo application, waterborne based lacquers, and powder coatings. The contact was not sure about the willingness of management for a site visit.

Freightliner Parts Manufacturing Plant: This facility generated 2 percent of this SIC’s hazardous paint waste (all of their waste are sent for fuel blending). Freightliner manufactures heavy duty trucks. This facility fabricates aluminum and steel fixtures for holding various pieces onto the chassis of the truck. Parts from this facility are shipped to the Mount Holly and Cleveland facilities where the trucks are manufactured (See SIC 37 discussion). At this particular facility, they have 2 top-coat booths and 1 electrodeposition coating (e-coat) booth (is., a dip tank) for coating the manufactured parts. The parts are generally coated with an e-coat primer and a single top-coat. Air-assisted spray guns are used to apply the top-coat. They tried to use HVLP, but this application system does not work well with the high-solids metallic paints they frequently apply. The e-coat is PPG Uniprimer

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(Le., aqueous solution with some glycol ethers) and the top-coat is DuPont Imron 5000, which is a 2-part activated isocyanate paint. Between top-coat color changed the guns are flushed with a gun cleaner. Also, guns are cleaned at the end of shifts. Filters are changes and spray booths are cleaned about once a week. The e-coat booth usually does not require cleaning. The contact person pointed out that the e-coat booth generates very little waste. Concerning pollution prevention, they have eliminated lead and chromium in their top-coats and have

pyrollidone. By switching from the MEK, which is much more volatile, they have reduced their solvent use for cleaning by 50 percent. A site visit is possible but coordination of specifics would need to be discussed.

Fenestra Corporation, Harrisburg Division: This facility generates 2 percent of this SIC’s hazardous paint waste (all of their waste goes to fuel blending). At this facility, hollow metal door and door frames are manufactured. The fabricated metal items are cleaned with spray washers, sent to a 5-stage cleaning and phosphatizing process, and then coated with VOC- based high-solids baking enamel. There are 4 spray booth on-site, 2 have automated guns and 2 have manual guns. Two of the booths are equip with Ransburg Turbobell electrostatic guns and two with airless guns. For a color change, the lines are flushed out into filters. The peel coating applied to the spray booth walls are removed about 2 times a month and the paper in the floor is changed daily. Filters are also changed daily. Future pollution prevention activities include eliminating the use of xylene and toluene as solvent degreasers. They used to have on-site recycling, but they did not generate enough waste solvent. They receive the NCPPP newsletter. They were initially interested in the grant program, but the application forms were much too long. Site visit is possible with management approval.

Crown Cork and Seal Company: This facility generates 1 percent of this SIC’s hazardous paint waste (all of their wastes are sent to solvent recovery). At this facility steel cans for food are manufactured. An interior and an exterior strip is sprayed onto the can weld for protection using an automated arm. Approximately 10 percent of their cans receive a 360 spray for the interior of the can when extra corrosion protection is needed. For stripping, air atomized guns are used to apply a vinyl-type (i.e., solvent-based) lacquer. For the 360 spray, airless guns are used to apply a water-based epoxy. Their application equipment and filters are cleaned weekly. Concerning pollution prevention, they have changed from a solvent mixture of Varsol and l,l,I-TCA to a water based formulation. They have modified and built new collector boxes for spray nozzles. Switched from a solvent-based 360 coating to a water- based coating. They would be willing to participate in a site visit (contact James Griffee).

Curtis-Wright Flight Systems: This facility generates 1 percent of this SIC’s hazardous paint waste (all of their waste are shipped off-site for transfer facility storage). At this facility,

solvent-based enamel and primer. The coatings are applied manually with air atomized guns. The application equipment is cleaned every day with a paint thinner. Guns are disassembled and cleaned. The paint is run through the lines for cleaning purposes. The spray booths are cleaned once a week and the filters changed and cleaned once a week. When mixed, the

switched from using MEWacetone mix as the gun cleaning solvent to using n-methyl ~ ~ ~~~

~

aluminum and steel aerospace components are manufactured and painted with a 2 part ~~

- ~ ~ _ _ _ _

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paint has a 14 hour pot life. If all the paint is used before the expiration time, the excess paint is discarded. They have looked at less hazardous paints and solvents, but any changes must be approved by Boeing. One change that they have instituted is that they used to apply both primer coat and top-coat to the actuators, but now they only apply the primer coat. A site visit is possible.

Walter Kidde Aerospace, Inc.: This facility generates 0.4 percent of this SIC’S hazardous paint waste (they ship their waste off-site for transfer facility storage). At this facility, fire suppression equipment for aircraft and aerospace vehicles are manufactured. Fire bottles and enclosures for electronic controls and smoke detectors are painted. There are two coating operations. One operation consists of a zinc phosphate wash, chromate primer application, and epoxy application. The other operation includes nickel plating, etching, primer application, and lacquer application. The type of coatings applied include lacquer, 2 component epoxy, chromate-based primers, and air dry enamels. The paints can be heavy on chrome, lead, zinc, and cadmium. The FAA governs what type of coating can be used. Air atomized guns are used to apply the paints. Use of airless and HVLP guns have been investigated. The products that are painted are round and difficult to cover. Therefore, there is a lot of overspray. Spray guns are cleaned with solvent. It appears that a large portion of this facility’s waste is generated as spent paint generated from color changes or paint stored on-site longer than the FAA specified shelf-life. They are trying to order their paints in smaller amounts. The contact stated that they had not received assistance from NCPPP. However, NCPPP records indicate that an on-site waste reduction assessment was conducted and a report was prepared. They were receptive to the idea of a site visit.

Engineered Control International: This facility generates 0.03 percent of this facilities hazardous paint waste (waste handling practice was not specified). This facility manufactures LP gas valves and regulators. An air spray gun and an airless rotor disc are used to apply acrylic (Le., solvent-based) enamel to the valves and regulators. The paint lines are purged between color changes. NCPPP has conducted an on-site assessment and prepared a report. The contact stated that NCPPP had provided suggestions on solvent reduction in the degreasing operations. A site visit would require permission from the plant manager.

Accudyne, Inc.: This facility reported 0 pounds of hazardous waste. The contact person stated that this facility does not do any painting or coating. They appear in the hazardous waste database with paint waste because they had a fire and some of the wall paint waste was disposed of as hazardous waste.

2-Digit SIC Code: 35 Number of facilities contacted: 19 Number of facilities responding: 15 Quantity of paint waste generated by SIC 35: 697,917 Ibs/yr Quantity of paint waste combusted 510,351 Ibs/yr

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Quantity of paint waste Iandfilled: 0 Ibs/yr

Asmo North Carolina: This facility generates 5 percent of hazardous paint waste generated by this SIC. At this facility metal housings and end-frames are degreased, phosphate coated, dried, painted with two epoxy based coatings, dried, and touched-up with air brushes. Application equipment used at the facility include air guns, manual spray guns, touch-up brushes, and spray booths. In 1993, this facility installed a Binks centrifuge sludge removal system and have reduced hazardous waste booth sludge volume by 50 percent. Willing to participate in visit.

Matsushita Compressor Corporation: This facility generates 0.6 percent of hazardous paint waste generated by this SIC (all waste is fuel blended - D008). At this facility, steel and copper compressors are painted. The compressors are hung on a conveyer and painted by electro-deposition in a dip tank. The paint is water-based and contains lead. The dip tank is cleaned annually and the tank bottom sludge is sent off-site as hazardous waste (10-12 drumdyear). Additional hazardous waste includes cloth filters (6 drums/yr). To reduce waste they repositioned filters and extended the life of the filters 3-fold. Currently, they are working with a vendor to substitute paint with a lead-free water-based paint. Possibility of a visit.

~

-~

Cooper Industries: This facility generates only 0.5 percent of hazardous paint waste from this SIC (all wastes are sent to fuel blending). This facility paints steel coil retractable measuring tapes, folding wooden rulers, and a nylon measuring tapes. The measuring tapes are painted with a yellow water-borne liquid paint, an iron-phosphate mixture is electrocoated on, and black ink is used to print on the measurements. Finally, a clear coat epoxy that is high in solids is roll-coated onto the steel coil. The folding wooden rulers are dip coated with a solvent based paint, ink is used to print on the measurements, and a high-solids epoxy is applied as a clear coat. The nylon measuring tape is roll-coated with a white solvent based paint and then measurements are printed. Rollers are cleaned by dripping a solvent mixture onto the rollers and then the rollers are wiped with rags. Rags and a solvent mixture are used to wipe down the measurement imprint equipment. The spent solvent and the contaminated rags are classified as hazardous waste. Currently, switching from MEK based cleaning solution to less toxic methyl propyl ketone and ethyl acetate solution. Company stated that NCPPP conducted a waste minimization audit 2 years ago and motivated the company to look into water-based paint. They are going to switch to water-based paints for dipping the wooden folding rulers. Very willing to host visit.

Pneumafil Corporation: This facility generates 8 percent of hazardous paint waste from this SIC (all waste fuel blended). This facility paints air filters and military cabinets and I

furniture. The majority of the paint is applied with an air spray gun and the remainder is applied electrostatically. Five spray booths are found on-site: 1 waterfall; 2 down-drafts; and 2 dry filters. There are four types of paint used on-site. The majority of which are solvent-

- _______

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based. Between colors, the system is purged with solvent. The spent solvent is reclaimed on- site. The reclaimed solvent is used for paint thinning and equipment cleaning. If the reclaimed solvent exceeds the needed the amount, then excess is blended for fuel. The following identifies the approximate composition of the hazardous paint waste generated at this facility: 42 percent is leftover paint and solvents; 28 percent is filters and used rags; 16 percent is cleaning sludges from paint booth; and 14 percent is still bottoms from solvent recovery system. They stated that they receive the NCPPP newsletter but have never requested help. They will continue to investigate alternative spray equipment. Possible visit.

Americane Crane Corporation: This facility generates approximately 2 percent of hazardous paint waste from this SIC (reports all wastes going to waste solvent recovery - thin film evaporation). This facility paints mobile cranes (45 per year). For painting some parts, they use electrostatic, air atomized solvent-based paint. An airless spray (toluene-based) is used for a finishing coat. Spray guns are cleaned with a solvent mixture of toluene and xylene. The spent solvent is shipped off-site for fuel blending. They stated that they only generate 1 or 2 barrels of waste a month and this is too small of a quantity to warrant investigation of pollution prevention initiatives. Would need to ask company president for visit.

Deere-Hitachi: This facility generates approximately 7 percent of hazardous paint waste from this SIC (energy recovery - sludges). This facility paints hydraulic excavators. Manual spray guns are used to apply a urethane paint onto a variety of steel parts. Painting is conducted in a down-draft paint booth that is equip with a fiber filter. Between color changes the system is flushed with methyl n-amyl ketone (MAK). The MAK is drummed and sent off- site for incineration. The spray booth is cleaned once a year with water. Solids from booth cleaning are sent off-site for incineration. The facility has a PP consultant on staff. Recently switched from a chromium-based paint to a urethane-based painted. If financially justifiable, they will install a recycling still for solvent recovery. to visit.

Gilharco Inc.: This facility generates approximately 2 percent of hazardous paint waste from this SIC ( all waste to energy recovery - sludges). This facility paints steel gas pumps. Two types of paint are applied to each pump. The first coat is a powder paint applied in an automated spray booth. Two colors are applied in separate spray booths. The second coat is a solvent-based high-solids paint applied primarily for appearance. This coat is applied manually with spray guns. Numerous colors are applied. Between colors, the system is purged with a solvent (primarily butyl acetate). Some of the butyl acetate is recycled, some that is contaminated is drummed and sent off-site. They have switched from solvent-based liquid paint to powder paint. Facility stated that they requested information from NCPPP. The provided information was moderately helpful but really needed more site- and process- specific information. Currently, looking into changing 1 or more of the solvent-based colors to powder coating. Too busy for visit now.

Balcrank Products: This facility generates approximately 1 percent of the hazardous paint waste from this SIC (all wastes to incineration). This facility paints air operated transfer

NCPPP sent information. Receptive

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pumps, grease pumps, and hose reels. These parts are made of aluminum and steel. The parts are painted manually with a spray gun. 1 coat of bake enamel is applied (high-solids paint). Six different colors can be applied. There is one spray booth but 6 different guns (i.e., one for each color). Once a month the spray booth is scrapped down and the paint wastes are put into drums with filters and shipped off-site for incineration. 70 percent of their hazardous waste is comprised of paint filters. The remaining thirty percent is comprised

paint. Due to color changes, they determined that powder was not practicable. Would consider site visit with proper credentials and supervisor approval.

VME Americas, Inc.: This facility generates 3 percent of this SIC’s hazardous paint wastes (all waste go to fuel blending). This facility applies touch-up paint to front loaders with manual guns. The paint, which is applied to a variety of steel parts, is a solvent-based. Two colors are applied. The same spray booth is used for both colors although separate guns and paint lines are used for each color. The guns are cleaned with a citrus-based cleaners. They used to use MEK but switch to the citrus solve since it contains no hazardous constituents. Paint lines are cleaned periodically with the solvent that is mixed with the paint, and then the spent solvent is recycled back to the paint. Floor and paint scraps are collected, drummed, and sent off-site for fuel blendinghcineration. Paper filters are compressed into drums and incinerated. Visit possible with proper approval.

Outboard Marine Corporation (OMC), Andrews: This facility generates 0.2 percent of this SIC’s hazardous paint wastes (all wastes to incineration). Motor parts are painted and coated with three operations. One operation is the life-anited system which involves a chromium dip for aluminum parts. The company has investigated substitutes for the chromium but nothing seems to protect as well against corrosion. The chromium waste is treated to trivalent and landfilled as a filter cake. The second operation is an electrostatic painting operation that is applied with a spray gun. The paint used is a liquid paint that has some MEK mixed into it. The paint is applied to a variety of steel and aluminum parts. The third process is Corefilm 19. In this operation, solvent-based paint with barium is applied in a dip tank. This coat protects against rust on gears. The waste generated from this operation comprises the majority of the hazardous waste generated. The remainder of the hazardous waste comes from cleaning the guns with MEK. They have switched from using l,l,l-trichloroethane to using a slightly caustic cleaner on the gears prior to painting or coating. They are interested in finding a corrosion protection solution that does not contain chromium. Very receptive to visit, just give 1 or 2 day notice.

Honda Power Equipment h4FG.: This facility generates 27 percent of this SIC’S hazardous paint waste (half of the waste goes to energy recovery and the other half goes to transfer

of spent cleaning solvent. Concerning pollution prevention, they have switched to high-solids ~

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facility storage). Steel lawn mowers are painted with electrostatic low VOC paint. First the . parts go through a 14-stage zinc-phosphate precoating and then through 2 automated T-wheel

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discs, and then through a 2 gun manually operated system. Approximately 11 different colors can be applied. Color changes require flushing of lines with a methyl n-amyl ketone solvent. Spray booth solids are sent off-site for recovery and recycle. The facility is looking for

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disposal options for F019 (waste filter cake) waste. F019 currently comprises half of their waste generated; F019 wastes are currently landfilled. They are not willing to participate in a site visit.

Altec Industries: This facility generates approximately 7 percent of the hazardous paint waste from this SIC (all waste goes to transfer facility storage). Steel truck and trunk parts are painted. Liquid paint is applied manually with spray guns. Two types of paints are used: 1) high-solids and 2) Dupont Imron paint. Also, one primer, DuPont Corler, is used. There are six spray booths. For color changes, paint thinner (i.e., toluene) is used to flush the lines. Spent solvent is drummed for fuel blending. Line cleaning accounts for the majority of their hazardous waste. Concerning pollution prevention, they have switched to high solids paint. Also, have switched to using cleaning solvent that contains less toluene. Within one year, they hope to start up a distillation process. They are not interested in participating in a site visit.

Consolidated Diesel Corp.: This facility generates 18 percent of the hazardous paint waste from this SIC (waste is sent to fuel blending or incineration). Diesel engines are sprayed with solvent-based paint. Two robots are responsible for the majority of the painting. Two people in a spray booth are responsible for touch-ups with spray guns. Color changes occur from engine to engine. With each color change, lines are flushed with air and xylene. The xylene paint mixture is sent off-site as hazardous waste. The majority of their hazardous waste results from line cleaning. They have investigated alternative paint application techniques. As a result of an informative meeting with NCPPP, the facility was able to focus in on pollution prevention efforts. In the future, they hope to phase out low VOC paint currently used and capture emissions from painting operations. Willing to participate in site visit but would need proper approval.

Outboard Marine Corporation (OMC), Bumsville: This facility generates approximately 10 percent of this SIC’S hazardous paint waste (all waste to fuel blending). Paint is applied in a spray booth by one person. Painting occurs under electrostatic conditions using a liquid paint. Approximately all of the hazardous waste is generated from flushing paint application lines with methyl ethyl ketone. In the past, they used MEK to thin the paint. Currently, they are using methyl n-amyl ketone to thin the paint. NCPPP conducted a helpful waste minimization audit. They are researching the feasibility of using metal filters. They would be willing to participate in a site visit.

Jackson - Division of Textron: This facility generates approximately 1 percent of this SIC’S hazardous paint waste (all wastes are sent to fuel blending). This facility has two painting operations on-site. As part of one operation, powder is applied in a booth. In the other operation, a VOC liquid paint is applied in a paint booth. In both operations, metal parts of various shapes and sizes are painted with one coat of paint. Most of the hazardous waste is generated from solvent cleaning of guns. Within the next two years, they hope to replace the liquid spray booth with another powder spray booth. Possible site visit with proper approval.

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2-Digit SIC Code: 36 Number of facilities contacted: 19 Number of facilities responding: 16 Quantity of paint waste generated by SIC 36: 309,825 lbdyr

Quantity of paint waste landfilled: 0 Ibs/yr Quantity of paint waste combusted: 263,934 Ibs/yr

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Square D Company, Monroe: This facility generated 22 percent of this SIC’S hazardous paint waste (all their waste is sent to fuel blending). This facility manufactures large, custom-made transformers. The primary painting task is to provide exterior protection for the casings of the transformers and transformer components. The coatings applied are designed to withstand severe weather conditions. Two coatings are applied, a primer (urethane-based epoxy) and topcoat (polyester urethane). Both paints are high-solids and meet specifications in the Rule 66. Both coats of paint are applied in a down-draft spray booth with HVLP hand-operated guns. There are two sets of filters used to catch overspray. One filter is replaced weekly, while the other is replaced every six months. Guns and lines are cleaned between colors. The guns are cleaned with a solvent mixture containing MEK. The spent solvent (from cleaning the guns and lines) is recycled using distillation and the solvent is reused in cleaning. The still bottoms are sent off-site as hazardous waste. Occasionally, a special Zn- rich paint that provides excellent rust-protection is used for extremely harsh conditions. Hazardous waste generation has been reduced by 40 percent by switching from high VOC paint to the high-solids paint. Future pollution prevention plans include investigating a non- hazardous solvent for cleaning guns and lines. A site visit is possible.

AT&T This facility generates approximately 0.5 percent of this SIC’S hazardous paint waste (all of their wastes are shipped off-site for facility storage). This facility makes general electronic equipment for commercial and residential use. Painting at the facility is associated with metal equipment racks, covers, and housings. The facility only recently moved to a new facility site. At the new facility site, sheet metal and steel parts are prepared for painting using the following: 1) aqueous cleaner; 2) rinse; 3) iron-phosphate; and 4) non-chrome sealer. Aluminum parts are prepared for painting using 1) non-chromate acid dip, 2) phosphoric dip, and 3) sodium hydroxide cleaner. At the old facility site, oxide cleaners and perchloroethylene were used to clean the parts before painting. The switch from these cleaners represents a major waste minimization step. The surface prepared parts are painted in a single paint booth with hand-held air guns (HVLP guns are not affordable). Most of the paint applied at the facility is high-solids. Some of the paints applied are water-based. The guns are flushed with xylene and MEK-based solvents. In the past, the facility tried to flush guns with safety clean. However, the paint sets quickly and therefore the safety clean approach did not work. Paper paint booth filters are changed approximately every 6 weeks. The ultimate pollution prevention goal is to switch completely over to powder paint. The major obstacle to switching is getting the military, the facility’s major client, to accept

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powder paint. The facility is IS09000 certified. The state could help the facility by providing detailed information on technologies that have been successfully implemented at other facilities. A site visit is possible.

Caterpillar, Inc.: This facility generates 4 percent of this SIC’s hazardous paint waste (all of their wastes are sent for fuel blending). Tractors are assembled at this facility. The assembled tractors are painted with an outer coat after the parts are cleaned with an aqueous solution. A single coat of paint is applied to the tractors in a paint booth using electrostatic, hand held guns. A low-VOC, 2-part polyurethane (isocyanate-catalyzed) paint is used. Overspray from the painting operation is collected using a water-wash system. The paint i s separated from the water-wash using centrifugation. The residue is shipped off-site as hazardous waste for fuel blending. Spray guns are cleaned daily with a solvent that contains acetone and xylene. The spent solvent is shipped off-site as hazardous waste for fuel blending. The facility is only three years old. Waste minimization was a key factor considered in designing the plant. A site visit has been set-up at this facility for Dec. 7, 1993.

General Electric Co., Hickory: This facility generates 5 percent of this SIC’s hazardous paint waste (all their waste is sent to liquid incineration). Transformers for residential and commercial use are manufactured at this facility. The painting operations at this facility primarily involve the painting of the casings of the transformers. All the transformers pass through the same aqueous-based preparatory process. Once prepared, the transformers are sent to one of two paint lines for coating. Pole mounted transformers receive one to two coats of powder paint. Pad mounted units pass through a more complex painting process involving both wet and dry paint application. For those pad mounted transformers that are expected to endure extreme conditions, the initial coating is zinc-based (80% solids, using butyl acetate as the solvent). This Zn-coat is a rust inhibitor and is applied in a paper filter booth using HVLP guns. The next coat is powder paint. For those units not expected to endure extreme conditions, a primer coat of epoxy (50 % solids with non-toxic solvents- alcohols) is applied using conventional air guns. The final coat applied to all pad mounted transformers is a urethane (high solids). The finish coat is applied with conventional air guns. The conventional guns used to apply the wet paint are cleaned with ethyl acetate and EEP (a safety solvent). The spent solvent is shipped off-site as hazardous waste. The paper filters from the Zn-paint application are changed every 2 months. The facility is beginning to implement TQM and is hoping to be IS09000 certified in the future. The ultimate goal of the facility is to use all powder-based paints. The facility would like to reuse the spent solvents from cleaning guns, but the urethane and epoxy paint entrained in the solvent makes reuse impossible. The NCPPP helped the facility in improving the method used for part preparation or washing (not directly tied to painting operations). Little assistance was offered in the area of painting, since the NCPPP felt that the facility was focusing on the issue and making good headway. A recommendation for the State was made to gather and disseminate information on painting technology that is innovative and successful. A site visit is possible.

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Facility Identification is Confidential: This facility generates 2 percent of this SIC’S hazardous paint waste (the majority of their waste is transferred off-site for facility storage). Switch boards and power panels for industrial and commercial use are manufactured at this facility. The steel outer cabinets of these panels are painted. There is a primary 1 1-stage paint line in use at the facility for applying the standard 2 colors appearing on most of the facility’s products. This line is comprised of the following stages: 1) alkaline wash; 2) water

coat dip tank; 9) rinse; 10) powder paint booths-one for each of the two colors applied; and 11) baking oven. The 8th stage (i.e., e-coat dip tank) uses a charged system to apply water- based paint. The powder paint booths use automated and hand-held guns to apply a standard polyester-based powder. There is also a smaller paint line for applying special order colors. Special-order products are removed from the primary paint line just prior to the e-coat dip tank and sent to the smaller line. These products are painted in a spray booth with quick-dry enamel that is applied with standard guns. Overspray is collected using fiberglass filters (considered hazardous waste). When a color change is necessary, the guns are flushed with xylene-based solvent. The spent solvent is classified as hazardous. Regarding pollution prevention, they are planning to phase out the use of the e-coat dip tank and to switch exclusively to powder paint. The facility is trying to get the filter-residue and sludge collected in the preparatory aqueous tanks (Le., stages 1-6) delisted. These wastes are currently classified as hazardous because of the production process associated with them. A site visit is possible.

Hamilton BeachProctor, Clinton: This facility was responsible for generating 1 percent of this SIC’s hazardous paint waste. However, this facility shut down in August, 1993.

Square D Company, Ashville: This facility generated 13 percent of this SIC’s hazardous paint waste (all of their wastes are sent to incineration or energy recovery). Electrical control devices are manufactured at this facility. Parts are cleanedpaintedhaked on a single continuous hook-line. Before painting, there is a 5-stage cleaningkonversion coating process that involves alkaline cleaning, rinsing, iron-phosphatizing, rinsing, and application of chrome sealer. Painting is conducted in a wash-water spray booth. Electrostatically charged high- solids acrylic paint is applied with manual HVLP guns. The painted parts are fixed in an oven at 350 degrees. The contaminated wash-water is treated with a polymer that causes the paint to settle. This residue is classified as hazardous due to its alkalinity. This paint residue could be neutralized. However, the neutralized residue would contain more water and would lower the Btu value of the residue. This lower Btu value would increase the cost of sending the waste to fuel blending. Therefore, they stated that the cost-savings incurred by not having the residue classified as hazardous would outweigh the dollar losses of the reduction in Btu value. The paint guns are cleaned daily with MEK. A still for recycling the MEK has been installed but is not yet operational. A site visit would be welcomed.

rinse; 3) iron phosphate bath; 4) rinse; 5) non-chromate sealant; 6) rinse; 7) drying oven; 8) e- ~

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Alcatel Network System: This facility generated 7 percent of this SIC’s hazardous painting waste (all wastes are sent to fuel blending). Telecommunications equipment is manufactured at this facility. The parts that are painted at this facility include the housings for the

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equipment and some of the internal components. The materials that are painted are sheet steel and aluminum. In both cases, the metal is cleaned, plated, and then painted. There are two separate painting lines, one for steel and other for aluminum. Currently, the facility is using powder paint on 20% of its painted parts. The goal is to use powder on 90% of painted parts by 1994. The remaining 80 percent of the parts are coated with a 2-part polyurethane liquid paint. This paint is applied in water-wash spray booths with HVLP hand-held guns. The water-wash is recycled and the settled sludge is shipped off-site as hazardous waste. The HVLP guns are cleaned with MEK at least once a day or when a color change is necessary. The spent MEK is shipped off-site. The facility received assistance form the State when they switched from a vapor degreaser to an alkaline degreaser. Specifically, the State provided information on alternative methodologies to the vapor degreasing approach. A site visit is possible.

Ohio Electric Motors: This facility generated 2 percent of this SIC’S hazardous painting waste (all wastes are sent to incineration and phase separation). Electric motors are manufactured at this facility. Painting of external parts of the engine (e.g., housings) is accomplished using the following approach. The parts are cleaned with caustic wash (non- hazardous pH). Spent wash along with water used in cleaning the facility floors is collected, neutralized, and distilled. The still bottoms are classified as non-hazardous. After cleaning, the parts are painted with a single coat of alkyd enamel. The enamel is applied with hand- held HVLP guns. In the past, they tried electrostatic painting but it did not work. Overspray is collected using a filtered booth. The filters are scrapped several times a day and changed once every 2-3 days. The guns are cleaned daily using a solvent that includes some toluene, xylene, and mineral spirits. The spent solvent from the cleaning is reused to thin the paint that is sprayed. Armatures (Le., the electrical heart of the motor) are painted using two coats. First, a dielectric epoxy primer is applied by dipping the part in a fluidized bed. A suction device collects all dust stirred up by this process. The collected dust is disposed of as non- hazardous waste. A second coat of polyester resin is applied by drip application. The waste from the application of the polyester resin comprises 20 percent of the facilities paint waste. The remaining 80 percent is from the filters used in the paint booths. The facility just changed its status from a large quantity generator to a small quantity generator. In 1991, the facility switched from painting the assembled units to painting individual components of the units. By switching to component painting (with its use of paper filters) and by moving away from the use of degreasers and phosphates in the surface preparation step, they have reduced their overall hazardous waste generation rate by 60 percent. They facility has tried using water-based paints, but they were not satisfactory. The problem with the water-based paints is that machined surfaces have oil-residues that are hard to remove and will not allow water based paint to adhere. A site visit is possible.

Hamilton Beach/Proctor, Mount Airy: This facility generated 1 percent of this SIC’S hazardous painting waste (all wastes are sent to energy recovery). toasters and toaster ovens. The primary parts painted are plastic panels and steel outer coverings. Both steel and plastic parts are cleaned and coated on the same paint line. A different line is used to electrostatically plate chrome onto the steel parts that are not painted.

This facility manufactures

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The paint line is comprised of a 5-stage prep-process (cleaning and conversion coating) and a 2-stage coating process. The prep-process involves; 1) mild alkaline spray wash; 2) rinse that is filtered to remove residue; 3) iron-phosphate bath; 4) rinse incorporating a wetting agent to facilitate the removal of water; and 5) reverse osmosis rinse. The first step of the 2- stage painting process involves the application of an electrostatically water-bome acrylic enamel with a turbine-disk. In the second stage, paint is applied using a similar process

atomized paint. Both coatings are applied in a spray booth that uses filters to remove excess paint. The filters are changed daily. The only hazardous waste that results from the painting process is the toluene-impregnated rags which are used to wipe dried paint off the machines. TQM at the facility is used to address waste minimization issues. The facility has considered using powder, but powder can not be used on plastic. Therefore the single paint line would need to be divided into 2 lines. As a consequence, the operations would be more compkx and costly. Also, the facility is considering the use of precolored molding plastic. The contact stated that the State could assist the industry by disseminating information concerning successful implementation of new and innovative solutions to technical challenges. A site visit is possible.

Westinghouse Electric, Arden: This facility generated 1 percent of this SIC’S hazardous painting waste (all waste is transferred off-site for facility storage). Switch units and starter motors are manufactured at this facility. Both the inside components and the casings are painted. Painting operations at the facility involve a single line and only one color of paint is used. Prior to painting, the parts are cleaned using a heated alkaline cleaning system. The alkaline cleaner is changed every 2 months. The spent cleaner is shipped off-site as hazardous waste. Next the parts are sent through an iron-phosphatizing treatment process. The parts are then rinsed with deionized water and painted using an electrostatic paint bath. The paint used is a water-based epoxy. After painting the parts are permeate-sprayed and subjected to a deionized rinse. The aqueous rinses used before and after the Fe phosphatizing stage are treated using filtration and neutralization to separate the metal sludge from the water phase. The resulting sludge is pressed and shipped off-site as a hazardous waste. The rinse water that is collected after the parts have been painted is filtered to remove the paint from the water. The filtered paint is returned to the paint-bath and the water is reused to rinse the parts. Over the last three years, the facility has made significant changes in the type of paint used in the paint baths. Originally, an acrylic water-based paint was used, but it did not have the protective qualities that were needed. Therefore, a switch was made to epoxy water-based paints. The facility plans to switch to a powder paint system by 1994. A site visit is possible.

Facility Identification is Confidential: This facility generated 2 percent of this SIC’S

large, high-powered lights for street, stadium, and special applications. The primary painting that occurs at this facility is the painting of the light housings. All paints applied at this facility are water-based acrylics that include a small amount of glycol ether. All housings pass through the same cleaning process. After cleaning, the housing either continue on the

(turbine disk application) although the disks are smaller and generate more of a cloud of ~

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hazardous painting waste (all wastes are sent to fuel blending). This facility manufactures ~ ~ ~~

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same line and are painted in an automated system or they are removed for hand-painting of special request colors. The automated line uses an electrostatic paint bath. Spill over from the paint bath goes to an evaporative system, where solids are separated from the aqueous liquid and sent off-site as non-hazardous waste. Custom colors are applied in paint booths using a hand-held HVLP gun. The HVLP guns are cleaned with MEK. The spent solvent is shipped off-site as hazardous waste (330 gallons/year). Overspray is collected on paper filters that are changed every week. Electrostatic powder paint is used on external parts. The powder is applied using automated guns in a spray booth. A portion of the facility’s hazardous waste results from excess or off-spec paint. The facility is implementing an IS09000 program. 5 years. Currently, they are investigating paints that would emitted fewer VOC’s than their current water-based paint containing glycol ether. policy that specifies the following hierarchy: source reduction, recycling, waste separation and concentration, energy and materials recovery, waste incineration or treatment, and disposal. A site visit is possible.

ILCO Unican Corp.: This facility generated 0.4 percent of this SIC’s hazardous painting waste (all wastes are sent to energy recovery). Push-button access code locks used in buildings are manufactured at this facility. There is one primary paint line designated to coat the main casings for the locks. Prior to painting, the parts are cleaned using the following spraybath system: aqueous degreaser and Fe-phosphate surface preparation and two cold water rinses. Paint is applied to the parts using an electrostatic paint system. The plastic-like powder paint is applied in a spray booth using automated guns. For touch-ups, hand-held guns are used. Aqueous waste from rinsing and Fe-phosphate process are recycled on-site using a waste treatment system that includes neutralization and flocculation. A resulting sludge is pressed, dried, and sent off-site as hazardous waste. The facility used solvent-based paints until 1990. However, strict VOC regulations developed by authorities in Winston- Salem spurred the implementation of the powder paint approach. A site visit would be welcomed.

Hazardous waste generation has decreased by 75 percent of over the last

This corporation has a waste minimization

Channel Master: This facility generated 0.6 percent of this SIC’s hazardous painting waste (all wastes are sent to fuel blending). Satellite dishes for commercial use are manufactured at this plant. There are several different coating processes associated with different components of the satellite dishes. Polyurethane powder paint is applied to steel and aluminum structural parts. The powder is applied electrostatically with automated guns. The dish-component of the satellite dish is painted with a water-based paint. The paint is applied with hand-held HVLP guns. Concerning waste minimization, the facility is investigating the use of in-mold painting instead of hand-held HVLP guns. By the end of 1993, the facility will be IS09000 qualified. It would be helpful if the State would assimilate and distribute information on proven technologies. A site visit is welcomed, although a letter from the State explaining the purpose of the visit would be required.

Westinghouse Electric, Fayetteville: This facility generated 2 percent of this SIC’s hazardous painting waste (all wastes are transferred off-site for facility storage). This facility makes

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electrical control devices. The cabinets for these devices are painted at this facility. Prior to painting the parts are cleaned with a caustic cleaner and then treated in an iron phosphate bath, and then dipped in a chromic acid rinse. The parts are e-coated with a water-based acrylic paint. After the paint application step, the parts pass through two rinse stages. The spent rinse which contains excess paint is recycled into the e-coat dip tank. The facility would like to switch from the e-coat approach to a powder paint system. The major obstacle

visit is not possible for at least 2-3 months; the facility is currently being sold.

Exide Electronics: This company (2 facilities) generated 21 percent of this SIC’S hazardous paint waste (wastes are sent for fuel blending or off-site facility storage). This company manufactures uninterruptable power supplies for commercial use. The outer skins or cabinets of these supplies are painted with an 8-stage operation: 1) aqueous rinse; 2) rinse: 3) phosphate preparatory surface treatment bath; 4) rinse; 5 ) etching of metal surface; oven drying; 7) painting in paint booth; and 8) oven drying. A urethane paint is applied in the paint booth with hand-held HVLP guns. The booth uses paper filters. The spent filters are considered hazardous waste. Guns are cleaned with a solvent. Some of the spent solvent is recycled on-site. The remaining spent solvent is shipped off-site. Assistance from the State in identifying ways to reduce the generation of hazardous waste would be helpful. When their supplier provides a water-based paint that meets product specifications, the facilities will switch to this paint.

in making this switch is securing enough funds to purchase the necessary equipment. Site ~~

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2-Digit SIC Code: 37 Number of facilities contacted: 10 Number of facilities responding: 8 Quantity of paint waste generated by SIC 37: 948,991 Ibdyr Quantity of paint waste combusted: 482,416 Ibdyr Quantity of paint waste landfilled 1100 Ibdyr

N.C. Department of Transportation (Ferry Division): This facility generated 2 percent of this SIC’S hazardous paint waste (all going to fuel blending). At this site, the exteriors of steel hulled sea-going vessels are painted. The painting occurs outside in an uncovered shipyard. A full recoating involves sandblasting the surface of the vessel down to the bare metal. The metal surface is washed with a solvent cleaner (low xylene content) which is allowed to air- dry. To the clean surface, three coats of primer, one main coat, and a anti-fouling coat are applied. All of the paints are epoxy in nature. They are applied using high pressure air guns. The guns are cleaned after each use (Le., several times per day) with xylene solvent. Two pollution prevention strategies have been implemented at the facility. For some older painted surfaces, they now wash the surface with a high pressure aqueous nontoxic cleaner instead of sand blasting. Secondly, they are testing longer lasting paints. They are will to participate in a site visit.

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Dana Corporation: This facility generated 0.1 percent of the hazardous paint waste from this SIC (all wastes going to landfill). This facility manufactures and paints truck axles. One coat of water-based non-hazardous paint is applied to the axles in a spray booth with high pressure guns. Overspray is caught on a cardboard shield. This cardboard is then recycled. The guns are cleaned daily and the spray booth is cleaned twice a year. In 1992, the facility switched from a solvent-based paint to the water-based paint. Since they have switched they have not generated any hazardous waste. Prior to switching, the cardboard used to capture overspray was classified as hazardous. Site visit is possible with management approval.

IBM Corporation: This facility generated 0.05 percent of this SIC’S hazardous paint waste (all going to fuel blending). The paint waste reported by this facility is generated from exterior painting of the building. Management was concerned of the liability of the waste and therfore was treated as a hazardous waste.

Allied Signal Aerospace Co., Rocky Mount: This facility generated 0.2 percent of the hazardous paint waste from this SIC (wastes to transfer facility storage). Paint aluminum housings of hydro-mechanical fuel control systems for jets. Prior to painting, the parts are cleaned with 1,l.l-trichloroethane. All residues from this cleaning step are sent off-site where 70 percent of the waste is reclaimed by the TSDF. The coating at this facility is a plating process that involves the use of dip-baths and conveyor belts. The type of coatings applied include: hard coatings; anodized-chromium coatings, immunized coatings and copper plating. Additionally, coating process using an air-gun is used to apply Aladine 1200 (30 percent chromium). Overspray from this process is captured on filters and handled as hazardous waste. In recent years, they have switched from using solvent-based cleaners in the part cleaning step to using aqueous cleaners. By doing this, they have decreased their hazardous waste by 125,000 Ibs/yr. A site visit is possible with management approval.

Midland Brake Incorporated: This facility generated 1 percent of the hazardous paint waste from this SIC (all wastes going to transfer facility storage). Based on our conversation with the facility contact, the contact is not sure why their waste is reported with the hazardous waste, EPA ID of DO08 (lead). This paint remanufactures air-brakes for large trucks. The painted parts are composed of cast-iron, aluminum di-casts, and zinc. Prior to painting the old paint is removed from the parts by either oven-baking and shot-blasting or cleaned with mineral spirits. Then all parts are cleaned with an alkaline aqueous cleaner and coated with a rust inhibitor before painting. Painting involves applying a high solvent paint in a spray booth with airless and conventional spray guns. Overspray is collected in a water-bath. The collected solids from the bath are not hazardous. The guns are cleaned using a lacquer thinner and handled as hazardous waste. The spray booths are cleaned once a month. The waste from this cleaning is not hazardous. 2-3 years ago a change was made during the cleaning of the guns and painting equipment. The solvent used to clean the equipment is now sprayed into a 55 gallon drum instead of into a spray booth. Also, 3-4 years ago, they switched from a lead based paint. Site visit possible with management approval.

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Thomas Built Buses: This facility generated 11 percent of this SIC’S hazardous paint waste (all waste going to energy recovery - reuse as fuel). This facility manufactures mostly public school buses. There are several painting operations at this facility. One operation paints parts with an epoxy powder paint with a robot using a spray gun. The second operation includes painting of parts with a red oxide airless spray gun. The third operation involves painting the bus interior with an alkyd baked enamel using an air atomized spray gun. Three

high-solids urethane. Next the buses are painted with one coat of school bus yellow or some other alterative color. Two separate lines are used to apply these colors ( i x , one line for yellow and the other line for all other colors). For the yellow line guns are cleaned weekly. The guns in the other line are cleaned after each paint color change. 50 percent of their waste is paint residue and the other 50 percent is spent solvent used to clean paint guns and equipment. the majority of their pollution prevention efforts have focused on reducing VOC emissions. A switch has been made to high solids urethane for the exterior coat to reduce VOC’s and make use of more durable paints. A site visit is possible.

Freightliner, Mount Holly: This facility generated 22 percent of this SIC’S hazardous paint waste (wastes are sent to fuel blending). The freightliner company manufactures class 6, 7 , and 8 custom made heavy duty trucks. This facility manufactures the chassis and cab of the trucks and assembles the final product using parts from the Gastonia facility. Some cabs are sent to Cleveland for final truck manufacturing. 68 complete trucks are manufactured daily at the Mt. Holly facility. The cab is e-coated, seam-sealed, undercoated, topcoated, and the inside is dressed. Cabs that are sent sent to the Cleveland facility receive only a black undercoat. The chassis manufactured at Mt. Holly are also painted. At this facility there are 4 cab coating, 5 touch-up, 1 wax, 1 piece parts, 1 chassis coating, 1 e-coating primer, and 1 wheel coating booths. In the paint booths both water curtain and dry filters are used. Air- assisted airless spray guns are typically used at this facility. They tried using HVLP guns, but these guns do not work well with the high-solids metallic paints that are frequently applied. Also, electrostatic application is not appropriate for two reasons: 1) flake orientation in coating does not look good and 2) they use a lot of water-based paints and are concerned about safety. The types of coatings that are applied are as follows: e-coat is PPG Uniprimer which is an aqueous solution with some glycol ethers; cab topcoat is DuPont Imron 5000 which is a 2-part activated isocyanate paint and Imron 6000 base coatlclear coat series which is a water-based paint with some solvent; undercoat is an asphalt/quaker coat formulated with IPA, water, and solvent; chassis black topcoat is an Akron Co. waster-based paint; and Essex seam seal (low VOC - mineral spirit based) is used for steel. Transfer efficiency is about 25-30 percent based on both vendor information and corporate measurements. The guns are cleaned by flushing the guns with a cleaner. The activated portion of the spent cleaner is collected as paint waste. The unactivated portion is sent to an on-site tank for recycling. Approximately 600-800 gallons of cleaning solvent is generated each day. The e-coat booth typically does not need cleaning. Spray booths are cleaned and filter replaced about every 2-3 days depending on the level of use. Their hazardous waste consists of waste paint, filters, and spent gun cleaning solvent. The majority of their waste is generated from the cab painting operation (60-70 percent). Concerning pollution prevention,

operations are available to paint the exterior of the buses, All bus exteriors are painted with a ~

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they have instituted block building of the trucks (i.e,, schedule blocks of the same color together), eliminated lead and chromium in topcoats, and switched to water-based paints where possible. Also, they installed a plural component paint delivery system that mixes the two-component paint at the gun rather than having to mix batches of paint. They have switched from using MEK to clean their guns to using n-methyl pyrollidone (NMP). NMP evaporates much more slowly and as a result they have reduced their evaporative losses ( i t . , cut solvent use for cleaning by 50 percent). Also, they distill paint waste and NMP on-site for reuse. Lastly, they have installed a Miller mix machine that uses a computer to mix precise amounts of paint as needed for the job. Future pollution prevention plans include looking at ways to reduce paint wastes and ways to reduce water use. The companies major concern in implementing any pollution prevention initiative is product quality. All trucks are custom made and customers are very concerned over quality. Lack of resources and is also an issue. In 1991, NCPPP conducted and on-site waste reduction assessment and prepared a report for the facility. It would be helpful if the State could provide information on water reuse and use reduction. Site visit is possible but specifics would need to be coordinated.

Freightliner, Cleveland: This facility generated 59 percent of this SIC’S hazardous paint waste (wastes are sent to incineration or fractionatioddistillation). As discussed above under Freightliner, Mt. Holly, Freightliner manufactures class 6, 7, and 8 custom made heavy duty trucks. This facility manufactures the chassis and the cab of the trucks and assembles the final product using parts from the Gastonia facility. Also, this facility receives cabs from Mt. Holly that it dresses, topcoats, and uses in final truck manufacturing. They painting operations at this facility are very similar to those discussed for Mt. Holly. Like at Mt. Holly, guns are cleaned by flushing the guns with NMP. The activated portion of the spent cleaner is collected as paint waste. The unactivated portion is sent to off-site for recycling. Approximately 600-800 gallons of cleaning solvent is generated each day. The majority of their waste is generated from the cab painting operation (60-70 percent). See Mt. Holly discussion for details on current and future pollution prevention initiatives.

2-Digit SIC Code: 97 Number of facilities (Le., bases) contacted: 10 Number of facilities (Le., bases) responding: 8 Quantity of paint waste generated by SIC 97: 444,491 lbs/yr Quantity of paint waste combusted: 185,532 Ibdyr Quantity of paint waste landfilled: 0 Ibs/yr

U.S. Marine Corps. Air Base, Cherry Point: This facility generated 43 percent of this SIC’S hazardous paint waste (wastes are sent to fuel blending, incineration, for energy recovery, or off-site for facility storage). Primary painting operations include the coating of aircraft and aircraft components. This site has six paint booths: one for painting aircraft; one for painting engines and transmissions; two for painting general aircraft components; and two for painting miscellaneous equipment. The aircraft painting process involves cleaning the aircraft with

C - 25

and aqueous cleaner. Following the cleaning, the aircraft are moved to a paint hanger where they are masked and buff-sanded. Residue from sanding is captured in a down-draft filtration system that uses paper filters. This residue is classified as hazardous waste since it contains chromium. The aircraft is wiped down with a solvent impregnated cloth. The solvent contains ethyl acetate, diacetone alcohol, n-butyl acetate, and MEK. The spent rags are treated as hazardous waste. After wipe-down, the aircraft are painted with an epoxy polyamide prime coat followed by a polyurethane top-coat (both paints are high-solids, low- VOC’s). HVLP and air assisted airless guns are used to paint the aircraft. The guns are

. ~~~ ~ ~

-~ cleaned in an automated paint gun washer. Overspray is collected on paper filters. As discussed above, there is one paint booth dedicated for painting engines and transmissions. HVLP guns are used in this booth to apply paint that must meet tough performance requirements. HVLP guns and paper filters are used in the two booths that are dedicated for painting aircraft components. In the two booths used for painting the miscellaneous parts, HVLP guns are used. One of the booths is a dry filter booth, while the other uses a water- wash system to capture overspray. TQM is used to address painting and coating operations that may arise. The base is also trying to eliminate the use of MEK in the wiping down aircraft prior to painting.

USCG Base Fort Macon, Atlantic Beach: This facility generated 2 percent of this SIC’S hazardous paint waste (wastes are sent off-site for facility storage). This base paints above water parts of boats (70 percent of painting) and miscellaneous base-related objects (e.g., buildings). Boats are prepared for painting by sanding using hand sanders. The paint residue collected from the sanding is shipped off-site as non-hazardous waste. The sanded boats (above water parts only) are wiped down using solvent soaked rags.. The rags are air-dried and shipped off-site as non-hazardous waste. Occasionally, steel surfaces are prepared using a zinc-based primer for rust protection. The boats are painted using rollers and brushes for smaller projects and HVLP guns for larger tasks. A large variety of paints are applied to the boats, although most of the paint applied is low VOC, alkyd or silicone enamels. The paint thinner is used to clean brushes and rollers. The spent solvent is considered hazardous waste. The base uses a TQM approach to address identified problem areas. Currently, the base is in the process of developing a pollution prevention program. Key areas on the program agenda will include substitution of citrus-based cleaners for solvents used to clean rollers and brushes. Additionally, the use of disposable brushes.

US. Air Force Base, Seymore Johnson: This facility generated 6 percent of this SIC’S hazardous paint waste (wastes are reused for energy). This facility has two types of painting operations. One is used to paint aircraft (touch-up and complete repairs), and the other is used to paint smaller objects (e.g., vehicles, aircraft components, and helmets). The aircraft are prepared for painting in a hanger. They are sanded using a dustless sanding system that traps 99.995 percent of chromium containing paint dust. After sanding, the aircraft are wiped down with MEK soaked rags. These rags are classified as hazardous waste since they contain MEK and Cr paint residue). A single paint booth is used for painting aircraft. This paint booth is the most modern in use in the country for the painting of aircraft. The most - innovative aspect of the paint booth is the filtration system. This is a three part filter system:

.~

C - 26

1) particulate prefilter; 2) catalyst based VOC extraction; and 3) after-filtration that collects any fragments that break away from the catalyst stage. This filter system reduces VOC emissions by 98-99 percent. The system is much more effective than the granulated charcoal system since it traps the solvents by chemically binding them. Also, the catalyst system lasts longer than the charcoal filters. The paints applied to the aircraft are high-solids polyurethane containing chromium. The paint is applied with HVLP guns; the base is currently switching to electrostatic paint application. The guns are cleaned with MEK. The spent MEK is recycled using a distillation-based approach. The painting operation that is used to paint smaller objects consists of five paint booths. A filtration system that includes a catalyzed entrainment of VOC’s is used in these booths. In the booths, a high-solids polyurethane paint is applied with HVLP guns. The reduction of VOC emissions associated with this approach is estimated to be 80 percent (appears to completely remove toluene and methylene chloride). The facility is currently looking into substituting a safer solvent than MEK. However, a substitute solvent must be able to meet military specifications. Also the base is trying to demonstrate the claim of 98-99 percent reduction of VOC’s in the main paint booth. The base would appreciate State assistance in this effort. The contact at the base also suggested that the State provide assistance in sharing their pollution prevention successes (e&, catalyst removal of VOC’s) with NC industries.

U S . Marine Corps Base, Camp LeJeune: This facility generated 10 percent of this SIC’s hazardous paint waste (wastes are shipped off-site for storage). This base has three painting operations: 1) touch-up of chemical agent resistant coatings (CARC) on military vehicles; 2) complete repainting of vehicles not designated for military combat; and 3) general painting of objects (e.g., signs and bookcases). Touch-up of CARC coatings on vehicles involves surface preparation using a sander or grinder and application of an extremely toxic isocyanate-acrylic paint using brushes. Excess CARC paint and used brushes are classified as hazardous waste. Painting of non-combat vehicles involves sanding of rust spots, application of solvent-based paint using paint guns in a spray paper filter paint booth. Solvent is used to clean the guns. 90 percent of the spent solvent is recovered using a distillation system. Painting of miscellaneous items occurs in a water-wash paint booth. In the paint booths, water-based paint is applied using either brushes or guns. The water-wash residue is recycled using a recirculation system. The residue is collected and shipped off-site as hazardous waste. Conceming pollution prevention, the base encourages the use of water-based paints when possible. Future pollution prevention efforts will focus on reducing the amount of paint thinner used.

USCG Support Center, Elizabeth City: This facility generated 2 percent of this SIC’s hazardous paint waste (wastes are incinerated or recovered). This base is the primary repair center for Coast Guard aircraft. Smaller aircraft (helicopters and jets) are painted at the facility. Prior to painting, the aircraft surface is prepared by blasting the surface with plastic beads. MEK is used to prepare smaller parts for painting. Then the aircraft and the smaller parts are washed with an alkaline, aqueous cleaner. Bead and paint residue resulting from the bead-blasting process are collected and shipped-off site to a facility that uses the residue to make bath tubs. The aircraft and smaller parts are painted in a hanger that serves as a paint

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booth. A low VOC paint (i.e., Imron) is used to paint the aircraft. The paint is applied with HVLP hand-held guns. Overspray is collected on paper filters. These filters are change once a month and classified as hazardous waste. The guns are cleaned daily with MEK. The spent solvent is shipped off-site as hazardous waste. Concerning pollution prevention, the base switched to low VOC paint about a year ago. Recycling of head-blasting residue began 3 years ago. The base is trying to install paint booths that will allow greater than 99 percent transfer efficiency. Also, they are trying to find a substitute solvent so that the use of MEK can be phased out.

US Air Force Base, Pope: This facility generated 3 percent of this SIC’s hazardous paint waste (wastes are sent off-site for storage). This base paints aircraft and ground support equipment. The aircraft are both touched-up and repainted at the facility. Currently, the base paints aircraft in a modified hanger that can accommodate the forward portion of the aircraft (Le., excluding the tail). Aircraft are huff-sanded and moved to a separate hanger where the aircraft is cleaned with an aqueous cleaner. Paint residue from sanding is collected and shipped off-site as hazardous waste. After cleaning, the aircraft is retumed to the original hanger. The aircraft is painted with a base coat (i.e., epoxy primer with strontium chromate) and a top coat of high-solids, low VOC polyurethane using hand-held HVLP guns. No effort is made to capture overspray; Overspray is allowed to accumulate on the floor of the hanger. A new structure for painting the aircraft is under construction. The new structure will have two hays each capable of enclosing and entire C130 transport. One bay will he used for washing and the other will he for sanding and painting the aircraft. Pneumatic sanders designed to collect sanding residue will be used. Paint will be applied with both hand-held HVLP and air-assisted airless guns. Overspray will be collected through the use of dry filtration. The base is also in the process of constructing two water-wash spray booths to he used in painting smaller pieces of equipment. Hand-held HVLP guns will he used to apply the same type of paints discussed above. The water-wash residue with entrained residual paint will be treated on-site. Prior to painting, the pieces of equipment are blasted with plastic shot. Residual shot with the paint residue will be shipped off-site to a facility that makes counter tops out of the spent material. As discussed above, new spray booths are being installed as part of a pollution prevention effort.

US Army Fort Bragg: This facility generated 29 percent of this SIC’S hazardous paint waste (wastes are sent off-site for storage). Currently, the painting operations at this facility involve the painting of tactical ground equipment (e.& tanks). The aircraft associated with Fort Bragg are presently painted at Pope Air Force Base. Although, plans are being developed to construct aircraft painting facilities at Fort Bragg. Prior to painting tactical equipment, old paint is removed from the equipment using hand sanders. If there is significant rust on the surface then the surface is blasted using an aluminum oxide agent. Residue from the blasting is collected so that the aluminum oxide can be reused. The residual paint dust is collected and treated as hazardous waste. Once old paint and rust is removed, an acid wash is used to neutralize the surfaces. Several coats of paint are applied in a paint booth using conventional spray guns. The first coat is a primer coat (Le., water reducible epoxy primer). After the primer coat is applied, two coats of a green polyurethane paint containing isocyanate are

~

- .~

C - 28

applied. There are three paint booths on-site. These booths use a dry filtration system. The filters are changed 2 times a week. Guns are cleaned using a gun washer maintained by Safety Clean. Concerning pollution prevention, they will be switching from conventional spray guns to HVLP guns. The contact person stated that he had found a publication produced by the Steel Structure Painting Council to be helpful in identifying pollution prevention ideas. Also, he regularly attends DOD and industry meetings that focus on painting and coating technologies.

U S . Military Ocean Ter., Southport: This facility generated 0.2 percent of this SIC’S hazardous paint waste (wastes are sent off-site for storage). This base repairs truck trailers. The paint operations at this base are used to paint older trailers. The amount of painting done at this base is very small. The painting operation is a 2-step process involving the sand- blasted of trailers outdoors and the painting of the trailers inside a paint booth. No attempt is made to capture the residual from the sand-blasting. The trailers are painted with a low VOC paint using airless guns. Overspray is captured with paper filters that are changed very infrequently (is., have not been changed in two years). The guns are cleaned daily with solvent. The spent solvent is reused in the paint stock. Several years ago, the military switched to low-VOC paints. The base has found the NCPPP Focus publication helpful. Several years ago, the base received large quantity generators status based on a one time occurrence. Specifically, a large amount of hazardous waste was generated when they refinished outdoor railings on-site.

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Appendix D

Sample Site Visit Confirmation Letter

D - I

November 30, 1993

David Miller Cochrane Furniture Company, In. P.O. Box 220 Lincolnton, N.C. 28093

Dear Mr. Miller:

I am sending this letter to confirm our site visit scheduled by Zack Pekar for Wednesday, December 15, 1993. As discussed with Zack, Research Triangle Institute (RTI) is working on a joint non-regulatory project with the North Carolina Pollution Prevention Program (NCPPP) and Hazardous Waste Section to identify pollution prevention opportunities for painting and coating wastes that are being incinerated. Once opportunities are identified, materials that can he used by your industry in implementing these strategies will be developed and disseminated. In addition to these materials, the NCPPP staff will be available to assist your industry in implementing these strategies.

To assist us in our efforts, we have requested that you arrange a tour of your facility’s painting/coating operations. The purpose of the visit is not regulatory in nature. During the visit, we would like to familiarize ourselves with your operations and to collect information to supplement the information that was collected during the telephone survey. For example, specifics may include information on paint type used, painting techniques, application equipment, equipment cleaning, costs associated with operations and waste management, and information on past, present and future pollution prevention activities. Also during our visit, we would like to obtain copies of material safety data sheets (MSDS’) on any paintdcoatings, solvents, or solutions (e.g., equipment cleaning solution) used in your painting/coating operations.

Enclosed you will find an agenda that we wish to follow during the site visit. Thank you for agreeing to this visit. If you have any questions, please do not hesitate to contact me at (919)541- 6308.

Sincerely,

Donna Womack Research Chemical Engineer Project Leader

DS W/ds w Enclosure 94U-5773-000

D - 2

Appendix E

Sample Site Follow-up Letter

E - 1

December IO, 1993

David Miller Cochrane Furniture Company P.O. Box 220 Lincolnton, N.C. 28093

Dear Mr. Miller:

Thank you for meeting with us and allowing us to tour your facility’s paintingkoating operations. As a result of our project, we will be assisting the NC Pollution Prevention Program (NCPPP) in compiling materials that can be used by your industry in implementing applicable pollution prevention strategies. In addition to these materials, the NCPPP staff will be available to assist your industry in implementing these strategies.

For your information, I have enclosed a brochure that discusses the Pollution Prevention Program and highlights the various services offered by the Program. If you have any questions about the project or the NCPPP, do not hesitate to contact Terry Albrecht of the NCPPP at (919) 571-4100 or me at (919) 541-6308.

Sincerely,

Donna Womack Research Chemical Engineer Project Leader

DSWIdsw Enclosure 94U-5773-000

E - 2

Appendix F

Site Visit Questionnaire

F - 1

Specific Types of Information to be Collected During Site Visits:

1. Background information on paint operation(s):

. Construct a flow diagram on the painting process showing material balance.

. What substrates are coated?

. What volume of work is coated per month (ft2/month)

What are the most important performance characteristics of the coatings? . Drying time, colodgloss, application qualities, adhesion, corrosion protection, chemical resistivity, etc.

. What types and amounts of coating are applied? Usage per month (see reference) low VOC, water-borne, etc. collect MSDS on these paints, reducers (thinners), additives.

. How are paints mixed or batched? % reduced or thinner? designated fluid

In what size containers is paint purchased? What is shelf life? Inventory

lines?

. control measures?

. How are left over paints and solvents managed?

What types of application equipment are used? . What is the performance and age of the equipment?

2. Stripping and Reworking:

. What % of parts must be recoated or touched up?

Are the reasons for these quality problems tracked and addressed?

Do these products require stripping? Explain this process and its contribution

.

. to hazardous waste generation.

F - 2

. What are the costs associated with stripping and reworking?

3. Economic Information

. What are average operation costs associated with the painting operations? paint costs per gallon? exhaust requirement and costs? filter costs, treatment chemical costs? bake oven operation cost if applicable? labor and maintenance costs?

. What are the Total Waste Management Costs?

Waste disposal (handling, hauling and disposal/recovery) Regulatory oversight costs: reporting, manifesting, monitoring, inspecting,

Liability costs: penalties, cradle to grave liability Insurance costs:

recordkeeping, etc.

4. Cleaning Up Practices:

. What is the time spent and frequency of clean-up operations (line flushing, gun cleaning, filter replacements, booths cleaning, etc.?

Are cost information on these activities available?

. How are lines flushed and how is equipment cleaned? (It would be best if the

Would the facility consider using an enclosed solvent collection system for

What type of solvent is being used for clean-up?

How are dry filters/or water wash sludge being handled?

How much hazardous waste is generated per production index or other

assessor can witness this activity).

. clean-up if it is not already using one?

. Would the facility consider changing solvents?

. How often?

. measure? Specifically, what percentages are coming from where?

5. Operator Training:

F - 3

. Are there formalized training programs for the operator? If so, what kinds and who conducts it?

6. Maintenance and Housekeeping Program:

. What kinds and frequency of maintenance is there? ( e g , how frequently are

Is a lack of maintenance or housekeeping adding to waste generation?

spray gun needles replaced?

. How might this be improved?

7. Other Environmental Releases:

. What are the other environmental releases associated with this operation? What are the VOC releases? What are the wastewater releases associated with watenvash booths? Are excessive non-hazardous solid waste being generated (such as empty containers or non-hazardous filters)?

8. Documenting any innovated waste reduction practice:

. If the facility has implemented a useful waste reduction technique please fully document this - for a case study format (if information has not been collected on the technique).

9. Background on facility management and its affects on pollution prevention:

. What factors have influenced the implementation of pollution prevention

Are employee suggestion programs being used to reduce waste or heighten

Are TQM, EQM, or other special waste management strategies, cost allocation system, etc. in place?

Are total waste management cost assessment for new projects being conducted

technologies or management strategies at the facility?

. awareness?

.

. which account for less obvious costs such as liability compliance oversight, health costs, etc.? If not, what do they typically account for?

10. The next step in Waste Reduction Practices or Technology Implementation:

. What will be the next step or plans in P2 implementation?

F - 4

. What is the planning and scheduling of such projects?

Why or why not have the next step in P2 been taken? . 11. Addressing a company’s current and future needs:

. What are the company’s current or future needs to take the next step in P2 implementation?

How can a company overcome barriers that it is experiencing?

Are the perceived means and real means for taking the next step in P2

.

. promotion different?

12. Other qualitative evaluation to be made during the site visit through observation?

. P2 Implementation Potential: How should a company be assessed to determine

What is the awareness level of the advantages and disadvantages of P2

What is the level of commitment of management to pursue such strategies?

What is the managementkmployee relationship?

if it has a high potential for P2 and has the commitment to see it through?

. strategies?

.

.

F - 5

Appendix G

Site Visit Reports

La-2-Boy Furniture Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2 Cochrane Furniture Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6 Eaton Corportion . Gulf Pride Division .................................. G-10 General Steel Drum Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-18 VMEAmericas,Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-26

Caterpillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-44 FacilityA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-50 NC DOT Ferry Maintenance Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (3-53

OMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-33

G- 1

Site Visit Report for

La-Z-Boy Furniture Company Hammary Plant #15

OVERVIEW

Facility Profile La-Z-Bov Chair Comuanv, owner of Hammaw Plant #15 (HPF), has 20.000 - . ,.

employees. Hammary Plant #15, one of three Hammary Plants, employs 125 people, of which twenty are finishing operators. HPF uses a nine-step process to finish wooden casegoods, such as tables. Assembled casegoods are placed on cardboard covered pallets that travel on a conveyer system at 25 feet per minute; the cardboard catches over spray from coating applications. Daily, 500 to 1000 casegoods are finished.

Process Profile The finishing process consists of spray applications of toner, washcoat, glaze, sealer,

hand sanding, lacquer, shade staining, and two additional coats of lacquer. These coats are oven-dried twice, once following the glaze step and again following the final two coats of lacquer. These coats of finish produce a high build finish using high solid coatings according to the facility contact.

FINISHING COATINGS

Storage & Equipment HPF has three bulk storage tanks with a capacity to store 12,000 gallons of product

per tank. Two bulk storage tanks hold two types of lacquers, 10- and 45-sheen lacquers; the other tank stores sealer. HPF purchases materials shipped in tankers, 55-gallon drums, and 5-gallon buckets. Although coating materials are stored onsite, inventory is kept low; normally forty to one hundred 55-gallon drums are stored. To minimize waste, discontinued products are mixed with currently used products and applied to the casegoods. When discontinued products cannot be mixed with currently used products or when their shelf life expires, the product is disposed of with other wastes. Stains and glazes normally have a two-year shelf life.

Both air-assisted and high-volume, low-pressure (HVLP) spray guns are used to apply coatings. Typically, stain and glaze are applied with HVLP spray guns. In the past, these coatings were applied with air-assisted guns. However, the facility switched to using the HVLP guns to improved transfer efficiency and reduce the amount of material used. As a consequence of this switch, hazardous waste generation has been reduced (i.e., overspray). At the time of the site visit, the HVLP guns were not operable and air-assisted spray guns were being used to apply the coatings. -

HVLP guns are more susceptible to wear than the air-assisted spray guns and are replaced frequently. The cost for HVLP spray guns ranges from $600 to $800 per spray gun.

6 2

According to the facility contact, HVLP spray guns are more expensive than conventional air-assisted spray guns, but they use one third less finishing materials.

Operator Training

applications. To improve application techniques and to conduct safety training, operators view videos.

Operators are normally experienced individuals who are familiar with spray

Finishing Operation Each coat of finish applied during the finishing process has a specific purpose. The

first coat is toner, or stain; ii Is applied io add uniform color and to accent natural wood grains of the casegoods. Next, the wash coat is applied to seal wood pores from subsequent coating applications and to promote coating build. The wash coat helps maintain color and prevent fading. During the third step, glaze is applied. Glaze adds a rich color and fills open pores and is hand-wiped after application. Following the glaze application, the casegoods are oven-dried. Then, sealer is applied; its primary purpose is to provide adhesion, enable sanding, and seal the wood to establish a foundation for artistic enhancement. Following sealer application, the casegood is hand sanded to remove raised wood grain, and lacquer is applied. Shading is the subsequent step; shade stain function is to highlight the wooden casegoods. Finally, two additional coats of lacquer are applied and oven-dried. Lacquer is a topcoat or clear coat; its function is to protect the color coats, enhance the casegood, and provide a durable final finish.

This company is experimenting with waterborne coating at one of its other Hammary Plants. The particular waterbome system of interest is a hybrid water system. A hybrid water system is a system where the first coats are waterborne, and the subsequent topcoats are conventional. Constraints for the water system have to be overcome. Two of those constraints are drying time and humidity control. Another factor to overcome is the additional cost for stainless steel hardware such as pumps. Stainless steel pumps cost three times more than the conventional pump which average $1000 per pump. HPF has purchased three new stainless steel pumps to prepare for the switch to the new water system. Stainless steel pumps will replace all currently used pumps at this facility in three to four years.

Cleaning & Preventive Maintenance

immaculate housekeeping is attributed to maintaining established maintenance schedules. Great care has been taken to assure that all containers and storage vessels are closed and labeled properly. The floors in the spray room and pumphouse were free from noticeable excessive spills. Monthly inspections are conducted to perpetuate good housekeeping and operable equipment.

This facility is cleaned daily, which was obvious during the site visit. The facility’s

To prevent lacquer and sealer spills, daily valve inspections were done. Operators document releases from the vessel on sign-out sheets that revealed the initials, dates, and times that individuals released finishing materials from the vessel. This method holds individuals responsible and assures spill prevention. Inspecting valves have saved about 1,000 gallons of lacquer. However, should a spill take place, spill stations with appropriate

6 3

equipment are available.

Spray guns are cleaned daily. They are soaked overnight in one gallon of wash-off solvent in a five-gallon bucket. Wash-off contains acetone and lacquer thinner. Wash-off is also use to remove substandard quality finishes from casegoods before repairs. Casegoods are washed off in a covered wash-off tank. The wash-off tank stands about three feet from the floor and is about six feet by four feet. The contact at this facility estimates that less than ten casegoods are redone per month.

~

~

Spray booths are cleaned daily, weekly, or monthly depending upon the spray application. Peelable booth coatings collect over spray from finishing applications. Spray booths will be upgraded soon. The toner booth will increase by 12 or 13 feet, and the length of glaze and lacquer booths will also increase.

The outside storage area holds all 55-gallon drums of materials to be sent off-site for disposable andor recycling. This area is about 25 feet by 15 feet and is covered to prevent contamination. Incompatible chemicals were segregated. Empty product drums are returned to the coating supplier for reuse, and rubber seals cover waste drums to prevent corrosion. Each rubber cover costs $13.95.

This facility plans to color code affluent and effluent lines from outside bulk storage vessels to day pumps that deliver coatings to spray booths as another precautionary measure. Liquid waste is pumped from 55-gallon drums into a tanker, and the drums are reused to collect liquid waste.

HAZARDOUS WASTE

Waste from this facility is generated from cleaning and finishing processes. Various options have been tried to reduce solvent usage, but formal research has not been studied. Solid waste is generated from lacquer dust swept from lacquer spray booths, cardboard used to cover conveyer pallets, and sludge that settles from liquid waste. Wash-off is recycled onsite periodically by a recycling service. One service requires nine drums while another service requires 18 drum to be filled before they will come on-site to recycle. Approximately 80% wash-off is recovered for reuse.

The components of liquid waste are acetone, naphtha, acetone, and methyl ethyl ketone (MEK). Solid waste contains nitrocellulose, mineral spirits, and cardboard pallet covers, which may be disposed quarterly. Solid waste is compacted using a drum compactor. The contact said that disposal cost for each drum and is not dependent upon the drum weight. Therefore, this facility packs as much solid material in the drum as possible to reduce disposal cost. Disposal cost for solid waste is $165 per drum, and liquid waste is $170 per drum.

RECOMMENDATIONS

Since much of the information received by this facility is from finishing and equipment suppliers and the American Furniture and Manufacturing Association (AFMA), the facility contact suggests that information can be transferred through these contacts. Another means to distribute information, also mention by this contact, is through specific required training seminars, such as DOT and Haz Mat seminars, attended by representative of the furniture industry.

6 5

Site Visit Report for Cochrane Furniture Company Plant #10

OVERVIEW

Facility Profile ~

~

has 200 employees. Forty-five employees are finishing operators. CFC uses a nine-step spray process to finish wooden casegoods, such as dressers and tables. The dresser drawer side panels are finished using a flatline or rollcoat process. Assembled casegoods are placed on cardboard covered pallets that travel on a conveyer system at 20 feet per minute; the cardboard catches over spray from coating applications. Hourly, 144 pallets carrying casegoods circulate through the finishing process; therefore, over 1,000 casegoods are finished during an eight-hour day.

Process Profile

hand wiping, painting, and three coats of lacquer. These coats are oven-dried three times, once following the glaze step, after the first topcoat, and lastly a topcoat of lacquer. According to the facility contact, the high solid coatings are sprayed.

FINISHING COATINGS

Storage & EQUiDment CFC uses four bulk storage tanks with a capacity to store 3,000 gallons of product per

tank. Two bulk storage tanks hold two types of lacquers, 5- and 60-sheen lacquers; the other tanks store sealer and lacquer thinner. CFC purchases materials shipped in tankers, 55-gallon drums, and 5-gallon buckets. Although coating materials are stored onsite, inventory is keep moderate. According to the area supervisor, less than one drum a year of old paint is discarded as waste.

Cochrane Furniture Company opened its Casegood Plant #10 (CFC) in 1985 and now

The finishing process consists of spray applications of stain, washcoat, glaze, sealer,

Spray booth operators use conventional, HVLP, and airless spray guns for spraying applications in the finishing process. Stain is applied using conventional spray guns, and glaze is applied using airless spray guns. The tip orifice of several spray guns has been reduced to the smallest possible tip size allowable to maintain production speed. This adjustment attributed to a daily savings of 20 gallons of product. HVLP spray guns were tested for stain applications. However, they did not produce an acceptable finish. The area supervisor said that airless spray guns generated a good transfer efficiency at 28 to 30 pounds of pressure for stain applications.

This company is testing a two-coat lacquer topcoat system. CFC hopes to switch from the three-coat lacquer topcoat system that is currently used to a two-coat lacquer topcoat system. Currently, CFC is trying to correct a drying problem with the new system. Precatalyzed coatings will replace conventional nitrocellulose topcoat and eliminate a need for the washcoat. This will reduce the material usage and waste. The facility’s engineer said

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that he would like to convert wet spray booths to dry a spray booth within a year. Currently, spray booths that are used to spray color coats are wet booths, and spray booths used for clear coats are dry spray booths. A conversion from wet to dry booths will reduce liquid waste. The facility’s engineer would also like to develop a washable or recyclable filter. However, until accomplished, washable metal filters will be used.

Operator Training

applications. To improve application techniques and to conduct safety training, the facility’s engineer plans to make several training video tapes. Area supervisors support these efforts. This facility has open communication with employees and encourages their suggestions, but it does not have a formal TQM program.

Finishing Operation Each coat of finish applied during the finishing process has a specific purpose. The

first coat is an equalizing stain; it is applied to add uniform color and to accent natural wood grains of the casegoods. Occasionally, the first coat in the process is paint. The paint is applied in one of three colors, black, white, or green. Selection of the first coat depends upon market demands. Painted casegoods account for five to 10 percent of the facility’s production. Next, the washcoat is applied to seal wood pores from subsequent coating applications and to promote coating build. The washcoat also helps maintain color and prevent fading. It is a low solid coating with about 7% to 9% solids. At this facility, washcoat is formulated using one part sealer and two parts lacquer thinner. During the third step, glaze is applied. Glaze adds a rich color and fills open pores. It is hand-wiped after application using a three-stage process. This method allows for better use of rags. Following the glaze application, the casegoods are oven-dried at 110 degrees F for about ten minutes. Then, sealer is applied; its primary purpose is to provide adhesion, enable sanding, and seal the wood to establish a foundation for artistic enhancement. Following sealer application, the casegood is sanded to remove raised wood grain, and three coats of lacquer are applied. Lacquer is a topcoat or clear coat; its function is to protect the color coats, enhance the casegood, and provide a durable final finish. Shade stain or spatter may be done between coats of lacquer. Its function is to highlight or distress the wooden casegoods.

Operators are normally experienced individuals who are familiar with spray

The area supervisor estimated that 35 to 40 gallons of coating are used daily per gun in each spray booth. That amounts doubles for stain because two spray guns are used in the stain booth. The stain booth is 56 feet long while all other booths are about 36 feet long.

If casegoods are blemished or have color variations, refinishing is necessary. Lacquer thinner is used to wash off old coatings in a wash-off tank. Then, the casegood is sent through the finishing process again. The covered wash-off tank is about one foot deep, ten feet wide, and six feet long. The area supervisor says that one casegood per week may be refinished.

Dresser drawer side and bottom panels are precoated using flatline and rollcoat processes. The edges of the panels are stacked and coated using a flatline process. Then, the sides of the panels are rollcoated. These processes are followed subsequently. One coat of

6 7

100 percent solids lacquer is applied and UV cured

Monthly, 30 to 40 gallons of lacquer is used with the flatline and rollcoat processes. Volatile organic compound releases are less than one pound per month. Once coated, the drawers are assembled, and the newly coated panels are covered with cellophane. The cellophane protects the clear coat from additional color coats. However, should the panels

clean with lacquer thinner.

Cleaning & Preventive Maintenance

become blemished with glaze or stain during subsequent spray applications, they are wiped ~

~

To facilitate color changes occur in the finishing process, this facility sprays the new color through the spray system into a five-gallon bucket for a predetermined period. A spray system consists of spray guns and lines leading to spray guns. When time has lapsed, the new color traveling through the lines is sprayed onto casegoods. This method began about one year ago, and spray booth operators have maintained records of the amount of materials sprayed to clean the line after a color change. The average collection is about 130 gallons for a six-month period. Sprayed materials are reclaimed for reuse and blended with other coatings. Using this method reduced spray gun cleaning. Currently, spray guns are cleaned weekly in lacquer thinner.

Reclaimed materials are blended in the pumphouse. To capture spills in the pumphouse, a washable absorbent material covers the floor. is taped to the floor outside the spray booths. The cardboard also absorbs spills and over spray from finishing materials. A cleaning service launders the washable absorbent floor covers and rags used to wipe away excess glaze. However, once air-dried through solvent evaporation, the other types of absorbent floor covering used inside the spray booths and the cardboard used outside the booths are both landfilled.

In the finishing area, Cardboard

To capture lacquer dust, lacquer spray booths have peelable booth coatings that are blowndown with compressed air weekly and brushed daily. Dry spray booths with metal filters follow a similar schedule. The peelable coating is replaced about once every two years. about once every two months. Sludge from wet spray booths, like the glaze booth, is removed using buckets.

HAZARDOUS WASTE

The glaze booth is covered with sheets of thick plastic. Plastic sheets are replaced

Waste from this facility is generated from cleaning and finishing processes. The facility contact is concemed with both solid and liquid waste and said that better operator training might reduce lacquer dust. Solid waste is generated from lacquer dust swept from lacquer spray booths, cardboard used to cover conveyer pallets and floors; booth coatings and plastic used to cover the glaze booth, and sludge that settles from liquid waste. Cardboard pallet covers are landfilled about once a year. Currently, no additional recycling programs, other than material reclamation, are used. This facility produces one 55-gallon drum per week of waste from spray booths. The cost is $250 per drum for disposal. This facility plans

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to purchase a drum compactor to packs a much solid material in the drum as possible to reduce disposal cost.

RECOMMENDATIONS

This facility representative has attended several State sponsored seminars and suggests that information can be transferred through seminars, forums, and trade associations.

,G9

Eaton Corporation - Golf Pride Division Laurinburg, N.C. Site Visit - November 19, 1993

Overview The Eaton Corporation makes 80% of the world’s golf grips at their Golf Pride facility in Laurinburg, NC. The facility’s product line is almost solely golf grips, however other products that are periodically manufactured on a small scale are rubber industrial air clutches, water ski rope handles, and hammer handles.

The golf grip production may be broken down into generic groups:

~

~

buffed grips, which are those that require painting, sanding, and buffing, and wiped grips, which are those that require painting and solvent wiping.

According to current production estimates, 50 percent of the grips produced are buffed and 50 percent are wiped.

All finished golf grips have recessed areas that have been painted to highlight product logos or pattems that are decorative or functional (e.g., aid in correctly aligning hands on the grip). The endcaps of the grips also have recessed areas that may or may not be painted. Depending on product specifications, the endcap may then be coated with a clear polyurethane.

The Eaton facility operates milling, molding, painting, and finishing departments (see Attachment A). In the milling department, rubber is compounded or “mixed together,” and then calendared into sheets. Next, the sheets of rubber are sent to the molding department where they are molded, through either compression or continuous injection machines, and cured into grips. Paint is applied to the grips after they have been cured and aged. At the finishing department, the grips are either sanded and buffed, or they are wiped with solvent. In the fiist instance, the buffed grips are sent to automatic sanding machines where excew paint is removed from the non-recessed areas of the grips. Next, the sanded grips are washed and buffed. The wiped grips are f i s h e d with an automatic wiping machine that uses solvent to remove excess paint from around the recessed logo.

Solvents Pure acetone is used to wipe clean the grip’s endcaps before they are painted with a clear, poly-urethane gloss. Pure acetone is also combined with Eaton Reducer Blend solvent to produce an acetoneblend mixture which is used as both a paint diluent and a cleaning mixture. The Eaton Reducer Blend contains 15-20% isopropyl acetate, 63% aliphatic petroleum distillates, 10-15% n-butyl acetate, and 10% acetone. Typically, the acetoneblend mixture is 60% acetone and 40% blend. However, the acetoneblend mixture may contain 50 - 80% acetone since the lack of climate control in the painting area can cause fluctuations in the temperature and humidity.

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G10

Paints The are approximately 50 active colors or paints used at this facility. The three primary colors used in golf grip painting are aqua, white and gold. All the paint is elastomeric and solvent-based paint. Depending on the paint color, the n-butyl acetate (solvent) comprises 63 - 74% of the paint's volume. Three parts (by volume) acetoneblend mixture is combined with one part paint to arrive at a "working paint", which is used in the actual paint operations. The elastomeric, solvent-based paint is specially made for Eaton by Armitage Paint Company to withstand the daily stretching and handling of the rubber grip.

Two to three years ago, the company switched from toluene-based paints to the current n- butyl acetate based paints. This switch was based primarily on environmental concems, not financial savings. According to the environmental engineer, Eaton is actually losing money as a result lower production and higher rejection rates with the n-butyl acetate paint. Since the cure time for the n-butyl acetate paints is not as short as the old toluene-based paints, Eaton now has to allow their grips a longer time to dry after painting. When using the toluene-based paint, the grips could be buffed 1 or 2 hours after painting. With the n-butyl acetate-based paint, the grips need a full 8 hours of drying before they can be buffed. Eaton attempted to compensate for the slower drying time by increasing the temperature of the infrared dryers that they use to cure the paint. This did not work since they found the increase in temperature caused the paint to become "gummy" instead of simply drying faster, as would occur with toluene-based paints. There is also a higher rejection rate associated with the n-butyl acetate-based paint, which results in a higher scrap rate.

The shelf-life of the n-butyl acetate paint is approximately 15 months. Eaton has had no past problems associated with the expiration of a paints shelf-life, except an isolated incident in 1992 (see Waste Generated - Liquids section).

Painting Operations Buffed Grips There are 2 rolling machines that do the majority of the painting over the course of two painting shifts (a third rolling machine had been recently decommissioned). The rolling machines are only used to paint the entire grip for the buffed grips. In this automated painting operation, the grips are placed on spindles which move along over paint rollers. The semi-absorbant rollers are half submerged in a pan, to which, paint is supplied as needed by a 5-gdon sump located below. The entire roll painting operation is enclosed and emissions are vented to a thermal oxidizer. After moving across the rollers, the endcaps of the grips are wiped against a strip of carpet. The strips of carpet are changed as needed, usually several times per shift. Then, the non-recessed areas of the endcaps are cleaned with pieces of carpet that rotate through a pure acetone bath. The 35-gallon tank that holds the acetone has plastic beads, approximately 1.5" inches in diameter, that float on top of the acetone in order to reduce the amount of acetone lost to evaporation. This tank is changed when the acetone becomes sufficiently contaminated with paint, which is approximately three times each year. After the acetone wipe, select endcaps are sprayed with a clear polyurethane gloss using two automatic HVLP guns inside a spray booth. The two Acu-Spray brand HVLP spray guns spray the paint at 14 psi, using compressed air, instead of a turbine system to atomize the paint. In the spray booth, a fumace filter catches excess paint and emissions before venting

Gll

to the thermal oxidizer. To maximize the use of their sulface area, each filter is rotated periodically. Eaton estimated that these filters are changed several times per shift. Excess paint that accumulates in the spray booth is removed (scrapped) daily and a water-based peel coat is applied to the inside of the spray booth once a week. After the endcaps are sprayed, the grips move through an infrared tunnel for approximately sixty seconds. After drying, the grips that need special decal color painting are sent to either an semi automated upspray paint gun or a manual air spray station.

The upspray area consists of nine conventional air spray guns that are located beneath the grips and emit paint directly upward. According to the process engineer at Eaton, HVLP guns could not be used in the upspray process because the low pressure guns would have a problem with clogging when they spray paint upward. The upspray painting area is where most of the color changes occur in the paint department, since a variety of colors are used to paint logos and decals on the grips. For color changes, which may occur up to five times per day per upspray station, the paint lines and pressure pot are flushed out with the acetoneblend mixture. Then, the new working paint is run through the lines until there is a desired consistent color.

The hand spray station contains three hooded (vented) spray areas; 2 are conventional air spray guns and one has a trial HVLP spray gun. Conventional air spray guns are being used because, originally, the HVLP hand sprayers were neither small enough nor comfortable enough for the employees. Now, currently available HVLP spray gun models are small enough for use at the station. The process engineer believed that the 2 conventional air spray guns will be replaced with HVLP spray guns by the end of 1993. The logo painting that occurs in the hand-spray paint booths is low volume. There are primarily two reasons for hand-spray painting the grips: 1) limitations in the upspray process (Le., the painting radius required on the grip may exceed capabilities of the upspray process) 2) use when the upspray machines are occasionally being repaired. The exhaust hoods for each spray gun contains a filter that last about 2 weeks and then it is disposed of as non-hazardous waste.

For some of the wiped grips, a gravity needle (syringe-looking applicator) is used to apply gold paint to a logo on the grip. According to the process engineer, hand painting with the gravity needle yields 3,000 grips with one gallon of working paint. With the semi-automatic upspray, 1,000 grips can be painted with one gallon of working paint. The gravity needle applicators are only used for small batches of wiped grips that have simple lettering. While the gravity needle applicators use less paint per grip, the application process is currently too labor intensive to expand to the majority of grip lettering and logos.

Wiped Grim The wiped grips are currently the most popular model that Eaton manufactures. This . . _ . particuiar grip requires the least amount of paint among all grips produced. A cotton swab is used to apply gold working paint to the recessed logo on the grip. After the wiped grips have been painted, they are sent to one of two automated wiping machines. At the wiping machine, a cloth strip rotates through a bath of acetone and wipes against the grips that are

per shift. Both of the wiping machines are vented to the thermal oxidizer.

- rotating on spindles. The process engineer estimates that 5 to 7 gallons of acetone are used .~

GI2

Production The overall production rate at the Laurinburg facility has remained relatively constant for 1992 and 1993. In 1992, Eaton - Golf Pride division manufactured products consisted of approximately 15% wipe grips and about 85% buffed grips. The projections of the product line for 1993 are 50% wiped grips and 50% buffed grips. The greater demand for the wiped grips has had a noticeable impact on paint and solvent usage at the facility. According to the process engineer, from 1992 to 1993, the volume of paint used at the facility will decrease by approximately 25%, while solvent use will remain about the same because solvent is used to remove excess paint from the wiped grips. In 1992, nearly 100% of the waste solvent was from flushing the paint lines between color changes. Currently, 75% of the waste solvent comes from wiping and 25% comes from cleaning the paint lines and pressure pots before changing paint colors.

Waste Generated

Paint-contaminated solid waste result from numerous processes along the paint production line. The small carpet strips, used in wiping the grip endcaps are changed as needed, usually several times per shift. The used carpet is disposed of as non-hazardous waste. Excess paint is scrapped from the HVLP spray booth daily and the peel coat is scrapped and reapplied once a week. These wastes are drummed and sent off-site for fuel blending. The filters used in the HVLP spray booth and the manual spray booths are periodically removed and disposed of as non-hazardous waste. The filters for the manual spray booths need to be changed about once every two weeks. The largest amount of non-hazardous, paint-contaminated, solid waste is generated by the sanding process performed on the buffed grips. The sanding process produces approximately 2,312 lbs./day of a fine rubber dust that is sent to an off-site landfill.

solids

Liauids The primary liquid waste material comes from spent acetone used in wiping the grips and the . - ketoneblend used in flushing the paint lines from the upspray station. -Thi acetone from the 35-gallon tank that is changed periodically throughout the year, also contributes to the liquid waste stream. Currently, all of the spent solvent and acetonejblend is drummed and sent off- site for fuel blending. Eaton hopes to work out an arrangement where the paint supplier takes the spent solvent and recycles it. In 1992 there was 8,400 pounds of off-spec paint, resulting from a combination of expired shelf life and inconsistent paint, that was sent off-site for fuels blending. There was no reported off-spec paint for 1993.

Year Waste per year - Type Cost per year

1992 162,000 lbs - paint waste and spent solvent $26,500

$14,000

$76,500

8,400 lbs. - off-spec paint

228,000 lbs - paint waste and spent solvent * 1993

2,312 Ibs/day - rubber dust from sanding $10,000

In the past, Eaton has attempted to distill the spent solvent on-site. Eaton was unable to produce a distilled solvent that would consistently meet quality demands. Also, Eaton experienced several mechanical problems with the distillation set-up, and due to safety concems the plant's still is no longer in operation.

Eaton has a major pollution prevention idea in place but current interpretations of environmental regulations are holding it back. Their idea involves a type of "closed loop

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614

recycling" for the spent solvent. Eaton has the capability to separate their used solvents according to which primary color they were mixed with (i.e. solvent used to clean grips painted aqua would be collected in a drum designated for aqua solvent only). Once the drum of used solvent is full, it would be sent off to Armitage Paint Company where the solvent would be microfiltered and used the make the same color paint for Eaton (i.e. recycled aqua solvent would always be used to make aqua paint). Microfiitering the solvent would remove any small paint particles. The normal process operations at Armitage already require "fresh' solvent to undergo a microfiltering process to remove impurities. In the near future, Eaton is planning is to use 330 gallon paint totes that will already have solvent mixed in. Once the tote is empty, it will then be kept outside and be filled with used solvent (from the same color). Annitage will then come to pick up solvent and microfilter the solvent/paint mixture to get the solvent to the quality level needed to eventually combine with the same color paint. Paint/solvent mixture would then be put back in tote and sent to Eaton, thus completing the loop. As a result of the paint being delivered pre-mixed, Eaton anticipates a reduction in VOC emissions caused by current in-plant of solvent with paint to obtain the appropriate working paint solution.

note: The Eaton environmental engineer and process engineer have been to several pollution prevention workshops. They commented that these workshops, even those workshops specifically designated for paintings operations, presented information that was often too general or too vague, i.e. there was not enough focus on painting or coating operations involving rubber substrates.

Attachment A

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ATTACHMENT I PROCFSS FI OW DIAGRAM

1 . 1 Scrap Scrap

I Scrap

. Uaed Warto Naphtha Warto Petroleum Naphtha UN12SS To Satetv-Kleen

Rubbor (L F8brlc- . Trench 011

for Recycle

E AT0 N CO RPO RAT I 0 N

Golf Pride Division Laurenburg, N.C.

D.M. Kldd 111110a

i l

Site Visit Report General Steel Drum Manufacturing

Charlotte, North Carolina December 17,1993

Overview

General Steel Drum Corporation (GSD) manufactures 55 gallon steel drums for chemicals, food and other products. Depending on the type of drum, GSD manufactures about 400 drums per hour. Drums are generally of two types: open head (removable cover) and closed head (attached cover). GSD fabricates a drum starting with rolls of sheet steel in various grades. Steel is cut to size, formed into a cylinder and resistance welded to form the drum "shell." The ends of the shell are flanged, and "rolling hoops" and optional side openings are added to the shell. The shell then passes through a 3-step phosphatizing process consisting of a wash and two rinses. Phosphatizing removes contaminants on the shell and prepares the shell surface for coating. The shell is conveyed through a dryer prior to further processing.

Between 60 and 70 percent of all drums manufactured at GSD receive an interior coating. If an interior coating is required, the shell is diverted to an interior coating line consisting of two automated interior coating stations and a curing oven which operates at 425" F. The customer's specifications determine if the shell will receive one or two interior coats. If one coat is needed, only one of the coating stations will operate.

Drum "parts" (i.e. drum covers) may be purchased in disc form or may be fabricated from coil cut sheets of steel. Depending on customer specifications, parts may receive an interior and exterior coating.

The shell and parts are then roll formed together to form a single container unit which is leak-tested. The drum is then forwarded to the exterior coating system, which rotates the drum while applying a coating to the exterior of the drum shell and, when present, the drum cover. After the exterior coating is applied, the drum is conveyed through two curing ovens operating at between 310" and 340" F and then through a cool down unit prior to finishing assembly and transportation to the customer. Some customers request that the drum chime (rim) receive touch-up, and this is applied by roller coating.

Coating Areas

GSD has four areas where it applies coating to drums and drum parts: two interior coating areas, a parts coating booth and an exterior coating booth. All equipment is about 3 to 5 years old and all booths are automated. The exterior coating booth is where GSD generates the greatest amount of waste.

G18

Exterior Coating Booth

Drums are conveyed through the exterior coating booth on their sides. The interior of the unit is about 8 feet across, 6 feet high and about 10 to 15 feet deep. The conveyor system carries the drum through the coating booth a couple feet off the ground, but the bottom of the booth is on the floor. Tracks guide the drum into the coating unit and a set of rollers starts the drum rolling in place at a rapid rate.

Air-assisted airless guns, mounted on an arm above the drum, apply the coating as the drum rolls. The arm contains two sets of three guns, positioned along the axis of the drum, for coating the shell, and a separate gun for coating the cover, when needed. Each gun coats about one third of the drum shell. Only one set of the guns operates at a time. One set of guns applies black or white coatings, which make up between 60 and 70 percent of the total coating used. The second set of guns is used to apply colors. Drum exteriors may be single color or multiple colors (striped), depending on customer requirements.

Exterior drum coating takes about 5 to 12 seconds. The length of time varies with the coating, since coatings have different viscosity and coverage characteristics. Once a drum is coated, it is ejected from the coating booth and conveyed to the drying ovens.

Since a variety of colors are used for exterior coating, the coatings in use at this line are located in a paint kitchen near the paint booth. Coatings are hooked into the paint system through paint lines that go to a manifold. When the paint guns are not in use, the paint system continuously recirculates the coating through the manifold, which keeps coating solids in suspension and maintains coating temperature. When the guns are activated, coating is diverted to the gun. This system helps reduce down time between paint changes, since new coatings can be engaged simply by throwing a switch to change between paint containers and then clearing the old coating from the manifold.

Booth operating parameters, such as spray gun pressure and amount of coating applied, are set based on the coating that is being used. Adjustments to the guns to ensure good coating coverage or correct problems are based on visual observation of gun performance and inspection of finished pieces.

GSD did not know the exact transfer efficiency of the exterior coating operation. However, GSD said that, according to their coating supplier, with perfect transfer efficiency they should be able to coat 43 drums with a gallon of coating. GSD’s operation coats between 28 and 35 drums per gallon of coating. Based on these numbers, the transfer efficiency of the coating operation is between 65 and 81 percent.

The paint booth contains air filters towards the back, which are pieces cut from rolls of filter material. Air drawn through the filters deposits paint solids. After the dry filters, air also passes through a water curtain to remove any residual solids that have gotten past the dry filters. Plastic and fire retardant paper are applied to the floors and other parts of the booth

G19

to catch paint overspray. GSD also uses a peel coating in the booth to make booth clean-up easier. Underneath the area where drums are sprayed, there are two drip pans which collect paint overspray and which are drained to waste containers.

Shell Interior Coating Areas

The two shell interior coating areas are essentially identical. The units are mounted around the drum conveyor system, about 3-4 feet off the ground, and are about 2-3 feet wide. The drum enters the unit on its side and is set into a rolling motion. An air-assisted airless gun mounted on an arm enters the interior of the shell and sprays downward as the drum rolls. Starting at the far end of the drum, the arm moves along the axis of the drum in thirds until the drum interior is completely coated. Coating is attached to the spray gun in a 55 gallon drum located at the booth. Paint overspray collects on the bottom of the unit and drips into a small bucket. Coating captured in the bucket is reamed to the coating container for reuse. The units also have air filters which remove coating solids from the air exhausted from the units.

Parts Coatinr! Booth

At the parts coating booth, drum covers on a conveyor line are coated using an air- assisted airless system. The booth is mounted about 3-4 feet off the ground and is about 4-5 feet wide. The unit coats two parts at a time using three air-assisted airless guns for each part (six total). The guns are mounted on an arm and apply the coating automatically to one side of the cover. The three guns each spray a pattern that covers one of the following sections: the chime, chime to center, or center of the part. The spray patterns of the three guns overlap to provide an even coating on the part. The cover is mounted on a spindle that rotates as the gun sprays to ensure uniform coverage. Only one side of the part is coated at a time. Covers receive exterior coats, and sometimes also receive an interior coat.

Coatings

Exterior

Exterior coatings are chosen primarily for their appearance and are subject to precise customer demands. Coatings must provide good surface coverage with no substrate visible and no runs. A typical exterior coating is between 0.6 and 1.1 mils thick, with lighter colors typically requiring greater application thickness. Due to the variety of customer demands, GSD provides more than 30 colors of exterior coating.

GSD currently uses VOC-based high solids alkyd melamine baking enamels. The VOC content of most of these coatings is around 40 to 45 percent by volume (about 3 pounds VOC per gallon), although some are as high as 60 percent VOC by volume. GSD uses lower-VOC formulations to maintain compliance with their air permit which limits their VOC emissions to 100 tons per year.

Interior

Interior coatings are chosen primarily for the combination of their chip-resistance and chemical resistance. To impart these characteristics, GSD uses VOC-based coatings that are either epoxy, phenolic, or a combination of epoxy and phenolic. The epoxy material imparts impact resistance, while the phenolic material provides chemical resistivity. The ratio of epoxy to phenolic material is chosen based on the specific customer needs. GSD uses 12 different interior coatings that vary as to their composition and color. Interior coatings are around 60% VOC by volume (4.3 pounds VOC per gallon). A typical interior coating will be between 0.8 and 1.2 mils thick when dry.

Waste Generating Operations

In the painting areas, hazardous wastes are generated during color changes and booth clean-out. VOC emissions are generated during these same operations as well as paint application and drying. The discussion below focuses on hazardous waste generation. About 68% of hazardous wastes come from the exterior painting booth, with about 22% from parts coating and 10% from interior shell coating.

Color Chanpes

Due to customer demands, GSD must provide numerous interior and exterior coatings for its drums. Although the rate of color changes varies markedly from day to day, GSD estimates that it must change colors about 8 times per day, on average.

Exterior Booth

Color changes at the exterior booth entail work by two people simultaneously, one working at the booth, and the other at the paint kitchen. The operator at the paint kitchen changes the paint line to the manifold from the old to the new color. The operator then runs the new color through the line to flush out the residual old color in the manifold. First, the old paint that is flushed out of the manifold is returned to the original paint container. When the new paint is about to appear at the end of the line, the flushed-out paint is diverted into a 55 gallon drum for storage. About a half gallon of mixed paint is generated during a color change. The mixture of paints from line clearing is returned to the paint supplier for reformulation into a black coating used by drum reconditioners. Once the manifold is cleared of the old color, the guns are activated for a few seconds to remove any residual coating. Occasionally, MEK is used to clean the lines, although GSD tries to limit their use of MEK.

The operator at the booth wipes down the spray guns with solvent on a rag, then scrapes the rollers of the conveyor system to remove excess paint that could carry over onto the subsequent run. Once the new paint has been hooked in at the paint kitchen, the operator sets the spray system parameters for the new coating and sprays paint from the guns to clear the last residual of the old color.

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A color change typically takes about 4-5 minutes to complete

Color changes generate paint from line-clearing that is sent back to the manufacturer for reformulation. GSD estimates that about a half gallon of paint is generated in this manner during a typical color change, or about one drum every two to three weeks. Line clearing generates about 10 to 40 gallons of waste MEK per month. Color changes also generate waste paint from line clearing through the guns. Some of this enters the liquid waste stream, and some adheres to the booth masking materials and air filters and becomes solid waste material. Color changes also generate paint and solvent-containing rags generated from cleaning off the exterior of the guns. GSD estimates that all paint booths together generate about 2.5 gallons of this waste stream per day.

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Interior and Parts Coating Booths

As with the exterior coating area, color changes for the interior and parts coating booths also involve clearing the lines and wiping down the guns. However, for these areas the coating is located near the application equipment, and waste coating cleared from the line cannot be returned to the manufacturer. Consequently, waste from line cleaning is collected in a 5-gallon container and then transferred to larger containers prior disposal. In the past, waste from these areas combined made up about one third of the total waste that GSD generated from painting and coating.

OversDrav and Booth Cleaning

Air filters in the exterior paint booth are changed daily. Filter changes take about 5 minutes to complete. Paper, plastic and other maskant material as well as peel coating is changed weekly. Weekly clean-out of the booth takes about 3 hours. The water curtain that removes paint solids that are not caught by the dry filters is skimmed periodically to remove paint solids and generates about 1.5 drums per year of waste.

Total Waste Generated

The rates of waste generation for GSD during the last year are given in Table 1. The decline in waste generated during the fourth quarter reflects a combination of the new practice of sending paint from line clean-out back to the vendor and a decline in facility activity in November and December.

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Table 1 - 1993 Hazardous Waste Generation At General Steel Drum Corp. (in drums)

Solids

1st Quarter 2nd Quarter 3rd Quarter 4th Quarter Total

20 19 17 15 71

Total 59 55 52 37 203

GSD uses about 2000 gallons per month of coating in both the interior and the exterior painting areas (4000 gallons per month total). Waste disposal costs for solids are generally about $300 per drum, while those for liquids are in the range of $40-50 per drum. Based on the information given for 1993 in Table 1, this translates into about $27,200 per year for waste disposal, of which about 80 percent of the cost is attributable to disposal of hazardous waste solids. However, the greatest cost of waste generation may be for wasted raw materials. GSD preferred to keep the costs of the coatings it uses confidential. However, Table 2 gives estimates for the cost of wasted coating material at the exterior painting booth using a range of assumed coating costs.

Table 2 - Wasted Raw Materials Cost for Exterior Paint Booth

Cost per gallon of Coating

$10

$15

$2Q

Transfer Efficiency Annual Cost of Savings per 0.05 Transfer

Efficiency Improvement

of Painting Wasted Raw Gallons of Coating Used per Month Operation Material

2000 0.70 $72,000 $12.000

2000 0.70 $108,000 $18,000

2000 0.70 $144.000 $24.0

$25

G23

2000 0.70 $180.000 $30,000

Waste Reduction Actions Taken

GSD has made major strides in waste reduction as part of its efforts to achieve ISO- 9000 certification. ISO-9000 certification indicates that GSD has a quality management and improvement program in place. This program has helped GSD reduce waste through process improvements. For example, GSD’s current parts rework rate is about 3 units per loo0 (0.3%), as compared with a reported rate several years ago of 3 units in 10 (30%). This program also ensures that each customer order is audited for quality, including checking specifications such as the mil thickness of the coating. This allows GSD to quickly identify and correct problems when they occur. In general, GSD keeps close watch on the amount of waste material it generates and where the waste material is generated.

~

GSD has taken several steps to reduce waste generation. Within the last three months, GSD has changed the methods by which they change colors. Rather than flushing the paint lines with MEK and disposing of waste MEK as hazardous waste, GSD now usually uses the new paint to flush the old paint out of the line. The old paint is collected and sent back to the manufacturer for reformulation into a black coating that it markets to drum reconditioners. While the impacts of this change on waste generation rates are not clear yet, it appears that liquid waste generation may be reduced by as much as 30 percent.

GSD has eliminated the use of all lead and most chrome-containing coatings. This has not actually reduced the volume of GSD’s hazardous waste stream yet, since waste liquid paints are still considered hazardous as F-listed and by the characteristic of ignitability. However, removal of heavy metals from coatings has reduced worker exposure and made it possible that certain waste paint-containing solid materials could be rendered non-hazardous. GSD reports that these new paints are substantially more expensive than the previous systems.

GSD is currently using a high-solids coating. They are interested in lower VOC content of coatings because in their current operation they are approaching the VOC emissions limit allowed in their air permit. GSD has looked at powder coatings and waterborne coatings. Powder coatings are likely not feasible at present, due to the frequency of color changes required and the fact that some drums involve a striped coating rather than a solid coat. GSD reports that they have not been able to find waterborne coatings that can meet the engineering specifications for their drums. Corrosion resistance is a particular problem. GSD also expressed concern that paint waste from waterborne coatings could not be as cheaply disposed of as that from VOC-based coatings since it has little BTU value.

GSD reports that it keeps good track of its materials in inventory and does not have a problem with material going “off-spec’’ while in storage.

624

GSD has tried to schedule color runs in blocks, where possible, but customer demands and variations in orders make this extremely difficult. GSD feels that, due to the highly competitive nature of its business, it has little ability to negotiate changes in order specifications with customers or charge mark-ups for unusual colors that generate more waste.

GSD reports that they have investigated the use of HVLP systems. GSD does not believe that HVLP would provide significantly improved transfer efficiency.

GSD has explored a number of altemative solvents and is very interested in finding a replacement for MEK. However, GSD has not yet found a satisfactory substitute for its current MEK applications.

Future Focus of Waste Reduction Efforts

At present GSD is most concemed with the hazardous solid waste that it generates. Although by volume this waste stream is only about half as large as the liquid hazardous waste stream, it is costing GSD almost four times as much to dispose of it. GSD is currently exploring whether paint filters can be sent through the drying ovens to cure the residual paint. GSD believes that the remaining material may then be a non-hazardous solid waste that could be landfilled.

GSD is interested in finding ways to reduce paint overspray, since this generates both waste paint and waste solid materials (e.g. filters, plastic and paper floor and booth covering). However, they are not aware of anything more that they can do in this area.

Waste Reduction Assistance Needs

GSD is very interested in waste reduction and is open to receiving information about waste reduction opportunities. GSD has indicated an interest in having the North Carolina Pollution Prevention Program conduct an on-site assessment for pollution prevention opportunities. GSD would also be interested in fact sheets, case studies and other pollution prevention information. Pollution prevention videos could also be of assistance, depending on the topic and the intended audience. Videos could be especially useful for providing information to line operators who generally do not have the time to read more in depth reports. Videos provide the added advantage that a group can watch them at the same time, thereby providing an opportunity for immediate follow-up discussion of information. GSD did not identify any specific topics that would be of most interest to them.

625

Site Visit Report VME Americas, Inc

Skyland, North Carolina November 18,1993

Overview

VME America manufactures heavy construction vehicles such as front-end loaders and articulated haulers. VME America's Skyland facility ("VME) fabricates and paints steel frames, buckets, wheel rims, dump bodies and other vehicle parts. VME assembles these parts and additional vehicle components imported from their parent company in Sweden to make the final product. Currently VME is producing about 130 units per month of various product mixes. VME employs about 200 workers, of which 8 work on the paint lines.

Vehicles must be coated to protect them against wear, weathering and corrosion as well as to satisfy customer requirements for vehicle appearance. Parts imported to VME come pre- painted. Consequently, parts fabricated at VME also are painted prior to assembly. Painted components are assembled into the final product, which then receives touch-up painting to repair any damage in the coating caused during vehicle assembly. About 50% of each vehicle is painted at VME.

VME's painting operations are carried out in the parts fabrication building and the vehicle assembly building. On the fabrication line, pieces fabricated at VME receive a complete primer coat and top coat. The size, shape and surface area varies by piece. Before the piece is painted, an overhead conveyor carries the piece through a steel shot blast booth for surface cleaning to remove rust and slag from torching. Air is blown over the piece to remove residual steel shot, after which the piece is transferred to the paint booth.

In the paint booth, a single painter manually applies a yellow primer coat to the piece and then set the piece aside for about 20 minutes to air dry. Once the surface of the primer coat dries sufficiently ("skins over"), either a flat grey or a yellow top coat is manually applied, after which the piece must air dry for an hour before it can be handled. The topcoat is allowed to air dry until the next day before the piece is assembled.

Painting operations on the assembly line are confmed primarily to touch up of the completed vehicles. Since vehicle parts are painted prior to assembly, the assembly process may scratch or otherwise damage the surface coating. In previous years touch-up painting was needed infrequently since VME fabricated all parts on-site and assembled vehicles prior to painting. Currently, however, VME imports a substantial number of pre-painted parts. Parts shipping and assembly cause scratches that must be touched-up. VME has made employees aware of the need to minimize damage to coatings and currently feels that the frequency of touch-up is acceptable.

During the paint touch-up process, the vehicle is first washed and then an orbital sander is used to clean and make smooth the areas requiring touch-up. Paper and plastic is wrapped around the painted portions of the vehicle to protect them from paint overspray. The vehicle

- .~

6 2 6

is driven into the booth and is then manually spray painted with the appropriate primer andor top coat. Following this the vehicle receives final paint touch up by hand as necessary, and the tires are wiped down with CitruSolv to remove any residual paint.

Painting operations at the fabrication booth are roughly constant and continuous throughout 2 shifts during the day. Painting operations at the assembly line booth are roughly constant throughout a single 10 to 12 hour shift during the day. The assembly line paint booth uses about 10,OOO gallons of coating per year, while the fabrication line booth uses about 1500 - 1600 gallons per year.

Coating and Other Raw Materials Information

VME uses a yellow oxide primer, a flat grey top coat and a yellow top coat in its operations. Coatings must meet a variety of specifications relating to appearance (e.g. color, gloss, sun fade), durability (e.g. hardness, weathering, salt spray and chemical resistivity) and ease of application.

The yellow oxide primer is a modified alkyd solvent-bome coating in a formulation that contains about 57% solids by weight. The solvent portion of the coating contains about 25% mineral spirits and 15% light aliphatic naphtha by total coating weight. According to the MSDS, the yellow oxide primer has a flash point of 78" F.

The yellow top coat is a modified alkyd solvent-bome enamel coating in a formulation that contains about 44% solids by weight. The coating is lead-free, and contains a mixed solvent carrier system composed primarily of toluene, propylene glycol mono methyl ether, butyl acetate, xylene, n-butyl alcohol and a petroleum distillate. According to the MSDS, the yellow top coat has a flash point of 40" F.

The flat grey top coat is a modified alkyd solvent-bome enamel coating in a formulation that contains about 46% solids by weight. The coating is lead-free, and contains a mixed solvent carrier system composed primarily of toluene, propylene glycol mono methyl ether, butyl acetate, xylene, and a petroleum distillate. According to the MSDS, the flat grey top coat has a flash point of 40" F.

VME purchases coatings in 55 gallon drums. Coatings are formulated ready-to-use, with thinners used to control the viscosity of the paint once the containers are opened. VME uses 2-butoxyethyl acetate ["Ektasolve EB Acetate"] and a xylendtoluene/Solvesso 150/monochlorotoluene solvent blend as thinners to control coating viscosity.

VME also uses CitruSolv as a paint cleaner for cleaning paint overspray from the vehicle tires. CitruSolv is primarily a citrus terpene cleaner that does not contain listed hazardous constituents. VME switched to CitruSolv to eliminate the use of Methyl Ethyl Ketone as a cleaner.

6 2 7

Inventory Controls

Prior to product use, VME stores paint and solvent outdoors in an uncovered area between the fabrication building and the assembly building. VME purchases coatings in 55 gallon drums. When coating is needed, the 55 gallon drum is moved to the spray booths and hooked directly to the paint lines, so that coating material is not transferred into other containers prior to use. VME tries to order materials on a "just-in-time'' basis so as to minimize product storage time and space. VME orders about 6 drums of material at a time. About 18 drums of coatings are used per month. During the site visit, VME had about 24 drums of the three coatings stored in the storage area. The drums are dated, and the facility uses material on a first-in, first-out basis. Coatings are used quickly enough that VME does not have a problem with material being stored in excess of shelf life. Occasionally temperature fluctuations and extremes cause coating material in storage to become unusable and VME must dispose of the material as hazardous waste. According to site personnel, this happens infrequently and the volume of material affected is minimized through inventory control procedures. Since VME currently uses solvent-borne coatings with low flash points, it cannot store coating containers indoors without appropriate safety systems. Currently, lack of available floor space to accommodate such systems prevents indoor storage of coatings.

Application Equipment and Booth Cleaning

Both spray areas use hand-held airless spray guns for coating application. The transfer efficiency for these guns and for the overall painting operation is not known. Each area has dedicated lines that run to 55 gallon paint containers for each coating. Paint in the drums is continuously stirred, 24 hours a day to keep the paint solids in suspension. The touch-up booth also uses an air atomizing spray gun with a paint pot for touch-up on small and hard to reach areas. This gun is used infrequently. After the touch-up area, small amounts of additional touch-up paint are applied manually either with paint brushes or with aerosol cans.

Booths contain banks of fiberglass air intake and paper exhaust filters which keep gross contaminants (e.g. dirt and bugs) out of the booth and keep paint solids in the booth. Brown paper maskant is taped down to the floor to catch paint overspray. In the touch-up booth, clear plastic sheeting is used to mask the light fixtures for faster and easier cleaning.

At the end of the day, the paint lines are cleaned with thinner, which is captured and used for subsequent paint thinning. Guns remain attached to the paint lines and are placed in a bucket of solvent for storage until operations begin the next day.

The frequency of booth cleaning is determined through either visual inspection of the air filters or pressure drop measurements across the filters. Depending on work load, booth clean-out happens at both booths about once per month. Since greater quantities of coating are applied at the fabrication line spray booth, this booth is cleaned more frequently than the assembly line booth. Booth cleaning involves changing out the filters, sweeping paint solids off the walls and floor of the booth, removing the floor and light maskant and applying new maskant. Booth clean-out takes about 4 hours.

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~

- _____

6 2 8

Maintenance usually cleans the booth, but the painting team sometimes cleans the booth and changes the filters themselves. The painting team also has the option of contracting out for booth cleaning services, but does not currently do this.

Operator Training

VME hires painters with prior experience in painting operations. VME does not consider operator training in paint application techniques to be a waste generation problem. All workers receive hazardous waste refresher training every year, and during this time course teachers emphasize the importance of waste reduction.

Paint Gun Maintenance

1990

1991

When painters feel that paint gun performance is failing, the gun is immediately replaced and painting continues. The old gun is sent to Maintenance for repair.

Hazardous Wastes

Liquids (gal) Solids (Ibs) Disposal Cost

453 1 1,650 $21,948

1126 10.720 $22.729

1993 (wgb

1) 1992 1 990 1 12,145 I $21,149 II 165 4,585 $9,961

629

re-test these wastes soon. If the new tests show that lead and chrome are below TCLP levels, VME will handle these as non-hazardous solid wastes in the future.

Hazardous waste liquids are generated from off-spec materials (exceeding shelf life), residual paint in drums, and waste cleaning solvent and thinner.

Non-hazardous solid waste from painting operations include empty paint and solvent drums, ~

waste maskant materials and spent aerosol cans of touch up paint. Currently a drum recycler picks up empty paint and solvent drums free of charge about twice every three years. Other non-hazardous solid wastes are compacted and sent to landfill.

VME currently monitors its VOC emissions in accordance with it’s air permit. In the future, VOC emissions will be affected by Clean Air Act regulations limiting the VOC content of paints and coatings. These regulations are scheduled for promulgation in 1995.

Economic Considerations

~

VME views waste management costs essentially in terms of the cost for disposal of drums of waste. Currently, the cost for disposal of hazardous waste solids is about $350 - $450/drum, while the cost for hazardous waste liquids is about $150/drum. In addition, VME pays a transportation fee of $500 for each load of waste. All hazardous waste is sent for off-site incineration or fuels blending. In spite of waste reduction efforts, overall waste disposal costs over the last 3 years have remained constant at about $21,000 - $22,0001year [see Table 11. The facility attributes this to the rapidly escalating costs of hazardous waste disposal.

Paint costs about $20 a gallon, while solvent costs $6 a gallon. Filter purchases total about $4600 in a typical year. VME was not able to supply information regarding other waste management costs such as regulatory oversight costs, liability costs, labor costs, etc.

Based on the waste generation information in Table 1, VME generates an average of about 11,500 pounds of solid hazardous waste per year. Based on the MSDS information, coatings are typically 50% solids, by weight, and weigh about 9.2 lbs per gallon. Assuming all waste paint solids are accounted for in the solids waste stream, and that all of the solid waste is paint solids, the that the transfer efficiency for coating application could be is:

100 x 11 - [11,500 lbs w a s t e p a i n t s o l i d s x x x 0 . 5 poundpaint s o l i d s 9.2 poundspaint 1

11,600 g a l l o n s g a i n t purchased 1 1 - 78 .46 transfer e f f i c i e n c y

Assuming a transfer efficiency of 80%, the cost of waste generation and disposal (i.e. including the cost of wasted raw materials such as wasted paint, solvents and filters), is roughly:

( $ 2 0 / g a l pa int1 (11,600 g a l s p a f n t u s e d / y r ) ( 0 . 2 0 g a l s m l n t w a s t e d / g a l used) +

$4600 f i l t e r s / y e a r + (,%/gal solvent) (1330 9alSlYr solvent1 + $ 2 1 . 9 4 2 / y r was te d i s p o s a l

= $ a 0 , 9 2 2 / y r

Using these assumptions, the raw materials cost for paint that does not get applied to the final product is about twice the cost of waste disposal. Another way of expressing the cost of imperfect paint transfer efficiency is that each 5% improvement in transfer efficiency translates into about a $11,600 savings in paint raw material and a $1400 savings in waste disposal charges.

Management Programs

Although VME does not have a separate pollution prevention program, VME has a Total Quality Management program that empowers workers to seek solutions to problems. As a result, environmental issues are seen to be everyone's concern and not just the concem of an environmental coordinator. In addition, waste disposal costs are assigned back to the individual paint booths and come out of the paint team budget. Awareness of these costs provides an incentive to the painting teams to look for waste reduction. For example, workers suggested the change to CitruSolv to eliminate the use of MEK, which generated a listed hazardous waste stream.

Prior Changes Leading to Waste Reduction

VME has made several changes to reduce hazardous waste generation, including product changes, process changes and management system modifications.

Paint formulations which VME uses are now free of lead and chrome. Prior to 1991, VME assembled a greater diversity of products lines and frequently customized the coatings used on these products to meet customer specifications. By reducing the number of product lines and eliminating customizing of product colors, VME is now able to use a single primer and only two top coats. This allows them to use dedicated paint lines for each coating, which saves time and reduces cleaning wastes that would otherwise be generated during coating changes. Eliminating custom color paint jobs has also eliminated some exotic paints with heavy metal hazardous constituents. Consequently, VME no longer uses lead or chrome-containing paints, which should lead to a substantial reduction or elimination of hazardous waste solids.

VME has switched from using Methyl Ethyl Ketone as a cleaning solvent to CitruSolv. CitruSolv is primarily a citrus terpene cleaner that does not contain listed hazardous constituents. The CitruSolv liquid has a flash point of 125" F, so that waste liquid CitruSolv is an ignitable hazardous waste (flash point less than 140" F). However, this solvent is generally used by applying it to a rag and using it for wipe cleaning. Used rags generally do not contain enough solvent to be an ignitable hazardous waste.

In 1992 VME changed their paint line cleaning practices so that they now re-use all solvent used for cleaning the paint lines as paint thinner. This has cut waste solvent generation by about 50%. In 1991, prior to adopting this practice, VME generated 819 gallons of waste

631

solvent (about 15 drums). By comparison, the generation of waste solvent during the first half of 1993 was only 165 gallons (three drums).

VME has changed their ordering of paint supplies to a "just-in-time" system that reduces the amount of paint stored on-site. This has reduced the amount of paint that has gone off-spec and become hazardous waste while in storage.

Next Steps

VME is looking seriously at new paint applicators such as electrostatic systems and High Volume, Low Pressure painting systems, and have considered paint heaters and powder coating. The cost of these modifications is a consideration. However, VME is currently reluctant to make any changes primarily because they expect Clean Air Act regulations to be promulgated in 1995 that will force a change in their current coating formulations. Rather than take a chance that a new coating application system might not be compatible with the new paint formulations, VME plans to wait until the new formulations become available before further exploring coating application systems. VME does maintain contact with two paint vendors to monitor new coating options that can reduce pollution and hazardous waste generation.

632

OMC - Burnsville Burnsville, NC Site Visit - November 29, 1993

Overview Facility machines parts and assembles parts into components for outboard motors ranging from 9.9 horsepower to 300 horsepower. Raw aluminum alloy castings come into the facility, as well as some partially assembled components. The raw castings receive a chrome conversion coating, which protects against corrosion and enhances top-coat paint adhesion. The partially assembled components may or may not already have a chrome conversion coating. Most parts are painted after machining and assembly, although some parts are painted prior to machining and assembly. The facility has numerous assembly lines. Parts/components that are to be painted are hung from hooks on an overhead conveyor and first go through an enclosed five-stage washing process consisting of 1) mild acid wash, 2) water rinse, 3) mild acid wash, 4)water rinse and 5 ) phosphoric acid "sealer." The phosphoric acid "sealer" provides the parts with an acid surface that enhances paint adhesion. After the fmal stage, residual water on the parts/components is blown/flashed off first with automated air blowing followed by manual air blowing. Air used for blowing off the water is heated to enhance water evaporation. The parts/components are then masked as needed with masking tape, and manually painted with an electrostatic spray gun. After painting the parts/components are passed through a drying oven. The maskant is removed and then the parts/components are prepared for shipping or sent to the appropriate assembly line for further assembly. Occasionally, touch up painting is needed and this is applied using aerosol cans of coating. Components from Bumsville facility are sent to Calhoun, Georgia for fmal assembly into marine outboard motors. See Attachment A for schematics of the facility and the assembly lines.

Production Rate Since OMC makes a mix of products at this facility, it is difficult to measure production levels. Generally production is measured in terms of units produced. The square footage that needs to be coated and the amount of paint that needs to be applied to various pieces is not known. However, according to OMC, production levels have been relatively constant over the last two years. The plant experiences several production shut-down periods throughout the year, which on average, equals 6 weeks a year.

Coatings Used The four primary types of paints/coatings used at OMC include a 2-component black epoxy, a grey acrylic paint, a green electrostatic primer, and a silicon black paint. OMC uses Methyl n-Amyl Ketone (MAK) to thin the paint as needed.

The grey acrylic paint and the silicon black paint are single component top coats.

The black epoxy used in the paint booth #1 is a 2-part, high solids, solvent-bome coating. The 2-p& coating consists of a "paint" component and a "catalyst" component which are

6 3 3

mixed together in the appropriate ratio (4 parts paint to 1 part catalyst) to make the coating. If the coating is mixed with too much paint and too little catalyst, the coating may not set properly, leaving a tacky coating on the piece. In the past, OMC used a chrome-containing coating due to its excellent durability and corrosion prevention. They have changed over to a chrome-free formulation due to the hazardous waste issues associated with chromium.

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Paint Booth #1 The size of the main paint booth is approximately 18' x 12' x 8'. The main paint booth is used continuously throughout the day shift, with a break before lunch, a lunch break, and a break after lunch. The coating is usually a black 2-part epoxy, high-solids, solventbome coating that is applied manually with an electrostatic air atomized spray gun. OMC estimates the transfer efficiency of their electrostatic spray guns to be about 75%. Occasionally a grey acrylic paint is used, but this is less than 2% of the time. For the application of the grey paint, a small pressure pot (- 2.5 gallons) system, complete with paint lines and air-atomized electrostatic spray gun, is used. Thus, OMC avoids color mixing in the paint lines and guns by having a separate application system for the black and grey paint. In the past, the two components of the coating or "working paint" (paint and catalyst) were mixed on a continuous basis using automated measuring equipment. However, the system did not meter the two components consistently and accurately, and this led to poor coating of the parts that required part rework. Recently the facility has changed to a batch system in which approximately 5-10 gallons of coating are mixed in a pressure pot which then feeds the gun. An agitator located in the pressure pot prevents the high-solids paint from settling during painting operations. Each batch mixed is sufficient for about 4 hours of operation (the booth uses about 16 - 20 gallons per day). Hand mixing has thus far provided much greater control of the mixture than the automated process, and OMC is happy with it.

From the perspective of the painter, parts are conveyed across the booth from right to left. Ducts supply air to the booth evenly through a bank of filters across the wall behind the painter. Air is drawn from the booth through a bank of filter material that covers the wall in front of the painter. Filter material for the air exhausted from the booth comes in large rolls from which appropriately sized sheets are cut and hung in the booth, approximately four panels across. The filters cover an area about 8' high and 15' wide. from several layers of fire retardant paper material and a layer of man-made fiber. The floor of the booth is covered with a fire-retardant paper, and the walls of the booth are coated with a "peel-coat.'' Parts are painted at a rate of anywhere from 4 parts per minute to 1 part every 2 minutes, depending on the part. After painting, the parts are transported by the overhead conveyer to a drying oven where the paint is cured for 45 minutes to 1 hour at 175" - 200" F.

Hands-on training in the technique of electrostatic painting is conducted by an operator who has been OMC since the start of the painting operations.

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The fiters are made

Paint Booth #2

50% of the time. This booth is used for certain parts that receive a green primer coat (which

-

The paint booth #2 is approximately the same size as paint booth #1 however, it is used only .~

GYI

is a 4 part primer:l part electrostatic activator) followed by a single component black silicone topcoat. In this booth parts are hung on racks and given the primer coat using a manually operated &-atomizing gun with a paint pot. After all pieces are primer coated, they are set aside for about 15 minutes to allow the primer to dry. During this time the paint gun and lines are cleaned out and the system is set for applying the black topcoat. The parts are then brought back in and the topcoat is applied. After application of the topcoat, the paint is cured ovemight at 525" F in a baking oven. Air filters in this booth are similar to the main booth.

Cleaning Paint booth filters in the main booth are changed every day. This is done not so much because of loss of performance, but rather because if the paint is allowed to set in the filters, the filters become too stiff to put into 55 gallon drums for disposal. The paper cover on the floor is also changed daily. Guns are cleaned prior to breaks (momhg, lunch and afiemoon) and guns are cleaned and lines purged at the end of the day. OMC uses Methyl Ethyl Ketone (MEK) as a cleaning solvent. Any residual paint in the pot at the end of the day is mixed back into the paint component of the two-part system. According to the facility, the amount of catalyst added to the drum of paint is small enough that this does not create any problems. Peel coating on the wall is removed and reapplied about once every 6 months.

Paint booth filters in the other paint booth are changed on average every 2-3 weeks, rather than daily because the paint used in this booth does not set up in the filter. The spray gun and paint lines are cleaned between the primer and the topcoat, and again after application of the topcoat.

Guns require servicing about once per month. While the gun is serviced, a replacement is used. Guns are about 3 years old.

Inventory Coatings are purchased in 55 gallon drums. Coatings are purchased about once per month, and about 16 drums of paint and 4 drums of catalyst are used every 6 weeks. Paint is usually not in inventory for longer than 2-3 months. Since the shelf life of the paint is about 6 months, material only rarely becomes off-spec. Off-spec paint is more a concem with the grey paint since it is used infrequently.

Wastes Generated solids Paint-contaminated materials have been the primary waste solids stream. In the past, OMC used a chrome-containing coating which rendered the paint-containing solids a hazardous waste. These were sent off-site for fuels blending. Now, however, OMC uses a chrome-free coating. However, the paint-contaminated solids are still being sent for fuels blending because the company does not want to landfill the waste material. Paint booth air filters comprise a major portion of the facility's solid, hazardous waste stream. In the main booth, the filters are changed daily, whereas in the other paint booth they are changed approximately evely 2-3 weeks. Floor paper is also changed daily in the main booth. Approximately twice a year the booth is cleaned more thoroughly, including removal and re-application of the peel- coating. In 1992, OMC generated about 64,000 pounds of hazardous waste solids, or about

6 3 5

250 drums of waste.

OMC also has a wastewater treatment plant to treat the wastewater from the chrome conversion process. This plant removes the chrome VI from the water, but generates a metal hydroxide fiitercake which must be stabilized and then disposed of in a solid waste landfidl. Currently OMC generates 50 tons per year of this material.

Liquids The primary liquid waste material comes from gun and paint line cleaning. OMC uses MEK for cleaning due to its excellent solvent properties. Several years ago, OMC had tried distilling and reusing the cleaning solvent, but the distillation did not produce a clean-enough solvent and the recycled material caused numerous problems. About two years ago, OMC tried to reduce the amount of MEK used to clean the guns and paint lines, by experimenting with a MEK/alcohol mixture. This mixture did not provide adequate cleaning of the lines and was not implemented. Currently, OMC generates about 440 gallons - or about 8-10 drums - of liquid hazardous waste per year. Since MAK is used solely for paint thinning, OMC has little or no waste MAK.

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Green Primer

Black Topcoat

Economic Information for Raw Materials

27.5 gal. per year $25/gallon - $690

27.5 gal. per year $40.56 - $1.120

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11 Raw Material 1 Usage

Black 2-part Epoxy - Paint

- Catalyst

~ I Cost per unit I Cost per year

- 16 55-gal. drum per 6 weeks - 4 55-gal. drum per 6 weeks

1 55-gal. drum per 2-3 weeks

1 - $890

- $25/gallon

- $25/gallon

I - 2 55-gal. d” per

- $169,000

- $42,000

I1 Filter Material 1 10 rolls per week 1 $25.68/roll 1 - $11.800

Economic Information for Waste Disposal

Solid Wastes (to include spent fiiters, floor paper, and Dee1 coat)

Waste Disposal Waste per year

(spent MEK) drumsbear

250 55-gal. drums/year

Transportation charge

waste water treatment)

and Roll-off Bin Rental for Filtercake

Filtercake (from

Transportation

$55-$235155-gal. - $1,200 drum (depending on solvent content)

258 55-gal. $33/55-gal drum - $8,500 drumslyear (average)

50 tonslyear - $15,000

- $7,500

$295/55-gal. drum - $74,000

Waste Minimiiation Implemented/Planned Most waste reduction work is being driven by economics (potential cost savings).

The facility looked first at reducing MEK solvent usage as much as possible. As mentioned before, OMC tried to reduce the amount of MEK used to clean the guns and paint lines, by experimenting with a MEKIalcohol mixture. However, this mixture did not provide adequate cleaning of the lines and was not implemented. Also, OMC tried distilling and reusing the cleaning solvent, but the distillation did not produce a clean-enough solvent and the recycled material caused a lot of problems. In the past, OMC has looked into other cleaning solvents but has not found one equal to the cleaning capabilities of MEK.

OMC next looked at the heavy metals content in paints. They changed to non-chrome containing paint about one years ago. Facility doesn’t have the ability to unilaterally change the production process or the choice of coatings, because these are determined through engineering specs from the parent company engineering group (i.e. water-based coatings do not currently meet engineering specifications). However, Bumsville facility took it upon themselves to test out the chrome-free altemative and demonstrate that it could meet the engineering specs. Gave information to engineering group, and engineering changed the specification. In addition to less hazardous properties, the non-chrome epoxy has a low

6 3 7

viscosity which allows a lower volume of paint to be sprayed from the air-atomized, electrostatic spray gun. OMC believes that the switch in paint formulations has led to a reduction in the volume of paint used. Numbers documenting this reduction have not been calculated by OMC at the time of our site visit. The epoxy paint is also a high-solids coating, so VOC releases are reduced.

Facility recently changed from automated paint mixing system to a manual batch system to eliminate reworking required when paints were not properly proportioned.

Facility has a TQM-type of approach and they encourage employee input as to solutions to environmental problems. Employees are aware of the waste generation problems - especially the ones who pack the drums. OMC parent company has provided a model pollution prevention plan to the facility titled, Toxic Substance and Hazardous Waste Reduction Plan. This plan contains the OMC hierarchy for waste minimization (similar to EPA’s), the corporations commitment to waste reduction, and suggested each facility form a Toxic Reduction Team of employees to look at waste reduction options. While the facility is in the process of developing this plan, a Toxic Reduction Team will not be formed at this time.

OMC looked at various types of application equipment when they made the change to electrostatics about 4 years ago. HVLP, airless and air-assisted airless did not work well with their high solids coatings. Powder coatings did not look feasible because of the highly irregular contours and deep recesses in the pieces which require coating. This is not a problem for the electrostatic system. Although the electrostatic system does not provide entirely uniform coating coverage, the coating performance is sufficient.

Facility is trying to reduce chemical use and to use different chemicals in the wastewater treatment plant. Overall, they want to reduce the weight of the filter cake that they send off- site for disposal.

OMC is now looking at waste volume, especially from paint filter waste. They are exploring possibility of using metal fiiters in place of paper filters, in fact, a prototype metal filter is being designed at the facility. Currently, the company has a bum-off oven to remove paint from the hangers that hold the pieces on the conveyor hooks during painting. If metal filters can be developed that can do the job, facility could reuse them by buming off the paint in the filter in the bum-off oven. Recently the bum-off oven has not been working at 100% capacity, which is needed in order to bum-off all the waste paint collected in the metal filter. The OMC process engineer hopes to switch to a working metal filter system within one year.

Information Needed How do other facilities set up their spray booths? How is air filtered and what is the set up of their air filters? Does anyone else use metal

What do other people do in looking at water curtain vs. dry filters?

Want infomation comparing various approaches that does NOT come from vendors (that

filters or other types of reusable filters? Is anyone else developing them?

information tends to be slanted).

Wants information on electrocoating operations (not the technology, but the actual use). E.g., design of racks and ways to orient parts to reduce air pockets and get full coverage; how to make the racks relatively universal so that they can handle a broad range of parts shapes and sizes. Vendors have not had much helpful information on this, so they haven’t looked too much further at electrocoatings.

Note: In the past, NCPPP performed a waste minimization audit for the OMC-Bumsville facility. An OMC representative felt that while the report was thorough, the amount of infomation presented was too overwhelming. OMC environmental personnel believed the audit would be more useful if the facility had prioritized its waste streams and had NCPPP focus their audit on a few of the higher priority waste streams and processes. OMC representatives felt the most effective way for NCPPP to disseminate info would be a bounded report with a presentation.

6 3 9

Attachment A

MAINTENANCE

DOCUMENTATION B U R N S V I L L L

G 4 1

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PAINT DEPARTMENT WASHER

1 1

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SANITARY DISCHARC-

PROCESS FLOW SCHEM Notes: 1. All flow rates are gallons OMC BURNSVILLE

& CITY WATER

SUPPLY per day (gpd). MARCH 2, 1990 2 . E (Evaporation) equals

%nn f-A\ fnr Plant.

I IECEIVIYO

I

I I

MACMINIYO OC UYRWI.H.0

PARTS

ClWUlED VCMDOI PART X b ASSCYBLV

LINES

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LUSI CARTS TO CUYT DEPT. W A S M E I S

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T I W A N T FLOOll 1CRUSSER

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c I OMC EURNSVILLE PRODUCTION FLOW DIAGRAM

6 4 3

Caterpillar Clayton, NC Site visit - December 7. 1993

Overview

headquarters for the Building, Construction and Production (BCP) Division of Caterpillar. The facility assembles and paints industrial tractors. The tractor parts are manufactured and coated with a primer at other Caterpillar facilities and then transported to the Clayton facility for final assembly and painting. sizes. The styles include a wheel loader, an integrated tool carrier, and a wheel -backhoe loader. All the tractors, regardess of size or style, are sent through the same sequential painting operation. A floor conveyer system moves the tractors through seven stages or booths at a speed of approximately thirty minutes per booth. The seven stage paint process includes: at 180" F, 4) a masking booth, 5) a paint spray booth, 6) a flash booth at ambient temperature, and 7) a dry-off oven operating at 180" F. See Attachment A for a schematic diagram of the paint operation

The environmental engineer for Caterpillar stressed that waste minimization was a key consideration in designing this plant. Caterpillar's philosophy is that it i s more cost effective to plan waste minimization strategies during the initial construction of the facility, than to come back later, after the facility is in place, and install waste minimization technology.

Production The Clayton facility, still in its start-up mode, has current production levels at 50%

capacity. Caterpillar anticipates reaching full-scale production by the end of 1994. For 1993, there were two painting shifts that produced, on average, 15 units per day (a token second shift currently produces 6 units). By the end of 1994, Caterpillar hopes to be producing near 30 units per day from two full-scale painting shifts.

Paint Kitchen

catalyst, and cleaning solvent (note: as production increases paint and catalyst will eventually be stored in 300 gallon totes). There is an agitator in each drum that helps guarantee a consistent product being sent to the paint booth. Also, the spent solvent/paint produced from the routine cleaning of the paint lines, is stored in 55-gallon drums in the "paint kitchen". When a %-gallon drum of spent solvent/paint is full, it is shipped off-site for fuels blending.

Paint The paint used at this Caterpillar facility is a two component, isocyanate catalyzed,

polyurethane paint. This paint is classified as a low VOC paint (3.4 lbs of solvent per gallon). The "working paint" is a 1 : l mixture of the low VOC paint and the isocyanate catalyst. The development of this paint was a joint effort between the paint vendor and Caterpillar engineers. This paint was developed to be corrosion resistant, quick-drying and produce a gloss-like finish that is more typical of a car than an industrial tractor. Greater

This facility, three years old, is one of two plants designated as the world wide

~

Three primary tractor styles are produced in a variety of

1) a vacuum-sanding area, 2 ) an aqueous wash booth, 3) a dry-off oven operating

The "paint kitchen" is an enclosed area that houses all the %-gallon drums of paint,

- ~

than 95% of the tractors are painted yellow. Any special color orders are done with separate pressure pots and paint lines

the mixed paint sit in the lines for more than 45 minutes because of quality demands. Because of this quality demand, Caterpillar must clean the lines between shifts (changes in shifts typically take one hour).

Under current production, 40 to 50 gallons of working paint are used per day. By the end of 1994, the environmental engineer anticipates Caterpillar using near 100 gallons of working paint.

Paint Operation

stages, each requiring a half-hour holding time for each tractor. The following section includes a discussion of each stage, in the order that a tractor would pass through. Vacuum-sanding area. Before loading the tractors onto the floor conveyor, each tractor is hand-sanded to eliminate any metal barbs and provide a textured surface to promote better paint adhesion. The sander is attached to a vacuum that collects the paint-contaminated dust, which is drummed and sent off-site as non-hazardous waste to fuels blending. Wash booth. In this booth, the assembled tractors are sprayed with a water-based cleaner by employees using hand-held wands. The aqueous wash removes any residual dust on the tractors surface. The aqueous cleaner-overspray and spent aqueous cleaner is collected and sent to an on-site waste water treatment system Dry-off oven. The dry-off oven operates at a maximum of 180" F. Mask booth. Before the actual painting, the tractors are masked using tape and five large, plastic bags to cover each wheel and the driver's cab. These bags are removed after painting and disposed of as non-hazardous waste. Paint booth. The paint booth is approximately 25' x 40' x 25' and has a water wash "pit" designed to capture the paint overspray. Air is drawn from the paint booth's ceiling through a steel-grated floor to a water curtain or "pit" below. A deflocculant is added to the "pit" water to keep the paint solids in suspension. Eventually, the water/paint overspray is run through a centrifuge to separate the paint solids from the water. The paint solids are shipped off-site for fuels blending and the separated water is sent to the waste water treatment system and then recycled back into the water "pit". To compensate for water loss due to evaporation during a shift, 1,000 gallons of water per day are added to the water pit during the summer months and 350 gallons of water per day during the winter months. At full production, the Clayton plant will have to dump the entire 13,000 gallons of water in the water "pit" twice a year to a P O W .

The paint booth typically contains three employees using air-assisted airless spray guns to apply the paint under electrostatic conditions to the tractors. estimated the transfer efficiency of these guns under the best of circumstances to be 70 -75%. The same Caterpillar representative felt that the air-assisted airless sprays guns achieve a better transfer efficiency than a HVLP gun system would. used by each employee, are hooked-up to the same painting unit. The "working paint" is supplied to each of the guns by an automated paint mixing system ("Precision Mix" by Graco). This system not only supplies the appropriate paint/catalyst mixture to the spray guns but also continuously recirculates the premixed paint from the paint booth to the drums

The working paint has a shelf life of about 2 hours, however Caterpillar does not let

As mentioned before the entire paint operation can be divided into seven sequential

The environmental engineer

The individual hand spray guns

6 4 5

WASTE TYPE

sanded uaint dust hon-haz)

II paint solids from centrifuge 26 - $200-$500 depending on II BTU value

# of 55-gallon drums per Disposal Cost

17 not mecified

year (per 55-gal. drum)

1) spent solvent/paint mixture 1 28 I - $300 I1

Pollution Prevention

minimization concepts even before the actual construction of the Clayton facility. Caterpillar utilizes a participatory management style, with worker teams being used extensively to solve issues associated with production and waste minimization. No pollution prevention activities are planned for the future, however caterpillar intends to keep its "eyes open" for new technologies and altematives that would increase waste minimization at the plant. The following discussion includes some of the pollution prevention avenues that the Clayton facility has already pursued.

Many solvent and painting systems were investigated during the initial start-up phases of the facility. Caterpillar looked into powder painting systems, however several drawbacks to using powder paint discouraged its implementation. First of all, powder painting does not lend itself well for application to massive amounts of steel. Secondly, these tractors contain volitile liquids such as fuel, oil, and hydraulic fluid, that limit the temperature of the paint curing process. Thus, powder paint, typically requiring a high cure temperature, is not feasible under the current production process.

weakest solvent that adequately cleans the paint lines. The engineers at Caterpillar tried Citri- Solve (a non-solvent based cleaner), but it was not strong enough to purge the urethanes from the paint lines.

Distilling the spent solvent at the Caterpillar site is considered not economically feasible due to the small amounts of spent solvent generated and depending on its composition, the solvent/paint/catalyst mixture often hardens to a solid.

At Caterpillar there was a major emphasis toward pollution prevention or waqte

Based on their extensive testing of various strength solvents, Caterpillar is using the

note: The Caterpillar environmental engineer felt that the State of North Carolina and EPA should be more accommodating to facilities acting in "good faith" to reduce hazardous waste generation. For example, the Clayton facility would like to switch from the current 3.4 lb VOC/gallon paint to a 2.7 lb VOC/gallon paint. However, current regulations prevent this. The 2.7 lb VOC/gallon paint being considered, has the slightly more of the regulated branch- chain solvent as the 3.4 lb VOC/gallon paint, however the amount of other solvents is reduced. For example, the 3.4 lb VOC/gallon paint may contain 0.4 lb/gallon of the regulated solvent and 3 lb/gallon of other solvents. The altemative paint may contain 0.6 lb/gallon of the regulated solvent, while reducing the other solvents to 2.1 lb/gallon. Because the amount of the regulated solvent (as a percentage of the overall solvents used) increases when total solvents are reduced in the altemative paint, EPA currently prohibits the use of the 2.7 lb VOC/gallon paint. The facility is frustrated by this since it feels that it is acting in "good fai th in attempting to utilize a new paint that will reduce the amount of solvent used. The State could be helpful if it would move to get regulations changed to allow this type of good- will effort towards reducing environmental pollution. (Note: the regulated solvent concentration in the paint cannot be reduced and still retain satisfactory paint performance.)

Attachment A

G-48

Facility A Hendersonville, NC Site Visit - December 14, 1993

~

Overview This facility manufactures large, high-powered lights for streets, stadiums, and other

special applications. The light housings that are composed of the aluminum dye-cast metal are painted at this facility. Prior to painting, all light housings are passed through a 4-stage cleaning system. After cleaning, the housing are painted by one of three painting processes at the facility. Ninety percent of the parts are painted using an electrostatic coating system, while the rest of the housing parts are painted in either a manual paint spray booth or in an automated powder spray booth. After the parts have been adequately dried and cured, they are ready for assembly and then shipped to the customer.

Facility A in Hendersonville, NC is an extremely large manufacturing plant. In addition to manufacturing light systems, Facility A also makes the actual casting molds for the light housings, utilizes various coating operation for copper wire circuitry and reflective light surfaces, and remelts and recycles aluminum scrap. Paint-related wastes comprise a small amount of the facility’s overall waste production and thus are not the main focal point for the facility’s waste minimization efforts. Currently, the facility is targeting the air emissions generated from the aluminum smelter for waste minimizatin..

Production

paint usage has remained relatively constant for 1992 and 1993. For 1992, 12,700 gallons of grey E-coat paint and 2,800 gallons of bronze E-coat paint was used. Currently, there are two painting shifts for the electrocoating and the powder systems and one painting shift for the air spray booth. These paint schedules are predicted to remain the same for the next couple of years.

~

Overall production at the plant has increased approximately 10% in 1993, however

Cleaning Process Once the light housings have been casted, they are dropped out of their molds and into

a water bath. The parts are then removed from the water bath and attached to an over conveyor/hanger system. The overhead conveyor transports the parts through an automatic wash process that includes 2 soap washes and two water rinses. All the wastewater from this unit goes to the on-site wastewater treatment system. After cleaning, the parts are sent to one of three painting processes.

Electrostatic Coating As mentioned previously, 90% of the painted light housings and fixtures are

electrostatically coated. The E-coat system has been in place for approximately ten years and was initially chosen for its cost-effectiveness. The E-coating process involves two primary colors, bronze and grey, each of which have their own separate dip tank. A white E-coat dip tank was disassembled and removed about ten years ago because of changing consumer

air are forced through the tank to prevent the paint solids from settling. The paint is a water-

- demand. The dip tanks measure approximately 8’ x 30’ x 4’ and have continuous streams of -~

soluble, glycolether based (10% glycol ether) paint that is delivered to the facility by bulk tankers. Facility A typically receives two to three 5,000-gallon shipments of this paint per year. The paint is kept in 15,000 gallon storage tanks that are housed in a separate concrete- lined building. The holding tanks then pump the paint to 100-gallon day tanks, which feed the dip tanks. Using a series of laboratory quality control (QC) tests, the solid composition and the conductivity of the paint in the day tank is continuously monitored. As determined by the QC tests, pure glycol ether may be added as a thinner to the paint to help keep the paint solids in suspension. To keep the appropriate solid level in the E-coat dip tank, an amine solubilizer is added as needed. Approximately 1-2 drums of the amine solubilizer is used per year.

The light housings and fixtures, which are attached to a hanger on the overhead conveyor, are dipped in the electrostatic paint tank, followed by a dip in a cleaning soap tank. This section of the overhead conveyor is in the shape of a "w", with the E-coat dip tank and the cleaning tank placed at the valleys of the conveyor chain. Before the parts are lowered into the paint dip tank, an electrostatic charge is "put on" the substrate by an power source located overhead. The electrostatic charge on the substrate allows for greater paint adhesion. Still on the conveyor, the parts are lifted out of the dip tank so that any excess paint drips back into the dip tank. Then onto the cleaning tank, where the parts are dipped into deionized water and then sent to a 350" F bake oven for 35 minutes.

process, any liquid paint in the tank is transferred to a temporary storage tank. Once the settled paint sludge and any parts that may have fallen off the overhead conveyor, are cleared out of the E-coat dip tank, the temporarily stored paint is pumped back in. The paint sludge amounts to less than one 55-gallon drum per year and is sent to an off-site disposal company which solidifies the sludge before landfilling.

Spray Paint Booth

than grey or bronze. twelve color varieties, is a low gloss enamel (glycol ether - based, 30% solids). percent of the parts to be sprayed in this booth, have been previously dipped in the electrocoating paint. While E-coating specifies a 1 mil thickness, the air-assisted airless spray gun applies an additional layer 2 mils of paint to the parts. The spray gun operates at a very low pressure approximately 20 psi as estimated by the paint operator. The same operator roughly estimated the transfer efficiency of these guns to be around 20%.

back wall to collect paint overspray. The filters, normally changed twice a week, are disposed of as non-hazardous waste. The paint is supplied to the spray gun by pressure pots, which vary in size depending on the size of the job to be painted. The same gun and pressure pots are used interchangeably for up to five colors per day. When changing colors, leftover paint in the line is sprayed into a waste drum and the line is flushed with Methyl Ethyl Ketone (MEK). MEK and rags are then used to wipe out the pressure pots and clean the spray gun tips. Regardless of the color changes, the gun tips are also cleaned at the end of the day. The MEK-laden rags are sent off-site to a special dry cleaning company that launders the rags and returns them to the plant. For 1992 and 1993, approximately 6-8 55- gallon drums of MEK are used for cleaning purposes at this spray booth.

The E-coat dip tanks need to be cleaned out once a year. During this clean-out

There is one air spray booth where aluminum dye-cast parts are painted colors other The paint, which is bought in one-gallon buckets and approximately

Ninety

The three-sided booth is approximately 6' x 10' x 8' with fiber air filters against the

6 5 1

This air spray booth has been in place for about twenty-five years and to the environmental engineers knowledge, the company has not looked into other altemative spray methods such as HVLP.

Powder Paint Booth The powder booth is an enclosed system consisting of the eight automated spray guns,

anti-static plastic wrap that covers the sides, and a vacuum system located at the booth's base to collect the overspray. Seventy percent of the powder painting occurs on aluminum dye- cast parts that have already been dipped with electrostatic paint. The remaining thirty percent of the powder painting occurs on steel substrates such as brackets and widgets. These parts enter the powder spray booth on an overhead conveyor and are painted under electrostatic conditions by eight automatic spray guns. After the substrates are powder coated, they are sent through a 450" F bake oven for 22 minutes.

Currently, there are five different color powder paints used. It is anticipated that the number of powder colors will eventually increase. The tumover time for changing colors in the powder booth is about 30 minutes and involves purging the spray guns with air, switching powder source to the spray guns, air-blowing the paint down off the walls of the booth, and rolling new anti-static plastic to cover the walls. The paint overspray captured by the vacuum system is sent to an on-site cyclone centrifuge where the "heavy" paint will be separated and reused. Approximately twenty percent of the captured powder overspray is too light and cannot be reused. This light powder is disposed of as non-hazardous in a county landfitl.

number of units or units that have grooved parts which may be difficult for the automated powder system to adequately paint.

Waste Generated

hazardous waste as follows: 65% spent MEK, 30% paint waste from the air spray booth, and 5% quality control samples from the E-coating day tanks. Approximately 6-8 55-gallon drums of spent MEWpaint waste was disposed of in 1992 at a cost of $200 per drum.

Pollution Prevention

emissions from their aluminum smelter, has used minimal effort to pursue pollution prevention alternatives for the painting operations. Even though the painting waste streams are a low priority at this site, the facility is in the process of looking into lower VOC paints for their E-coating and air spray processes. The facility also plans to eventually eliminate the air spray booth or change the booth to a powder paint system.

- note: This facility would like more information on other paint operations, specifically dealing with the time frame and costs associated with switching to a new painting system. The facility environmental engineer is also interested in the benefits of switching over to a particular painting system; he is interested in reasons, other than compliance-motivated, for switching paint systems.

~

Two manual powder spray guns can be brought into the powder booth to spray a small

The environmental engineer estimated the composition of the facility's paint-related

The facility, which has focused its waste minimization efforts towards to VOC

-

6 5 2

Appendix H

Waste Reduction Bibliography

H - 1

This bibliography identifies reference materials maintained in the RTI Pollution Prevention Program reference repository on waste reduction options for painting wastes. each reference, the bibliography identifies the subject of the reference and reference type (e.g., fact sheet, joumal article). The following defines the subjects and reference types that appear in the bibliography.

For

SUBJECTS

Pollution Prevention Assessment - These are documents that give either descriptions of a number of pollution prevention approaches or involve an actual site-specific identification of pollution prevention opportunities. This catgories is sub-divided as "general" when the information covered all painting and coating, "facility specific" when the information was for a specific facility, and "industry specific" when the information pertained to an industry (e.g. Automobile Refinishing).

Application Technologies - These are documents that tend to have information on specific coating application technologies, such as HVLP, electrostatics, powder coating, etc.

Booths - These are documents that have information on spray coating booths or booth ancillaries such as filters, peel coatings, etc.

Coatings - These documents have information about various types of coatings (e.g. lowho- VOC, waterbome, powder, uv-cured etc.)

Stripping and Surface Preparation - These documents have information about either surface stripping techniques (e.g. abrasive media blasting) or surface preparation techniques (e.g. phosphatizing).

Substrate - These documents have information about coating a particular type of substrate (e.g. wood, metal, plastic).

Management Systems - These documents have information about management-related topics such as inventory control, worker training, maintenance, etc.

Cleaning - These documents have information about some aspect of cleaning of the spray equipment, such as the guns, booths, lines, etc. They may also be documents that have information about solvents used for cleaning (e.g. alternatives to VOC-based solvents, solvent recycling technologies, etc.)

H - 2

REFERENCE TYPES

Introductoty Materials/Primer/Guide - This type of document is usually an introduction or overview of a particular subject area.

Literature/Industty Survey - This type of document involves summarized information based on a review of literature or a survey of industry practices.

Case Study - This type of document summarizes information about the effects of making specific pollution prevention changes at a specific facility.

Producflechnology Description - This type of document describes specific pollution prevention technologies or techniques.

Productflechnology Comparison - This type of document compares different technologies used in a similar application.

Reference/Handbook - This type of document gives detailed information about a specific topic.

Policy Piece - This type of document gives the point of view of the author as it relates to environmental policy.

Fact Sheet - This type of document is short -- general 1-6 pages -- and provides a summary of information on a specific topic in an easy to reference format.

Report - This type of document is an in depth analysis of a particular topic.

Journal Article - This is a document that originally appeared in a journal.

Presentation Overheads/Conference Paper - This is a document that is either a copy of slides or overheads used at a conference to present a paper on a particular topic, or is a copy of the paper that accompanied the presentation, or both.

Vendor/Product List - This is a documents that lists names of specific products of a particular type (e.g. aqueous solvents) or vendors for a particular type of product.

Research Brief - This is a brief summary (usually less than 6 pages) of information gathered through a specific research project or activity.

H - 3

BIBLIOGRAPHY

1. Wolf, Katy; Yazdani, Azita; Yates, Pamela "Chlorinated Solvents: Will the Alternatives be Safer?" August, 1991 Journal of the Air and Waste Management Association

Institute for Research and Technical Assistance

Subject:

(Vol. 41, No. 8 )

1055-1061

Cleaning Organic Solvents

Stripping and Surface Preparation Stripping

Chemical Strippers Type:

Policy Piece ProductlTechnology Comparison Journal Article

2. Center for Aerosol Technology "Organic Solvent Cleaning Alternatives: Status of Research and Development" October, 1992 Research Triangle Institute (for EPA) 46 pages Subject:

Cleaning Organic Solvents Water-basedAqueous Solvents Non-solvent Techniques

Stripping Stripping and Surface Preparation

Chemical Strippers Abrasive Media Other

Type: Literaturefindustry Survey ProductiTechnology Description ProductlTechnology Comparison Report

H - 4

3. UNEP "1991 UNEP Solvents, Coatings, and Adhesives Technical Options Report; Peer Review Draft" September, 1991 UNEP 328 pages (plus appendices) Subject:

Cleaning Organic Solvents Water-based/Aqueous Solvents

High Solids Waterbome Powder

Coatings

Type: Literaturehdustry Survey Report

4 EPA "Comuilation of Sueciation of National Emissions Factors for ConsumedCommercial Solvent Use" April, 1989 EPA 88 pages (plus appendices) Subject:

Coatings Physical/Chemical Properties Description

Type: ReferenceMandbook

5. Source Reduction Research Partnership "Source Reduction and Recycling of Halogenated Solvents in Parts Cleaning" 1992 Jacobs Engineering 82 pages Subject:

Cleaning Organic Solvents Water-basedAqueous Solvents Solvent ReuselRecycle Non-Solvent Techniques

Type: Literaturehdustry Survey Report

.

H - 5

6. Source Reduction Research Partnership "Source Reduction and Recycling of Halogenated Solvents in Paint Stripping" I992 Jacobs Engineering 82 pages Subject:


Abrasive Media Chemical Strippers

Other Stripper Recycle/Reuse

Booths Peel Coatings

Management Systems Inventory Control

Literature/Industry Survey Report

Type:

I . Bob Carter "Solvents: The Alternatives" April, 1993 Waste Reduction Resource Center for the Southeast 21 pages Subject:

Cleaning Organic Solvents Water-based Solvents Non-Solvent Techniques

Type: VendorProduct List

8. Unknown "Solvent Cleaning Options" April, 1993 Unknown 44 pages Subject:

C 1 e ani n g Organic Solvents Water-based Solvents Non-Solvent Techniques

Type:

H - 6

Presentation Overheads/Conference Paper

9. Kirsch, F William; Looby, Gwen P.; Kirk, Merritt C. "Case Studies: How Four Manufacturers Improved Painting Operations to Reduce Waste" Autumn, 1993 Pollution Prevention Review Vol. 3, No. 4 429-436 Industrial Technology and Energy Management 8 pages Subject:

Coatings Powder Coatings

Pollution Prevention Assessment Facility Specific

Substrate Plastic Metal

Type: Journal Article Case Study

10

"Using a Material Safety Data Sheet (MSDS) to Evaluate Your Company's Waste" MnTAP October, 1986 4 pages Subject:

Type:

___

Management Systems

Fact Sheet

11.

"Paints, Inks and Other Organic Residuals" MnTAP October, 1986 2 pages Subject:

_ _ _

Pollution Prevention Assessment General

Type: Fact Sheet

H - 7

Pagel, Paul "Increasing Transfer Efficiency through Part Placement, Spray Adjustment and Overspray Reuse" MnTAP April, 1993 2 pages Subject:


Substrate Wood

Type: Fact Sheet Case Study

13

"Waste Reduction Altematives for Spray Painting and Coating" MnTAP 1993 6 pages Subject:

.__


Type: Fact Sheet

14.

"Spray Nozzle Selection Reduces Solvent Waste Volume When Cleaning Paint Straining Equipment" MnTAP June, 1991 3 pages Subject:

Type:

.._

Cleaning

Fact Sheet Case Study

15.

"Soak Step Reduces Solvent Waste from Cleaning Paint Straining Equipment" MnTAP June, 1991 3 pages Subject:

_ _ _

Cleaning

H - 8

Type: Fact Sheet Case Study

16. Pagel, Paul "Water-Based Substitutes for Wood Finishing Lacquers" MnTAP December, 1991 2 pages Subject:

Coatings

Substrate Waterbome

Wood Type:


17.

"Waste Reduction and Recycling Tips for Empty Containers" MnTAP October, 1991 2 pages Subject:

Type:

._.

Other

Fact Sheet

18.

"Selecting a Still for On-Site Recycling" MnTAP May, 1991 3 pages Subject:

_ _ _

Cleaning Solvent Reuse/Recycle

Type: Fact Sheet

H - 9

19

"Auto Body Repair: Hazardous Waste Management and Reduction" MnTAP August, 1991 2 pages Subject:

_ _ _

Pollution Prevention Assessment Industry Specific

Substrate Metal

Cleaning Solvent Reuse/Recycle Gun FlushingEquipment Cleaning

Type: Fact Sheet

20.

"Manufacturers of Aqueous Cleaning Equipment" MnTAP April, 1992 3 pages Subject:

_ _ _

C 1 e ani n g Water-basedAqueous Solvents

Type: VendorProduct List

21

"Aqueous and Semi-Aqueous Cleaners for Metal Parts Degreasing" MnTAP August, 1993 2 pages Subject:

_ _ _

Cleaning

Substrate Water-basedAqueous Solvents

Metal

VendorProduct List Type:

H - 10

22.

"Brushing Unit Replaces Sodium Hydroxide for Paint Stripping in Drum Reconditioning Operation" February, 1993 3 pages Subject:

_ _ _


Abrasive Media Substrate

Metal Type:


23. Davis, Darryl "Marine Maintenance and Repair: Waste Reduction and Safety Manual" 1989 NCP3 89 pages Subject:


Substrate Metal

Coatings Stripping and Surface Preparation Cleaning

HandbooWPrimer ReferenceMandbook Report

Type:

24.

"Small Solvent Recovery Systems" NCP3 March, 1987 4 pages Subject:

...

Cleaning Solvent ReuselRecycle

Type: Fact Sheet

H - 11

25,

"Overview of Coating Technologies" NCP3 June, 1993 9 pages Subject:

_ _ _

Coatings

Application Technologies AdvantagesDisadvantages

AdvantagesDisadvantages Type:

Fact Sheet

26.

"Pollution Prevention Case Studies" NCP3 September, 1993 96 pages Subject:

...


Substrate Wood Metal

HVLP Electrocoating

Application Technologies

Type: Case Study Report

21. Kirsch, F. William and Looby, Gwen P. "Waste Minimization Assessment for a Metal Parts Coating Plant" for EPA July 1991 4 pages Subject:


Substrate Metal

Type: Research Brief

H - 12

28. Kirsch, F. William and Looby, Gwen P. "Waste Minimization Assessment for a Manufacturer of Outdoor Illuminated Signs" for EPA July 1991 5 pages Subject:


Substrate Metal


29. Kirsch, F. William and Looby, Gwen P. "Waste Minimization Assessment for a Manufacturer of Rebuilt Railway Cars and Components" for EPA July 1991 4 pages Subject:


Substrate Metal


30. Kirsch, F. William and Looby, Gwen P. "Waste Minimization Assessment for a Manufacturer of Brazed Aluminum Oil Coolers" for EPA July 1991 4 pages Subject:


Substrate Metal


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31. Kirsch, F. William and Looby, Gwen P. "Waste Minimization Assessment for a Manufacturer of Heating, Ventilating and Air Conditioning Equipment" for EPA July 1991 4 pages Subject:


Substrate Metal


32.

"Wast Minimization Opportunity Assessment: Scott Air Force Base" for EPA December, 1991 4 pages Subject:

_ _ _




Substrate

Abrasive Media

Electrostatic

Metal Type:

Research Brief Case Study

33. Kirsch, F. William and Looby, Gwen P. "Waste Minimization Assessment for a Manufacturer of Aluminum Extrusions" for EPA April, 1992 4 pages Subject:


Substrate Metal

Type:

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Research Brief

34. Kirsch, F. William and Looby, Gwen P. "Waste Minimization Assessment for a Manufacturer of Can-Manufacturing Equipment" for EPA April, 1992 3 pages Subject:


Substrate Metal


35. Looby, Gwen P. and Kirsch, F. William "Waste Minimization Assessment for an Aluminum Extrusions Manufacturer " for EPA April, 1992 5 pages Subject:


Substrate Metal


36. Kirsch, F. William and Looby, Gwen P. "Waste Minimization Assessment for a Manufacturer of Permanent-Magnet DC Electric Motors" for EPA April, 1992 5 pages Subject:


Substrate Metal


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31. Kirsch, F. William and Looby, Gwen P. "Waste Minimization Assessment for a Manufacturer of Motor Vehicle Exterior Mirrors" for EPA May, 1992 3 pages Subject:


Substrate Metal


38. Looby, Gwen P. and Kirsch, F. William "Waste Minimization Assessment for a Manufacturer of Sheet Metal Cabinets and Precision Metal Parts" for EPA May, 1992 4 pages Subject:


Substrate Metal


39. Looby, Gwen P. and Kirsch, F. William "Waste Minimization Assessment for a 1 for EPA June, 1992 4 pages Subject:


Substrate Metal


ni cturer of Components for itomobile Air Conditioners"

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40. Kirsch, F. William and Looby, Gwen P. "Waste Minimization Assessment for a Manufacturer of Military Fumiture" for EPA June, 1992 4 pages Subject:


Substrate Metal


41. Fleischman, Marvin; Hensen, Clay; Looby, Gwen P.; and Kirsch, F. William "Waste Minimization Assessment for a Manufacturer of Injection Molded Car and Truck Mirrors" for EPA September, 1992 4 pages Subject:


Substrate Plastic

Research Brief Type:

42. Jendrucko, Richard J. and Miller, Phylissa S . "Waste Minimization Assessment for a Manufacturer of Custom Molded Plastic Products" for EPA September, 1992 4 pages Subject:


Substrate Plastic

Research Brief Type:

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43. Edwards, Hany W.; Kostrzewa, Michael F.; and Looby, Gwen P. "Waste Minimization Assessment for a Manufacturer of Sheet Metal Components" for EPA September, 1992 4 pages Subject:


Substrate Metal


44. Gashlin, Kevin and Watts, Daniel J.. "Waste Minimization Activities and Options for a Fabricator and Finisher of Steel Computer Cabinets" for EPA October, 1992 4 pages Subject:


Substrate Metal


45.

"Guides to Pollution Prevention: The Automotive Refinishing Industry" EPA October, 1991 41 pages Subject:

_ _ _


Substrate Metal

Type: Introductory Materials/Primer/Guide

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46. Reisch, Mark S . "Paints and Coatings"

Chemical & Engineering News October 18, 1993 19 pages Subject:

Type:

_ _ _

Coatings

Joumal Article ProductlTechnology Description Literatureandustry Survey

47.

"Controlling Pollution from the Manufacturing and Coating of Metal Products" EPA May, 1977 96 pages Subject:

_ _ _

Application Technologies Coatings

Introductory Materials/Primer/Guide Type:

48. Randall, Paul M. "Pollution Prevention Methods in the Surface Coating Industry" EPA Joumal of Hazardous Materials Vol. 29, 1992 21 pages Subject:

Pollution Prevention Assessment

Application Technologies Coatings

Literaturenndustry Survey ProductlTechnoIogy Description Joumal Article

General

Type:

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49. Washbum, Claudia A. "Pollution Prevention for the Paint Industry: The Basics" Illinois Hazardous Waste Research and Information Center May 16, 1991 48 pages Subject:


Type: Presentation Overheads/Conference Paper

50

"Powder Coatings Technology Update" EPA October, 1989 78 pages Subject:

.__

Type:

Coatings Powder

Advantages/Disadvantages Application Equipment costs

Product/Technology Description Producflechnology Comparison Report VendorsProduct List

.

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51.

"In Living Color: Painting Challenges for the '90's" University of Tennessee Center for Industrial Services October 8, 1991 169 pages Subject:

_ _ _

Application Technologies HVLP Electrostatic Powder Coating

Coatings Powder Coating

Stripping and Surface Preparation Surface Preparation

Cleaning Line Flushing Gun FlushingEquipment Cleaning

Management Systems Training

Type: Presentation Overheads/Conference Paper Introductory Materials/Primer/Guide Product/Technology Description Product/Technology Comparison Case Study Journal Article

52.

"Recycling Program Delivers Finishing Savings"

Furniture Design and Manufacturing March, 1993 2 pages Subject:

_ _ _ _ _ _

Coatings Recycling

Type: Joumal Article

H - 21

53

"Guides to Pollution Prevention: The Marine Maintenance and Repair Industry" EPA October, 1991 63 pages Subject:

_ _ _


Substrate Metal


Chemical Strippers Abrasive Media

Type: Introductory MaterialdPrimedGuide

54.

"Draft: Pollution Prevention Options in Wood Furniture Manufacturing: A Bibliographic Report" for EPA September 9, 1991 20 pages Subject:

_ _ _


Substrate Wood

Type: Literaturehdustry Survey

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55.

"Solvent Waste Reduction and Recycling: Practical Advice for Small Businesses" Iowa Waste Reduction Center 1992 56 pages (plus appendices) Subject:

_ _ _

Application Technologies Air Atomized (conventional) Air-Assisted Airless Electrostatic

Powder Coating Coatings

Advantages Stripping and Surface Preparation

Stripping Abrasive Media

Management Systems Cleaning

Water-basedlAqueous Solvents Solvent Reuse/Recycle

Type: Introductory Materials/Primer/Guide

56. Brown, Larry W. "Benefits and Challenges of Powder Coating Aerospace Hardware" Hughes Missile Systems Company May, 1993 Subject:



Powder Coating Type:

Presentation OverheadsKonference Paper

57. Caldwell, Mary-Jo "Lower-VOC Coating System Conversion Costs for the Wood Furniture Industry" Midwest Research Institute May, 1993 Subject:

Coatings LowlNo-VOC

Economics Substrate

H - 23

Wood Type:


58. Ellicks, David F. . ~~

"Evaluation of the Environmental, Economic, and Materials Effects of Using Thermoplastic Powder Coatings/Application Process" ~

Department of the Air Force May, 1993 Subject:

~

Application Technologies Powder Coatings

Advantages/Disadvantages

Powder Coating Coatings


59. Grafflin, David M. "UV-Resistant Powder Coating Technology" Evodex Powder Coatings May, 1993 Subject:


Type: Presentation OverheadsKonference Paper

60. Grulich, Madeline M. "Evaluation of Transfer Efficiency" Pacific Northwest Pollution Prevention Research Center May, 1993 Subject:

Application Technologies Coatings Substrate

Wood Type:


61. Holder, Albert "Powder Coating" Naval Surface Warfare Center

H - 24

May, 1993 Subject:



62. Huang, Eddy W.; Watkins, Larry; and McCrillis, Robert C. "Development of Ultra-Low VOC Wood Fumiture Coatings" Center for Emissions Research and Analysis (for EPA) May, 1993 Subject:

Coatings

Substrate Low/No-VOC

Wood Type:


63. Jacobs, Patricia B. and McClurg, David C. "Water-Reducible Polyurethane Coatings for Aerospace Applications" Miles, Inc. May, 1993 Subject:

Coatings LowINo-VOC Waterbome


64. Jaffari, Mark "Advances in Specific Industrial Coating Technologies for the Aerospace Industry" Malek, Inc. May, 1993 Subject:

Coatings Waterbome


65. Keipert, Steven J. and Kinzer, Kevin E. "Low-VOC Dual Cure Aerospace Topcoat"

H - 25

3M Company May, 1993 Subject:

Coatings UVEB Cured


66. Laird, Edwin C. "Low-VOC Coatings for Plastics" Coatings Resource Corporation May, 1993 Subject:

Coatings Waterborne UVEB Cured

Plastic Substrate


61. Leland, T.D. and Wong, C.M. "Low-VOC Organic Coatings for Commercial Aircraft Application" Boeing Commercial Airplane Group May, 1993 Subject:

Coatings High Solids Low/No-VOC Waterborne Powder Electrocoating


68. Marwick, William "Waterborne Lacquers for Aluminum Foil" Alcan International, Ltd. May, 1993 Subject:

Coatings

Substrate Waterborne

Metal

H - 26


69. Maurer, David W. "Spred 2000: 'The Clean Air Choice"' The Glidden Company May, 1993 Subject:

Coatings Low/No-voc


70. Miller, Wayne and Morrison, Tom "The UNICARB' System for Spray Coatings" Union Carbide Corporation May, 1993 Subject:


Coatings Supercritical Fluid

Low/No-VOC Type:


I I .

Riffe, William J. "Two Surprises from an Inorganic Zinc Coating System" Marine Environmental Research, Inc. May, 1993 Subject:

Coatings Inorganic

Type: Presentation OverheadslConference Paper

72. Ryder, Peter C. and Hope, Peter "New Environmentally Acceptable Metal Coating Systems" Hawking International, Ltd. May, 1993 Subject:

Coatings

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Electrocoating Type:


13. Sfirri, Michael "Long-Term Corrosion Protection With Zero-VOC, High-Ratio Zinc Silicate" Inorganic Coatings, Inc. May, 1993 Subject:

Coatings

Substrate Inorganic

Metal Type:


14. Stanley, Christine L. and Foscante, Raymond E. "Inorganic Chemistry as an Option for Formulating High Solids, Low- and Zero-VOC Architectural, and Industrial Maintenance Coatings" Ameron May, 1993 Subject:

Coatings

Substrate Inorganic

Concrete Metal

Type: Presentation OverheadslConference Paper

15. Stowe, Richard "Radiation Curing Technology: Ultraviolet and Electron Beam Processing" Fusion UV Curing Systems May, 1993 Subject:

Coatings

Substrate UV/EB Cured

Wood Metal Paper Plastic


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16. Zozulin, Alex J. and Bartak, Duane E. "A New Inorganic Coating for Magnesium Alloys with Superior Corrosion Resistance" Technology Applications Group, Inc. May, 1993 Subject

Coatings Inorganic

Presentation OverheaddConference Paper Type:

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