Toxics Use Reduction Case Studies
Parker Hannifin Corporation, Nichols Aircraft Division. 1995.
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| By purchasing aqueous deaning equipment based on cleaning needs at various stages of their process, Parker Hannifin was able to replace two vapor degreasers with five remote cleaning stations with a total project payback period of approximately one year. Download PDF file (598.14 kB) |
Export Case: Lead Free Electronics Industry. 2006
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| Work over the last several years to develop lead-free solder alloys has identified numerous technical challenges. Because no "drop-in" lead-solder replacement has been found, lead-free requires a change in design of whole products. Industry has been actively working on developing alternatives, with many industry consortia sharing R and D resources. In 1997 one of the largest consortia conducted a study of 80 lead-free solder alternatives, recommending 3 alloys for further study. However the rapid time frame of EU legislation, combined with technical difficulties, concerns that new solders will become future regulatory targets, and difficulty agreeing on either a lead-free solder or a standard definition of "lead free", have made for a difficult transition with many companies scrambling to meet EU guidelines. Download PDF file (124.51 kB) |
Import Case: Formaldehyde in Construction. 2006.
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| Formaldehyde was discovered in 1867. It is a widely used basic building block chemical that is now in a plethora of products and processes including adhesives, hard surface building materials, insulation, floor finish, and composites. In 2003, 4 million metric tons (MMT) of 37% Formaldehyde was used in the US and 24 MMT was used worldwide. Formaldehyde-free products have slowly become more available. Initially imported from specialty manufacturers to meet niche consumer demand by chemical sensitive individuals and green-motivated builders, such products are increasingly developed by domestic and larger companies as demand increases. The U.S. Green Building Council (USGBC), founded in 1993, publicly launched the Leadership in Energy and Environment (LEED) certification in 2000. In 1997 the American Institute of Architects (AIA) Energy committee expanded to become the Committee on the Environment. Many other green building groups have emerged. LEED in particular has advanced green building, creating "bragging rights" for green firms and owners. Green-building cost premium estimates have reduced from +20% to +2-5% in up front cost (that pays for itself) . This change is attributed to greater availability of green technology and building materials. Download PDF file (337.70 kB) |
Local Case: Perchloroethylene in Dry Cleaning. 2006.
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| Perc was introduced as a drycleaning solvent in the late 1930s. It first replaced other synthetic solvents, and then gradually replaced petroleum derived solvents until it became the dominant solvent in the early 1960s. Perc was effective, reusable, noncorrosive, inexpensive, nonflammable and less toxic than existing alternatives. After regulation in 1993, a number of alternatives began to be developed (petroleum or hydrocarbon, carbon dioxide, silicone based, and "wet" cleaning). However, adoption of these alternatives is slow. Perc is still used by over 70 % of drycleaners nationally. With better practices and equipment, the amount of Perc the industry consumes has declined dramatically. Download PDF file (172.59 kB) |
Learning from the Solutia EMS Experience. 2005.
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| TURI Methods and Policy Report No. 24. The Solutia, Inc. Indian Orchard Plant in Springfield, Massachusetts (Solutia IO) is currently improving an existing environmental management system (EMS) and certifying it to the ISO 14001 standard, primarily because its customers are demanding it. Solutia is a leader in developing chemical application solutions for its customers, including manufacturing laminated safety glass, performance films, pharmaceutical chemicals, water treatment chemicals, heat transfer fluids, aviation hydraulic fluids, and nylon products. In the fall of 2004, Solutia IO received a grant from the Massachusetts Toxics Use Reduction Institute (TURI) to host a series of meetings for a work group of peers -- lead staff from other Massachusetts companies working on EMS projects. Download PDF file (478.07 kB) |
Surface Cleaning Laboratory Case Study #3: A.W. Chesterton Company, Inc., Groveland, MA. 1995.
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| Agitated aqueous cleaning combined with manual scrubbing proved successful for cleaning stainless steel and cast iron parts contaminated with epoxy resinsand curing agents. Tests were performed to determine an acceptable replacement for a methanol, xylene and methyl ethyl ketone (MEK) cleaning operation. Potential operator exposure to solvents will be eliminated and waste disposal problems reduced when the hazardous solvents are substituted with an aqueous cleaning process. The company estimates a significant cost savings over solvent cleaning. Download PDF file (95.57 kB) |
Surface Cleaning Laboratory Case Study #2: Wyman-Gordon Company, Inc., North Grafton MA. 1995.
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| Aqueous ultrasonic cleaning of ionizing aluminum exhaust scrubber plates was successfully implemented at the Wyman-Gordon Company replacing a potassium hydroxide and glycol ether soaking operation. The company performs metal-working of ferrous and nonferrous alloys producing high strength alloy forgings for the aerospace and other industries.An in-depth investigation at the Surface Cleaning Laboratory of the Toxics Use Reduction Institute was conducted to assess the proper chemistries for removing airborne contaminants from the aluminum plates. Download PDF file (114.84 kB) |
Surface Cleaning Laboratory Case Study #1: Market Forge, Everett MA. 1995.
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| The project consists of technical, total cost, and substitution analyses of alternatives to chlorinated solvents for vapor degreasing. The technical analysis of alkaline aqueous degreasing was performed in TURI's Surface Cleaning Lab. Located in Everett, MA, Market Forge manufactures cooking steamers. Download PDF file (100.66 kB) |
Substitution Case Study: Alternatives to Solvent-based Paints. 1993.
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| TURI Technical Report No. 4. A Massachusetts producer of specialized metal tool cabinets has successfully switched from solvent-based to water-based paints in their coating operations. The painting process involves coating the metal drawers with a primer coat, and then spray painting the cabinets and drawer fronts with the color coat. Originally the components were spray-painted with solvent-based (xylene) paints for both the primer and color coats. In August 1981, the company switched over to a water-based first coat for the metal drawers, which is applied by electrodeposition in a fully automated process line. After the paint is applied, the drawer is low temperature baked at 25Q-2750f' and conveyed to the spray booths for color coating. Although the reasons for implementing the electrodeposition tank were based on the fact that the process provided a better finish and increased production capacity, use of the electrodeposition tank also eliminated the waste produced from the spray paint application of the primer coat. The entire cost for the electrodeposition system was about $500,000 and included purchase and installation of the baking oven, the 2500 gallon tank and the control system. Download PDF file (1.26 MB) |
TUR Case Study Summary Spreadsheet
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| A summary of toxics use reduction case studies from the TURA Program. Includes year of study, sector, chemicals, and TUR techniques. Download file (53.00 kB) |
Brooks Instrument, LLC. Lead-free Electronics Implementation. 2008.
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| TURI Technical Report No. 59. During 2007 and 2008, the Institute worked with representatives from Benchmark Electronics, Brooks Instrument, and Emerson Process Management to conduct and document a lead-free electronics implementation for a high reliability electronics product that is exempt from the European RoHS Directive. The research information provided by the New England Lead-free Consortium, as well as the information contained in this case study, is of high value to companies that need to transition to lead-free electronics for their high reliability products. The Institute's university research program continues to fund research efforts to reduce the use of toxic chemicals in the electronics industry. Download PDF file (5.56 MB) |
Improved Lead-Free Wire and Cable Insulation Performance Using Nanocomposites. 2006
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| TURI Technical Report No. 58. The goal of this project is the production of high-performance, low-cost lead-free PVC compounds for wire and cable insulation, to address the serious environmental issues surrounding the use of their leaded counterparts and the lack of market acceptance of current alternatives to PVC. Clay nanocomposite technology has been chosen as a means to achieve this goal, as it has been demonstrated that such systems can improve a variety of properties relevant to the performance of wire and cable insulation (thermal stability, barrier properties, flame retardance, etc.). Here we report on the characterization of transparent, lead-free PVC nanocomposites produced by melt blending with organoclay loadings of 2, 5, and 10 wt%. Structural studies carried out via x-ray diffraction indicate significant intercalation as well as orientation of the clay sheets in the flow direction. From MOCON testing, nanocomposites with 2 wt% clay showed a five-fold increase in oxygen barrier. While a substantial improvement in thermal stability was not observed in TGA experiments, the greatly improved oxygen barrier properties may nevertheless enhance thermal stability in real-world settings. From mechanical properties testing, the modulus of the PVC/nanocomposite was found to increase with clay content; nevertheless, 2 wt% was found to be the optimal loading level due to the degradation of ultimate properties with higher clay content. Download PDF file (579.60 kB) |
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