Toxics Use Reduction Case Studies
Brownell Boat Stands, Inc. 1999.
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| In an effort to reduce emissions of volatile organic compounds (VOC) from its coating operations, Brownell Boat Stands, Incorporated switched from low-percent solids paint thinned with toluene to high-solids coatings that could be thinned with acetone, a non-VOC. Brownell also enlarged its manufacturing facility to allow product inventory to be stored inside, and installed an automatic dip coating machine to handle a portion of the company’s production line. Thanks to these changes, the company has been able to reduce VOC emissions by half while steadily increasing production. Download PDF file (12.80 kB) |
Brittany Dyeing and Printing. 1999.
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| With assistance from a $425,000 grant from the U.S. Department of Energy's NICE3 program, Brittany Dyeing and Printing Corporation implemented a new technology for finishing fabric that is more efficient, cost effective, and generates less waste than traditional methods. The project was completed in December 1998, and is expected to provide the following benefits: reduce energy consumption by over 60% per unit weight of fabric; reduce air emissions by over 60%; increase production capability by over 100% through higher production speeds; reduce wastewater discharge almost 80%; and cut water use by over 65%. The company estimates that the new process will reduce annual operating costs (primarily energy, water and wastewater costs) by approximately $150,000, a 36% savings. Download PDF file (177.95 kB) |
Hampden Papers, Inc. 1998.
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| Hampden Papers, Inc. reduced emissions of volatile organic compounds (VOC) by 97% by using new aqueous-based acrylics and other coating systems developed by a Massachusetts coatings manufacturer. The reduction of VOC has resulted in lower compliance costs, savings on insurance premiums, and a safer work environment. The avoidance of expenditures on VOC controls has helped Hampden to afford investments in high-quality production equipment. Download PDF file (21.75 kB) |
Demonstration of Printwise: a "near-zero" lithographic ink and blanket wash system. 1997.
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| TURI Technical Report No. 39. This report presents the results of a demonstration of the Printwise lithographic ink and water-based presswash printing system, designed to reduce emissions of Volatile Organic Compounds (VOCs) to near-zero levels. The Printwise system employs vegetable oil-based ink containing a "solubility conversion mechanism" that reacts with the presswash to become water-soluble. Its use could allow printers to reduce or eliminate their major source of VOC emissions: conventional petroleum-based presswash. Download PDF file (5.74 MB) |
Poly-Plating, Inc. 1997.
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| Poly-Plating designed and installed integral repurification equipment which filters, recycles and concentrates wastes for reclamation. This equipment reduced acid purchases to 1%of 1989 levels. Reclaiming and recycling has cut disposal costs by 98%. Additionally, water use has been reduced to 880 gallons per day, down from 78,000 gallons per day. Download PDF file (329.14 kB) |
Lightolier. 1997.
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| Lightolier has eliminated the use of approximately 1.25 million pounds of Trichloroethylene at their Fall River, Massachusetts plant. The company found less toxic alternatives and modified their production process, which eliminated more than 4 million pounds of air emissions, with savings of more than $2 million. Download PDF file (2.10 MB) |
Korber Hats. 1997.
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| Korber Hats of Fall River, Massachusetts, a maker of custom straw and felt hats, has reduced emissions of volatile organic compounds (VOCs) by 80,000 pounds, 44,000 pounds of which was eliminated through process changes and chemical reformulation. The company, which was using 52,000 pounds of toluene and 17,200 pounds of methyl ethyl ketone in 1994, permanently eliminated the use of these hazardous air pollutants in 1995. Korber has successfully substituted a water-based stiffening process in its straw hat dipping operation. Once the company and its vendor reformulated a stiffener to a waterbased acrylic lacquer, Korber was able to eliminate the use of a solvent thinner which consisted of 30% methyl ethyl ketone and 60% toluene. Korber worked with its supplier to analyze existing coatings and create a new formulation, which would replace the solvent coating. The company has since successfully switched to an entirely water-based process with some process changes and minimal capital investment. After adjustments are made for production levels, this project has saved Korber a minimum of $36,000 annually in reduced chemical purchases and permitting costs. Download PDF file (25.43 kB) |
Crest Foam. 1997.
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| Crest Foam of Newburyport, Massachusetts recently embarked on an ambitious program to eliminate the use of volatile organic compounds (VOCs) in the firm's polyurethane foam process. The company eliminated the use of 190,000 lbs./year of methylene chloride by installing an innovative foam manufacturing process called the "Cardio Process". The Cardio Process uses CO2 instead of methylene chloride or CFC-11 as the auxiliary blowing agent. By making this change, Crest Foam avoided the need to install costly air pollution control equipment or reduce its production of foam products, either of which would have threatened the long-term survival of the facility. Download PDF file (23.35 kB) |
Acushnet Rubber Company. 1997.
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| Located in New Bedford, Massachusetts, Acushnet was the first company in Massachusetts to obtain certification in ISO 14001, an international standard for environmental management. The company was also the first in the world to become certified in ISO 14001, ISO 9001 (a standard for quality programs), and the American automotive industry's QS-9000 quality standards. The company was able to move quickly to achieve ISO 14001 certification by taking advantage of the work previously done in completing a toxics use reduction (TUR) plan. Download PDF file (30.98 kB) |
Cupric Chloride Etch Regeneration. 1997
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| TURI Technical Report No. 45. Tri-Star Technologies, located in Methuen, Massachusetts, has one of the world's largest facilities offering in-house printed circuit board design, fabrication and assembly, from prototype through production volumes. Their state-of-the-art, 120,000 square foot facility provides a "one-stop shop" for a full range of on-site services and expertise, providing the customer with the advantage needed in today's competitive marketplace. In its continuous efforts to implement toxics use reduction (TUR) and pollution prevention, Tri-Star Technologies evaluated, adopted and installed an electrolytic regeneration technology to reduce the amount of spent cupric chloride etchant generated. By making electrolytic regeneration an integral part of the process, Tri-Star is able to reuse the etchant and sell the recovered copper. This technology replaces the chemical regeneration system previously used, while reducing costs, worker exposure to hazardous materials, and environmental impact. TriStar has achieved many prior successes with TUR, including an 86%reduction in volatile organic compounds through the addition of a double-sided solder mask screening unit, a reduction in sulfuric acid use on the auto pattern plate line, and the elimination of bath contamination on the copper deposition line. Download PDF file (402.63 kB) |
Cleaning urethane, ink and paint manufacturing vessels. 1997.
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| In 1995, Raffi and Swanson, Inc. received a $20,000 grant from the Massachusetts Toxics Use Reduction Institute (TURI) to examine alternatives to toxic solvents in the company’s cleaning operations. Raffi and Swanson set a project goal of reducing chemical use and byproducts from these cleaning operations by 50%. Raffi and Swanson met this goal, reducing chemical use and emissions by roughly 50% (roughly 46,000 lb.) and chemical byproducts 50% (roughly 200,000 lb.). These reductions were achieved through the implementation of over thirty worker-identified changes to cleaning practices. These changes included redesigning equipment and procedures to eliminate the need for solvent cleaning, methods to increase solvent reuse, and more careful management of solvent distribution and application throughout the site. These changes have saved Raffi and Swanson approximately $18,000/yr. During the course of the project, Raffi and Swanson worked closely with the TURI Surface Cleaning Lab to evaluate alternatives to N-methyl pyrrolidone in the company’s urethane reactor vessel cleaning operation. The Surface Cleaning Lab evaluated seven aqueous cleaners and four semi-aqueous cleaners as replacements for N-methyl pyrrolidone. Two semi-aqueous cleaners were the most promising substitutes but the inability to recycle the cleaners makes them cost-prohibitive. Download PDF file (1.34 MB) |
Kidde-Fenwal. 1996.
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| By updating its coating operations with 1990s technologies including computer-programmed spray applications and ultraviolet (UV) curing, Kidde-Fenwal Incorporated reduced its air emissions by 75%, eliminated 20 drums per year of flammable waste, and reduced its production cycle by an entire day. The new system, which also reduced the amount of coating used per printed circuit board by 96%, is expected to save the company $300,000 annually, providing a payback on its investment in less than one year. Download PDF file (127.43 kB) |
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