Toxics Use Reduction Case Studies
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) |
Garment Wet Cleaning, Utopia Cleaners. 1996.
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| 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.
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| 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.
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| 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.
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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) |
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) |
Cranston Print Works. 1995.
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| 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.
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| 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) |
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