Toxics Use Reduction Case Studies / TURI Publications / Library / About / TURI - TURI

Toxics Use Reduction Case Studies

Garment Wet Cleaning, Utopia Cleaners. 1996.

TURI Technical Report No. 35. Perchloroethylene, or PCE, is the cleaning agent used by over 80% of U.S. dry cleaners. More than 30,000 dry cleaning machines nationwide used 270 million pounds of PCE in 1991, two thirds of which was lost to the atmosphere. Though emission control technologies have helped to reduce the volume of PCE that is lost, large amounts of PCE are still used by the dry cleaning industry. In recent years studies have identified ecological and human health hazards associated with PCE usage, prompting users and consumers to seek alternative processes. One garment cleaning alternative that has emerged uses water and biodegradable detergents to remove soils. Utopia Cleaners of Arlington, Massachusetts has purchased a DaeWoo wet cleaning machine which replaced its PCE dry cleaning machine, making Utopia a PCE-free garment cleaning facility. Download PDF file (120.82 kB)

Electron Beam Curing of Polymers in Coating Processes, Metallized Products Inc. 1996.

TURI Technical Report No. 34. Metallized Products, Inc. (MPI) chose Electron Beam (EB) curing over more traditional coating/curing methods, a choice which has allowed them to develop new, unique products and to have a lower impact on the environment than if they had chosen a solvent-based system. The coatings used in EB curing are solvent free and do not require thermal drying, allowing the process to run at very high speeds. EB curing also allows MPI to avoid the regulatory reporting and permitting requirements associated with solvent- and aqueous-based coating processes. Though capital costs of these systems are high, the production time, space, and energy requirements are low, making EB an economically attractive coating method. Download PDF file (200.40 kB)

Fit-to-Print. 1996.

Fit To Print Advertising Inc. found many benefits when it converted from conventional printing processes using solvent-based inks to ultraviolet (UV) cured inks. The UV process is now used in 80% of the company's production and, as a result, Fit To Print has increased productivity, opened new markets, reduced labor-intensive cleaning processes, and achieved compliance with wastewater regulations. The company's managers say the switch to mostly UV inks resulted in a 60% reduction in the amount of solvents used in their production processes, and a 20% increase in business. Annual savings to date have amounted to nearly $25,000 and available production time has increased by 33%. Fit To Print managers directly credit the switch to UV curing with their ability to win a large contract with a leading U.S. retailer, creating the need to hire five additional staff. Download PDF file (233.07 kB)

Parker Hannifin Corporation, Nichols Aircraft Division. 1995.

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)

Surface Cleaning Laboratory Case Study #3: A.W. Chesterton Company, Inc., Groveland, MA. 1995.

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.

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.

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)

Cranston Print Works. 1995.

Spurred by a desire to meet the goals of the Massachusetts Toxics Use Reduction Act, the managers of Cranston Print Works altered their wastewater pH adjustment process to eliminate the use of sulfuric acid. The company installed a jet aeration system with injected liquid carbon dioxide to replace the two 4,300-gallon sumps in which wastewater neutralization had previously taken place. This $115,000 project eliminated the annual use of 2.66 million pounds of sulfuric acid. Although financial profit was not the main goal of the project, the company saved about $80,000 per year in chemical purchase and maintenance costs. Download PDF file (23.29 kB)

Closed Loop Aqueous Cleaning. 1995.

TURI Technical Report No. 29. This report serves as an introductory guide to closed loop aqueous cleaning for metal parts and electronics components. It includes three short case studies from the metal finishing and manufacturing sectors. Download PDF file (779.94 kB)

Smith and Wesson. 1995.

Smith and Wesson implemented process changes to reduce the use of l,1,1-Trichloroethane (TCA) in its cold degreasing operations. The installation of agitating parts washers and drum top washers which use an aqueous solution has eliminated the use of TCA and saves the firm at least $6,870 annually. Download PDF file (25.02 kB)

Tubed Products, Inc. 1995.

In the early 1970s, Tubed Products, Inc., of Easthampton, Massachusetts, introduced production changes to allow the use of 100 % solids ultraviolet curable inks to decorate plastic squeeze tubes. Approximately five years later the technology to cure epoxy coatings for the tubes became available, enabling the company to convert to ultraviolet curing in all decorating and coating operations. This means that inks and coatings no longer need to be dried by heat-evaporation of solvents, and thus toxic solvents are no longer evaporated off into the surrounding environment. These changes have also resulted in increased line speeds, energy savings and more economical use of floor space. Download PDF file (23.25 kB)

Cranston Print Works. 1995.

Print Works altered their wastewater pH adjustment process to eliminate the use of sulfuric acid. The company installed a jet aeration system with injected liquid carbon dioxide to replace the two 4,300-gallon sumps in which wastewater neutralization had previously taken place. This $115,000 project eliminated the annual use of 2.66 million pounds of sulfuric acid. Although financial profit was not the main goal of the project, the company saved about $80,000 per year in chemical purchase and maintenance costs. Download PDF file (23.29 kB)