Case Studies archive
Korber Hats - Elimination of Hazardous Air Pollutants. OTA 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 (26.38 kB) |
Bio Based Floor Stripping |
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| The purpose of this project was to evaluate bio-based replacements at a VA Hospital against products currently in used at that facility. The first phase evaluated a heavy duty floor finish stripper. The second phase evaluated hard surface cleaning products. Both phases were based on the preliminary laboratory testing previously at the facility. Read more... | |
Smith & Wesson - 1,1,1-Trichloroethane Elimination. OTA 1995.
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| 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 (21.35 kB) |
Fit to Print Advertising, Inc. - Conversion to UV Curing. OTA 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 (229.00 kB) |
Novacor Chemicals, Inc. - Monomer Storage and Handling Improvements. OTA 1995.
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| The U.S.-based polystyrene division of Novacor Chemicals, Inc. updated the equipment of their monomer storage and handling facility in order to demonstrate the company' s environmental awareness and to reduce overall potential liability. This project eliminated the volatile hydrocarbon emissions that previously emanated from the monomer storage tanks, spelling a 50% reduction in the facility's overall emissions. The change also reduced the risks of fire and groundwater contamination, while eliminating the potential liability associated with collapse of the aged tanks previously in use. Download PDF file (23.96 kB) |
Cleaning Urethane, Ink and Paint Manufacturing Vessels - Alternatives to Toxic Solvents in Cleaning Systems. 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) |
Texas Instruments - Energy Conservation. 2003.
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| Texas Instruments (TI) is an established leader in toxics use reduction (TUR), implementing many innovative TUR techniques in the past ten years. As part of its on-going efforts, TI has employed innovative methods for minimizing its daily energy requirements and saving money. TI installed heat exchangers in its chiller systems to utilize atmospheric conditions to achieve its cooling needs, rather than requiring costly energy input from its on site power plant. It's peak shaving project utilizes ice-making capabilities to create alternative sources of cooling (ice) during low energy use times (evening). These technologies have resulted in a significantly reduced energy consumption profile at the facility, reducing its associated generation and emissions of polycyclic aromatic compounds and other toxic chemicals. Download PDF file (8.91 MB) |