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Toxics Use Reduction Case Studies

Improved Lead-Free Wire and Cable Insulation Performance Using Nanocomposites. 2006

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)

South Coast Technical Products. 2007.

SouthCoast Technical Products made changes to their operating processes which brought the company into compliance with Massachusetts environmental regulations and led to significant reductions in water use. By switching from an elaborate ultra filtration unit to a simple bag filtration process, the company was able to reduce more than 200,000 gallons of water and save $37,000 per year. Download PDF file (119.92 kB)

Learning from the Solutia EMS Experience. 2005.

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)

Phase III - Reliability Testing Results of Surface Mounted Lead Free Soldering Materials and Processes, 2005

Article published in SMT magazine related to TURI's Lead-Free work. The world-wide movement to phase out lead from electronic products presents many challenges for companies throughout the electronics supply chain. The University of Massachusetts at Lowell has brought together many Massachusetts/New England firms to collaborate on the manufacture and testing of lead-free printed wiring boards (PWBs). The results of the first set of experiments, published in 2001, showed that zero-defect soldering is achievable with lead-free materials. Following thermal cycling, the PWBs were visually inspected and the leads were pull-tested for reliability analysis. They compared favorably to a baseline of lead soldered PWBs A follow-on design of experiments was created in 2002 and a second set of test PWBs was made and tested in 2003. Three lead-free solder pastes based on Sn/Ag/Cu alloys were reflowed using either air or nitrogen with five PWB surface finishes, four component types with two types of component finish. Visual inspection and pull-testing were performed and published as completed in APEX, SMTI and IEEE conferences. This paper summarizes the testing results and introduces further research plans in volume manufacturing of lead free PWBs for the phase III testing sponsored by the EPA. Download PDF file (388.79 kB)

Alternatives Assessment for Toxics Use Reduction. 2005.

TURI Methods & Policy Report No. 23. One of the key challenges in toxics use reduction planning is alternatives assessment. This is the process whereby a chemical, material or product that has been identified as toxic is compared with alternatives to find a substitute that is safer for workers, communities and ecosystems. This report reviews nine methods for alternatives assessment of chemicals that have been developed by government and private organizations in the United States and Europe and is designed to assist Massachusetts companies in the process of alternatives assessment for chemical hazards. Download PDF file (673.18 kB)

Columbia Manufacturing, Inc. 2005.

Columbia Manufacturing Inc. in Westfield, Massachusetts eliminated the use of 150,000 gallons of water per day in their plating operations. Columbia saved $80,000 in sewer fees, among other cost savings, by upgrading the plating equipment and integrating a zero discharge wastewater treatment system. The new, efficient plating line enables the company to recover and reuse 98% of the plating chemistry resulting in a drastic reduction of hazardous waste generation. Download PDF file (22.13 kB)

Alpha Gary Corporation. 2005.

In 1998, the AlphaGary Corporation (www.alphagary.com) successfully launched a Lead Reduction Pilot Program, in which they evaluated the use of alternatives to lead compounds in their products, while producing materials of equivalent or improved quality. This evaluation allowed the company to successfully incorporate these alternatives into their design process, thereby reducing the amount of time to bring new products to market. By 2004, the company experienced a 30% reduction in the use of lead and lead compounds, as well as reducing other toxic materials such as cadmium compounds and other heavy metals. Download PDF file (23.03 kB)

Assessing the Electrical Properties of Alternative Wire and Cable Coatings: Metallocene EPDM. 2004.

TURI Technical Report No. 56. New regulations have led to the need for non-lead compounds to be used in wire and cable applications. There are two approaches for lead free EPDM wire and cable compounds. One is to find alternative stabilizers, and the other is to change resins. In a previous study, hydrotalcite was examined as a replacement for lead additives in applications using Ziegler-Natta based EPDM, and was very effective as an alternative stabilizer. In this research, the metallocene based EPDM was investigated as a potential replacement elastomer, which would not require lead stabilization. Download PDF file (502.78 kB)

Natural "Green" Dyes for the Textile Industry. 2003.

TURI Technical Report No. 57. The textile industry produces and uses approximately 1.3 million tonnes of dyes, pigments and dye precursors, valued at around $23 billion, almost all of which is manufactured synthetically. However, synthetic dyes have some limitations, primarily, (i) their production process requires hazardous chemicals, creating worker safety concerns, (ii) they may generate hazardous wastes, and (iii) these dyes are not environmentally friendly. This research explores methods where natural dyes are produced from plant tissue and fungal species. Download PDF file (378.90 kB)

Environmentally Benign Resins and Additives, for Use in the Wire and Cable Industry. 2003.

TURI Technical Report No. 54. The explosion of the information age has led to a scramble to increase the infrastructure of data carrying capacity. The building industry has seen a large increase in the demand for new housing. The electronic market continues to grow at an astounding pace. All of these industries require insulating wire for use in their products. As the amount of wire products increase special attention must be paid to the impact which these products make on the environment. Lately attention has been focused on polyvinyl chloride or PVC. New legislation in places such as California and Europe have begun to regulate the use of substances that are common additives to PVC. This project proposes to research the technical, economic and environmental feasibility of using alternative resins to PVC in the wire and cable industry. Download PDF file (436.70 kB)

Environmental, Health and Safety Issues in the Coated Wire and Cable Industry. 2002.

TURI Technical Report No. 51. Environmental, health and safety concerns with the basic raw materials used in manufacturing coated wire and cable are driving innovation and change in the industry. These concerns include the life cycle impacts of heavy metals such as lead, brominated flame-retardants, and resin systems based on polyvinyl chloride. Seeking to help Massachusetts' wire and cable industry deal with the complex regulatory and technical issues, the Toxics Use Reduction Institute at UMASS Lowell contracted the preparation of this background report. The report examines the sector's main environmental, health and safety issues, European and United States (U.S.) regulatory drivers, and the state of new materials development. The report also outlines a set of research and technology diffusion recommendations for the Institute and is meant to serve as an introduction and reference point for those in industry, government and academia concerned with wire and cable industry environmental, health and safety issues. Download PDF file (389.71 kB)

Cranston Print Works, Inc. -- Water Conservation. 2003.

An employee-owned company, Cranston Print Works Co. (CPW) achieved annual savings of over 110 million gallons of water and over $350,000 in costs by implementing 25 water conservation projects. These savings are attributed to the CPW's Water Conservation Team, which was formed in response to the company's commitment to continuous quality improvement. Download PDF file (133.93 kB)