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WASTEREDUCTION
STRATEGIESFOR FIBERGLASS FABRICATORS
David R. HillisECU, Department of Industrial Technology
A. Darryl DavisECU, School of Industry and Technology
Funding provided by
Office of Waste ReductionNorth Carolina Department of Environment, Health, and Natural Resources
Waste Reduction
Strategies
For Fiberglass Fabricators
David R. HillisECU, Department of Industrial Technology
A. Darryl DavisECU, School of Industry and Technology
Funding provided byOffice of Waste ReductionNorth Carolina Department of Environment, Health, and Natural Resources
Reprinted by:Division of Pollution Prevention and Environmental Assistance (formerly OWR)P.O. Box 29569Raleigh, NC 27626-9569
75 copies printed on recycled paper at a cost of $170.48 or $2.27 each.
Acknowledgments and Notice
Sincere appreciation is expressed to the following individuals who haveprovided support in the development of this manual: Gary Hunt, Office ofWaste Reduction; Sarah McPherson, proofreader, Greenville, NC; Doris Hunt,Secretary, East Carolina University School of Industry and Technology; Robert L.Cottrell, President of Arjay Technologies, Inc.; Doug Hoffman, Grady-WhiteBoats, Greenville NC; and Bob Arthur, Hatteras Yachts, High Point, NC. Specialthanks is extended to Dr. Celeste Winterberger, Department of IndustrialTechnology, East Carolina University, for contributing the chapter on StrategiesFor Working With Hazardous And Toxic Materials and to Dr. James P. Kohn forhis work on styrene testing.
Every effort has been made to insure that information provided in this manual isaccurate. However, neither the Authors or East Carolina University takesresponsibility for the information contained in this manual. No endorsementsare provided or implied for the services or products provided by any companiesor individuals mentioned in this publication. Comments which can improve theaccuracy or usefulness of this manual are welcomed by the senior author and bythe Office of Waste Reduction.
David R. HillisDepartment of Industrial TechnologySchool of Industry and TechnologyEast Carolina UniversityGreenville, NC 27858(919) 3284147(919) 32% 4250
Gary Hunt, DirectorOffice of Waste ReductionDepartment of Environment, Health,and Natural Resourcesl? 0. Box 27687Raleigh, NC 27607(919) 571-4100FAX (919) 5714135
Acknowledgments and Notice Page i
i.>:, -,0
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/ II
Table of Contents
IntroductionAcknowledgments and NoticeTable of ContentsPrefaceGlossary
Chapters I An Overview of the IndustryThe Industry and ProductsLamination Methods and ProcessesEstablishing Pollution Reduction Strategies
II Are Pollution and Waste Reduction Strategies Necessary?Profitability in Waste ReductionGovernmental IncentivesRegulatory Factors in Planning for Waste MinimizationRegulated RequirementsRegulated MaterialsEnvironmental ImpactWork Environment and Worker ProtectionLiability and Legal ConcernsLimiting Legal LiabilityLegal and Regulatory Barriers
The Need for Change and the Change ProcessSuccess and ChangeStarting the Change ProcessDetermining the Starting Point for ChangeThe Change Process
i. . .111
vii. . .
Vlll
1
23
55789
1010121213
13131418
III Strategies For Working With Hazardous and Toxic MaterialsBy Celes te Winterberger
Introduction 21
Definition of Terms 21,
RegulationsResource Conservation and Recovery Act (RCRA) 23
National Pollution and Discharge EliminationSystem (NPDES) 25
The Federal Water Pollution Control Act 27
The Clean Air Act 27
The Hazardous Materials Transportation Act (HMTA) 29
Employee Training 29
Table of Contents Page iii
iI ’
Hazard Communication 31
Emergency Planning and the Community Right to Know 32
Conclusion 32
IV Production-Based Pollution Reduction Strategies
IntroductionWet-Out Methods Using SprayConventional Spray GunsAirless Spray GunsAir Assisted Airless GunsHigh Volume Low Pressure (HVLP) SprayCombining Reinforcement with Resin Spraying Lay-Up
Liquid Wet-Out MethodsPrepreg Fiber ReinforcingIn-House Resin ImpregnationResin Rollers - Spray-Less Application SystemsVacuum Bag MoldingVacuum Bag Molding ProcessesInfusionInfusion with a Semi-Rigid CoverResin Transfer Molding (RTM)Rotational Molding, Examining Thermoplastic OptionsRotational Molding of Small TanksCombining Subassemblies to Minimize Waste
MaterialsLow Emission Resins - AdditivesCatalysts
Benzoyl PeroxideW Curing Resins
Low Styrene ResinsResin StorageResin Circulation System
V Managing Contaminated SolventsSolvent UseAlternatives to AcetoneIn-Plant Solvent RecoveryContinuous Feed Distillation EquipmentOut-of-Plant Solvent RecoveryIncineration of Contaminated Solvents
35
3737374041
4243465151555860646566
69707070727375
797981858689
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VI Management and Facility-Based Pollution Reduction Strategies
AppendicesA.B.
C.
Process Control StrategiesPlant Layout - Localizing and Isolating ProblemOperationsIsolating Problem AreasConfining Gel Coat ApplicationsApproaches to Gel Coat IsolationApproaches to Isolating Other Operations
Air Filtration and Recirculation SystemsFiltering Contaminated AirDry Filtration and RecirculationWet Filtration SystemsFume Incineration, Burning Styrene EmissionsControlling Air-Flow and ExhaustExhaust VentilationMaintaining Positive PressureLocal Exhaust
Case Studies
D.
1.
2.
3.
4.
5.
6.
A Case Study in Waste Reduction and ProfitabilityNorth Carolina - Department of Environmental,Health, and Natural Resources Map of RegionalOfficesSuppliers of Equipment and ServicesProcessing Equipment SuppliersSuppliers of Distillation EquipmentHazardous Waste ServicesHazardous Waste TransportersNorth Carolina Quality Leadership Award
High Volume Low Pressure (HVLI?) Spray Guns,Hatteras Yachts, High Point, NC
Venus Resin ImpregnatorSyntechnics, Inc., Paducah, KY
Resin RollerAjay Technologies, Largo, FL
Comparison of Resin Spray to Resin RollersGrady-White, Greenville, NC
Vacuum Bag MoldingFountain Powerboats, Washington, NC
93
99100101103104
105106108110113113113115
117
123
125127128129133
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45
49
50
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Infusion with Resin Injection Recirculation Method (RIRM)Structural Composites, Melbourne, FL 59
Table of Contents Page v
I
i
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t
7. Resin Transfer MoldingHatteras Yachts, High Point, NC
8. Composite Preform SystemStructural Composites, Melbourne, FL
9. UV Cured Resin
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International Marine, Miami, FL10. Mini-Bulk Resin Storage System
Warren Wilkerson, Belhaven, NC11. Acetone Replacement in a Fiberglass Laminating
Operation
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77
Carolina Classic, Wilson, NC12. In-Plant Batch Distillation Unit
Fountain Powerboats, Washington, NC13. Supplier-Based Solvent Recovery
Hatteras Yachts, New Bern, NC14. Plant Air Recirculation System
S2 Yachts Holland, MI15. Incineration System for Styrene Emissions,
Lasco Bath Fixtures, South Boston, VA
80
84
88
107
112
Table of Contents Page vi
Preface
Eight years ago the manual, Pollution Reduction Strategies in the FiberglassBoafbuiZding and Open Mold Plastics Industries, was published. The intent of theauthors was to provide practical information on reducing waste and pollution infiberglass laminating operations. That manual was well received bymanufacturers in the industry. However, over the past eight years technology,practice, and regulations have changed. Therefore, much of the content in theoriginal manual needed to be reviewed and brought up to date. Funding for theproject to revise and update the manual has been provided by a grant from theOffice of Waste Reduction, North Carolina Department of Environment, Health,and Natural Resources. Mr. Gary E. Hunt, Director of the Office of WasteReduction, and other members of his staff have also provided substantialsupport in reviewing and commenting on the content of the manual.
Concentrating on boatbuilding and open molding was considered importantsince manufacturers in this industry use large quantities of liquid resins andsolvents that have the potential to produce considerable quantities of airbornepollution and contaminated solid waste. Open mold fabricators utilize a numberof materials and processing methods which make knowledge of environmentalregulations and appropriate waste management strategies essential to thesurvival of their companies. The materials used include styrene based polyesterresins, methyl ethyl ketone peroxides, acetone, and other solvents and specialtychemicals. Since resins are often applied through an atomization process, airquality in and outside the facility is a major concern. Attention must also befocused on the entire manufacturing cycle which begins with product designand materials selection and continues even after waste disposal. The contents ofthis manual touch on the major aspects of this cycle.
The information presented comes from a number of sources. Federal and stateregulations were reviewed, and interviews with individuals from state andfederal agencies were also conducted to supplement our understanding. Muchof the technical content was developed as result of numerous in-plant visits andobservations as well as telephone interviews with a number of fiberglassfabricators. Firms engaged in production and marketing of processingequipment and supplies for the industry also provided valuable information andmany useful leads.
Preface Page vii
Glossary
Every industry has its own terms and jargon which become part of the language ofthose who work in or serve that industry. The fiberglass boat building and,open moldplastics industry is no exception. The following defines some of the key terms used inthis industry.
Catalyst In fiber reinforced plastics the catalyst is the substance added to thegel coat or resin to initiate the curing process. The catalyst usuallyoxidizes an accelerator creating free radicals which cause the resin orgel coat to polymerize or cross-link.
Closed Molding A molding process using two matched molds. This method ofmolding reinforced plastic provides a good inside and outside surface.This type of mold tooling is much more expensive than open moldtooling.
curing
FRP
Gel Coat
A polymerization process transforming the liquid resin to a solidcreating the maximum physical properties attainable from thematerials.
The initials of fiber reinforced plastics.
A colored resin used as a surface coat for molded fiberglass products.It provides a cosmetic enhancement and environmental protection forthe fiberglass laminate.
Hand Lay-up Placing reinforcement materials and resin onto a mold by hand. Theresin application is frequently accomplished with a spray gun.
Open Molding An open mold provides a finished and dimensional accurate surfaceupon which the lay-up can be placed. Gel coat is usually is sprayedfirst on the prepared surface of the mold. The reinforcement materialsare applied on top of the gel coat. This form of molding provides onefinished side.
Resin A class of organic products either natural or synthetic in origin,generally having high molecular weight. Most uncured resins used inopen molding are liquids. Generally resins are used to surround andhold fibers. When catalyzed, the resin cures going through apolymerization process transforming the liquid resin into a solid. Thecured resin and reinforcement creates a composite material withmechanical properties-that exceed those of the individual components.
Styrene An unsaturated hydrocarbon used in plastics. In polyester resin itserves as a solvent and as a co-reactant in the polymerization processthat occurs during curing.
Wet-Out Saturating reinforcing material (glass fiber) with resin. The rate orspeed of saturation is a key factor in effective and profitable molding.
Glossary Page viii
CHAPTER I
An Overview of the Industry
The Industry and Products-
Open molding or l aminat ing o f thermoset t ing p las t i c s i s a primarymanufacturing process carried out in a variety of North Carolina firms. Also,many companies use open molding as an adjunct process to produce accessoriesor components for more complex products which are assembled in theirfacilities. Open molding, consequently, is a key process that contributes valuableproducts as well as several thousand jobs throughout North Carolina. The firmsinvolved in lamination range from companies employing only one or twopeople to internationally recognized organizations which employ more than1,000 people. However, most of these firms are small companies with fewer than100 people involved in daily plant operations.
The product most commonly associated with resin lamination is the fiberglassboat. There are, according to the US Coast Guard,’ approximately 70 to 75fiberglass boat builders in North Carolina. Their products range from smallcreek boats to yachts as large as 130 feet. There are, of course, many otherapplications for open molding. The traditional fine wood and upholsteredfurniture industry in the state has expanded to include the development ofproduction facilities for molded furnishings ranging from restaurant seatingfixtures to lawn and garden furniture. An expanding demand for durablefixtures and corrosion resistant industrial equipment is also contributing to thegrowth of open molding operations involved in producing such specialtyproducts as cultured marble bath fixtures, bathtubs, large storage tanks, truckbody components, architectural panels, heat exchanger components, floating piermodules, and machinery housings.
Plants involved in laminating are locating in all geographic regions of the state.The State’s moderate climate is well suited to the requirements for processingthermosetting plastics such as polyesters. Since many open molding firms arealready located in the state, a good network of equipment and material suppliersis already well established. Because of these resources and the experienced workforce, North Carolina should continue to attract and support open moldingindustries. North Carolina also has an excellent market for many of the goodsproduced by the industry. The state is geographically situated so that shipment ofproducts to the heavily populated Northeast and the rapidly growing Southeastis relatively fast and inexpensive. Access to water is also important to boatmanufacturers who must ship finished yachts that are too large to transport bytruck or rail.
Open molding is particularly useful for highly engineered products designed tomeet a variety of application demands, particularly when requirements include
‘United States Coast Guard Marine Safety Office, Wilmington, North Carolina.
Chapter I Page 1
high strength, low weight, environmental stability, corrosion resistance, weatherresistance, or long life. The industry will continue to experience continueddemand for highly engineered products since start-up costs and productmodifications are less expensive and require less lead-time than other basic typesof material processing. For products with complex shapes and limitedproductivity the investments required for facilities, tooling, and equipment islow enough to attract the interest of large and small firms.
Lamination Methods and Processes
Al though the composition, shape, and size of open molded products can varysignificantly, the basic fabrication requirements change very little. To createproducts with a smooth durable finish requires a female mold which is smoothand highly polished. The mold is cleaned and coated with a release agent such aswax or a polymer coating. The first step of the lamination process begins with
’ the application of a gel coat resin (see Figure l-l). Polyester resins are used inmost gel coats and for most lay-ups (refer to the glossary. Currently the majorityof production systems deliver resin through spray guns. These guns spray the
4 resin and catalyst separately and therefore rely on the turbulence of the spraypattern to mix the resin and catalyst. In some cases short chopped fibers are alsointroduced into the spray pattern with the resin and catalyst. In large parts wherestructural strength is critical, fiber reinforcing in sheets are used instead of thechopped fibers. These sheets are placed in the mold and sprayed with catalyzedresin. Once the reinforcement is in place, hand rolling is almost essential forremoving voids, smoothing the surface, and insuring proper integration of resinand reinforcing material.
Fiber Reinforcement & Resin Gel Coat SprayedOn Mold Surface
FIGURE l-l. Open mold configuration.
Chapter I Page 2
Physical plant arrangements for most small producers consist of one or moreopen production areas. In these areas the entire lamination process is carried outalong with resin spraying. Styrene, the principle volatile organic compound(VOC) in polyester resin, is normally controlled through the use of a number ofexhaust fans. This production process leads to several potential pollutionproblems in terms of airborne solids, over spray, and styrene vapor emissions.Even when good exhaust systems are provided, there can be expensive problemsfor the producer. In many cases, air flow patterns are such that relatively cleanplant air is exhausted while a poor job is done in ventilating areas where aircontamination remains high. Current methods also present open molders withother potential pollution and safety problems in terms of storing hazardousmaterials, disposing of contaminated solvents and waste disposal, handlinghighly flammable liquids and vapors, and controlling dust.
There are many variations in processing in the industry because of the diversityof products produced. Methods used for molding a cultured marble bathroomcounter and sink are different from the approaches used to mold a fiberglass boathull. Basically similar products can also be produced using significantly differentmethods and techniques because of differences in facilities and the organization’sproduction concepts. Where high production outputs are required, largercompanies can invest in more complex tooling and equipment for each uniqueoperation thereby improving quality and reducing labor content. Smallerorganizations frequently are forced to perform a variety of operations usingsimple labor intensive methods within the same production area. In fact, mostsmall operations are set up in open general purpose structures with little regardfor anything other than basic lay-up and secondary finishing. Specialtyequipment, engineered facilities for specific operations, formal trainingprograms, and a management focus on waste reduction are frequently beyondthe capability of these smaller firms. Consequently, these companies need accessto strategies that integrate good business practice and appropriate manufacturingtechnology to achieve waste reduction in a manner that maintains their ability tocompete effectively. Although no one approach is appropriate for all firms, it ispossible to develop a strategy by selecting and blending appropriate techniquesdeveloped by others.
Establishing Pollution Reduction Strategies
Because of the nature of the materials used in creating laminates, the industry isbeing forced to increase its emphasis on safety and pollution prevention issues.Also federal and state regulations are becoming more stringent and areidentifying more materials which will require new approaches for managingtheir use and disposal. Worker safety is also an important issue formanagement. Consequently, pollution prevention and waste reductionstrategies are generally an outgrowth of problems created by these regulatory andenforcement demands. Managers, therefore, need to be aware of theseregulations and health standards as well as the manufacturing technologiesavailable, when they select materials for processing and develop productionprocesses. The prospects for the industry to effectively meet these current and
Chapter I Page 3
new regulations and standards are good. In fact, many producers have foundthat some pollution prevention and waste reduction methods are actually costeffective. A number of these techniques are reviewed in this manual.
In establishing a waste reduction strategy, a firm must be willing to take anoverall approach as well as a long term view of managing resources. In manycases the approaches to facility and process development in the open moldingindustry can be categorized as being shortsighted or simply staying with pastpractice out of habit. Profitable pollution prevention approaches are developedwhen careful attention is paid to using best manufacturing practices that includeminimizing variation, refining material flow patterns, conserving materials andutilities, separating incompatible operations, and instituting inventory controlprocedures. Therefore, it is possible that pollution related problems can beminimized through facilities design with a view towards future needs andregulatory demands.
Planning ahead will be essential to the survival of the industry. The materialsused in the open molding process are under constant scrutiny by health and
, environmental agencies. There seems to be little doubt that future regulationsregarding in-plant and out-of-plant air quality, worker exposure, and wastestorage and disposal will get tougher. Processing equipment and facility designsshould be selected with potentially tougher regulations in mind. Wherepossible, alternate materials and processing approaches should be explored toeliminate or reduce the problems created by the use of hazardous materials. At aminimum, existing facilities and equipment should be fine tuned to bringpotential environmental problems under control.
Chapter I Page 4
CHAPTER II
Are Pollution and Waste Reduction Strategies Necessary?
Profitability in Waste Reduction
The work required to maintain a profitable business in the open moldingindustry is complicated by the need to cope with a number of potential workersafety and environmental pollution problems. Management and investorsfrequently view compliance with pollution regulations and workplace safetyrequirements as efforts that do not add value to the product or improveproductivity. There is little doubt that strict environmental regulations haveresulted in costly changes to basic production techniques, the purchase ofspecialty equipment for pollution reduction, and the adoption of managementstrategies that are not entirely production centered.
However, there are many instances where environmentally sound approachesfor processing with hazardous materials do lead to cost savings. A number of thecase studies and examples included in this manual demonstrate that pollutionprevention and waste reduction strategies do not always have a detrimentaleffect on profits and productivity. In some cases pollution prevention strategieshave provided a substantial return on investment and have actually increasedprofits. An example is the case study reported in Appendix A.
When calculating the overall effects of implementing a pollution preventionand waste reduction strategy, it is often difficult to get a clear picture of the actualcosts and benefits of all available alternatives. A complete picture requiresmanagement to consider all the factors that go into a profit and loss statement inorder to evaluate a strategy properly. Management’s goal in this analysis shouldbe to select a waste reduction strategy that has a value added instead of a costincreasing approach to compliance. This comprehensive approach is generallytermed ‘Ire-engineering the business.” The end resul t wi l l make theorganization a stronger competitor able to work within the appropriateregulations. This approach sounds fine, but manufacturers know thatdeveloping a profitable strategy will take time, knowledge, money, and someoutside support. Fortunately, there are some resources available.
Governmental Incentives
A number of incentives for implementing pollution prevention strategies areprovided by the State of North Carolina, the Federal Government, localgovernments, and private agencies.
0 Incentives are offered by the State and Federal Government to:
Help complying companies by insuring that non-complyingcompanies do not enjoy a competitive advantage overcomplying companies;
Chapter II Page 5
c
2)
3)
Provide relief to industries forced to implement expensivechanges in order to comply with pollution or cleanuprequirements; and
Encourage compliance with state and federal . pollutionabatement requirements.
a Selected North Carolina incentives currently in existence include:
1) Special tax treatment for recycling and resource recoveryoperations can reduce or eliminate portions of:l Real and personal property tax,l Corporate state income tax,l Franchise tax on domestic and foreign corporations.
For more information about special tax treatment for recyclingand resource recovery operations contact your county taxassessor’s office. You can also obtain information from thearea supervisors of the Solid Waste Section of the NCDepartment of Environmental, H e a l t h a n d N a t u r a lResources. ’
The Eastern area suDervisor is at 225 Green St., Suite601, Fayetteville, NC 28301, (910) 486-1191.
The Western area sunervisor is at 8025 North PointBlvd., Winston-Salem, NC 27106, (910) 771-4600.
2)
3)
Tax Exempt Industrial Development and Pollution ControlBonds are available if they meet certain criteria and areapproved by appropriate local and state authorities. Contactyour regional supervisor for the Depar tment o fEnvironmental, Health, and Natural Resources Division ofEnvironmental Management. Appendix B shows the sevenregions in North Carolina.
Demonstration projects for manufacturers initiating,expanding, or converting to the use of recycled feed stockhave been established. During the FY 1994 - 1995 the statewill fund four projects in amounts up to $20,000. Additionalinformation on current programs and awards can be obtainedfrom:
NC Recycling and Reuse Business Assistance Center,Office of Waste Reduction, 3825 Barrett Dr., 3rd Floor,Raleigh, NC 27609, (919) 571-4100.
‘A listing of other programs that may offer tax and state incentives for pollution abatementequipment can be obtained from Bill Meyer, Division of Solid Waste Management, North CarolinaDepartment of Environment, Health, and Natural Resources, Box 2091, Raleigh, NC 27602, (919)733-2178.
Chapter II Page 6
4) Challenge grants for pollution prevention are being offeredby the North Carolina Pollution Prevention Program. a Thisprogram has been in operation since 1984 and has fundedover 100 projects. Approved projects can receive. up to$15,000. More information can be obtained from:
Program Manager, Pollution Prevention Program,Office of Waste Reduction, 3825 Barrett Dr., 3rd Floor,Raleigh, NC 27609, (919) 571-4100.0 Other potential incentives include:
1)
2)
Incentives offered by local governments or industrialdevelopment agencies for the purpose of attracting orretaining industries.
Public recognition that enhances the status of the company inthe eyes of the community and customers. One example ofthis type of incentive is the Governors Award for Excellencein Waste Reduction. This award has been given for the pasttwelve years to industries who have demonstrated excellencein eliminating and reducing waste. Eljer Industries (nowCarolina Classic), a fiberglass tub manufacturer in WilsonNorth Carolina won this award in 1990 for replacing acetonewith a water-based cleaner.
3) Limiting unforeseen long-term liabilities.
Incentives are constantly changing. Information should be sought from localagencies, state governmental agencies, federal agencies, tax specialists, andsuppliers of pollution reduction equipment and services. Industry associationssuch as the North Carolina Marine Trade Association can be of help inidentifying incentives and resources available to composite fabricators. You canreach the North Carolina Marine Trade Association at:
North Carolina Marine Trade Association,UNCW, Westside Hall, 601 South College Road,Wilmington, NC 28403-3297
Regulatory Factors in Planning for Waste Minimization
Currently North Carolina, along with approximately one-third of all other statesin the United States, has laws requiring companies to do some form of pollutionprevention planning. In 1989, the North Carolina General Assembly enactedlegislation requiring all persons holding air quality, wastewater pretreatment,hazardous waste generation, and/ or stormwater discharge permits to submitwith their payment of annual fees a written description of their current plans toreduce waste. As of 1994 the state has implemented these requirements forpollution prevention in the permitting process.
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In 1993 the state established a Pollution Prevention Advisory Council. Thiscouncil has recommended:
l Pollution prevention planning for certain industrial facilities and stateagencies;
l A statewide pollution prevention goal;l An incentive program to encourage North Carolina waste generating
facilities to incorporate pollution prevention into their business operations;l A comprehensive program to educate children, the general public, and
industry about pollution prevention.
Waste minimization programs are also being implemented or revised by the US.EPA. Information on waste minimization planning can be obtained from theOffice of Waste Reduction, (919) 571400. This office is able to provide guidanceon waste minimization programs, on-site waste reduction assessments, and thecurrent status of waste reduction goals and requirements.
Regulatory Requirements
4 As most manufacturers know, there are many local, state and federalregulations covering environmental and safety issues. According to the code offederal regulations, all industrial installations are legally obligated to properlyhandle, ship, store, and dispose of hazardous materials and waste. In addition,there are regulations specifically issued for the protection of employees in theworkplace. A few important regulations are listed in Table 2-l. A morecomplete description of these requirements can be found in Chapter III.
TABLE 2-1. Pollution and safety related regulations.
D Occupational Safety and Health Administration (OSHA) Major ProgramsPermissible exposure limits (PELs)
Medical surveillance programs for substance-specific standards
Ergonomics safety and health standards
Respiratory protection
Powered industrial trucks
Confined space entry
Face, head, eye, and foot protectionEmployee training in safety and health
0 Environmental Protection Agency (EPA) Major ProgramsClean Air Act, the 1993 compiled version (includes amendments)Storm-water Regulations of 1990
Pollution Prevention Act of 1990 (WA), public information on current practices andprojections of activities involving chemical waste
Resource Conservation and Recovery Act (RCRA)
Emergency Planning and Community Right to Know Act (EPCRA)
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Regulated Materials
Chemical control, use, and tracking are key parts of the government’s approachto protecting the environment and human health. The federal and stategovernments have several agencies to enforce the attendant regulations.Chapter III explains many of the regulations and responsibilities thatmanufacturers must accept to be in compliance. One of these responsibilities isknowing and making all your employees aware of the nature of the materialsthat are used in the business. You’ll have to ask your suppliers to identify andprovide Material Safety Data Sheets for all the materials you purchase.
Knowing what materials are regulated by governmental agencies, the regulationunder which the materials are governed, and the material’s permissible use areessential components for formulating a workable strategy for waste reduction.Although the fiberglass molding industries rely on sophisticated chemicalprocesses to fabricate their products, these processes involve only a smallnumber of materials with the potential to be hazardous to human health or tothe environment. A brief description of the most important chemicals follows.
l Styrene
Styrene is a colorless l iquid with a sweet aromatic odor at lowconcentrations. At higher concentration, the odor becomes sharp anddisagreeable. Styrene vapor is 3.5 times heavier than air. The flash point ofstyrene is 88’ F. The lower explosive limit is 1.1% and the upper limit is6.1% by volume. If a polymerization inhibitor is not present in sufficientconcentration, styrene can polymerize and explode in its container. Styrenewill corrode copper and is not compatible with oxidizing agents, strongacid, and catalysts for vinyl polymers. Styrene affects the central nervoussystem. It can also cause other conditions such as peripheral neuropathy,skin disease, and abnormal pulmonary function. It may be considered to beliver toxic, teratogenic, and carcinogenic.
l Methyl Ethyl Ketone Peroxide
Methyl ethyl ketone peroxide (MEKP) is the most popular catalyst in usein the industry. It is a clear colorless liquid with a slightly pungent odorand is a potential explosive hazard. MEKP has a flash point of 185O F. It isincompatible with very strong acids, bases, and oxidizers. It is an irritantfor the skin and nose and can cause blindness. It also affects the lungs andcentral nervous system.
l Benzoyl Peroxide
Benzoyl Peroxide (BPO) has been used for years as a catalyst for curingunsaturated polyester and vinyl ester resins at elevated temperatures. Thecatalyst is available in granular and wet forms. When diluted, the mixturecontains between 50 to 85% BPO. Aqueous forms of BP0 are commonlyused since this form reduces the explosive and fire hazards that exist with
Chapter II Page 9
the pure powder. The paste is also an easier form to use. At roomtemperature BP0 will slowly react with unaccelerated resins. Theaccelerators normally added to polyester resin for MEKP are not effectivewith BPO, therefore users will have to ask their resin suppliers forrecommendations for a suitable replacement. Users report that BP0appears to have some effect in suppressing styrene emissions.
l Acetone
Acetone is used as a general solvent for cleaning purposes. It is a colorlessliquid with a fragrant, mint-like odor. .Acetone has a flash point of 15’ F,and it is incompatible with acids and oxidizing materials. Acetone is anirritant for the eyes, nose, throat, and skin. It is also a central nervoussystem depressant. During the later part of 1994 there was some discussionconcerning the removal of acetone from the list of chemicals classified asVOCs. Regardless of the outcome, acetone will still be classified as ahazardous material.
Environmental Impact
Virtually any application of science and technology in manufacturing canproduce wastes and pollutants. Without proper control and treatment, thesematerials are a threat to the continued survival of the animal and plantcommunities of the ecosystem. Eventually, they may also threaten the existenceof the human community. For a conscientious company, environmentalconcerns should be a part of the day-to-day operation of the business. This isespecially true with respect to the discharge of pollutants into the air or nearbyrivers and streams. In addition, proper disposal of waste on the land should alsobe assured. Because air pollution, water pollution, and the accumulation ofhazardous and toxicwaste have created conditions which have adversely affectedenvironmental quality, federal and state governments have promulgatedregulations for the prevention of environmental degradation. A severe penaltyand possible imprisonment can be imposed under these regulations. The stateagency which is responsible for the enforcement of environmental legislation inNorth Carolina is the North Carolina Department of Environment, Health, &Natural Resources (Figure 2-l shows the departments within this agency). Thelaws are listed in “North Carolina Environmental Management Laws,” whichwas issued by the above mentioned Department (Publisher: The MichieCompany, Charlottesville, VA).
Work Environment and Worker Protection
The issues of environmental quality impact our work environment as well asour natural environment. Because the emphasis on worker protection isdifferent from that of environmental protection, regulation and standards arealso different. Consequently, worker health and safety is a critical aspect in thecreation of a good work environment.
Chapter II Page 10
FIGURE 2-l. Agencies within the Department of Environment, Health, & Natural Resources.
Chapter II Page 11
In the event of an injury an employer is bound by law through worker’scompensation to provide the injured employee with a paycheck. The law notonly provides work accident victims with reasonable income and benefits, theyalso encourage employers to reduce work accidents and human suffering. One ofthe most valuable features of these laws has been that they stimulate efforts toprevent occupational diseases and injuries. Since rates charged for worker’scompensation insurance coverage usually depends on the accident history of thecompany covered, it is profitable for a company to promote worker safetythrough the establishment of a strong safety program. The next chapter outlinesthe basics for establishing training and safety programs for handling hazardousand toxic wastes.
Liability and Legal Concerns
Long-term liability may be the most important factor in the decision makingprocesses related to pollution prevention strategies. This is true whenconsidering worker safety as well as the relationship of materials and processes tothe environment. The Resource Conservation and Recovery Act (RCRA)“cradle-to-grave” philosophy, as well as lawsuits being carried out under theComprehensive Environmental Response Compensation and Liability Act(Superfund), should attract the attention of management in the open moldedplastics industry. Even companies who legally and properly disposed ofhazardous waste in the past are now having to absorb cleanup costs for thosematerials. Lawsuits have forced companies to pay the cost of removing theirwastes from licensed landfills and disposing of them in a manner that meetscurrent standards.
Hazardous materials and processes create a number of concerns regarding workerhealth and safety. Existing and emerging regulations must be considered whenselecting equipment, designing production processes, and choosing materials.Chemicals used in resins and solvents, along with dust created by grindingoperations, make the open molding industry a prime target for lawsuits relatedto long-term worker health.
Limiting Legal Liability
The best approach to limiting long-term liability is to avoid using hazardousmaterials and generating hazardous waste. Operations which do not use thesematerials have no liability. However in the composites industry this is not likelyto happen. Where hazardous materials cannot be eliminated, an affirmativeaction approach to waste management, air and water discharge, and workersafety is essential to the reduction of long-term legal liabilities. Under presentstate and federal laws the generator of a hazardous waste is never relieved of theresponsibility for that material. Consequently, if production requires the use ofhazardous materials, strategies should focus on reducing the volume of thosematerials needed and minimizing waste. Decreasing the volume will also
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reduce the magnitude of the long-term liability because environmental effectsare frequently related to waste volume.
Development of production approaches which can eliminate or substantiallyreduce the quantity of hazardous materials used or generated as waste is notalways possible. If waste cannot be eliminated through source reduction thenprocesses such as in-house recycling should be considered to decrease the liabilityincurred in disposing of hazardous wastes.
Legal and Regulatory Barriers
Regulatory agencies and legal statutes provide a number of disincentives forfailure to insure worker safety and health and for improper or poor wastemanagement. There are many civil penalties for noncompliance or negligence.In some cases negligent actions or inaction can lead to criminal charges andpossible imprisonment. Regulations and penalties as disincentives includepolicies which prohibit the EPA from approving or recommending to privateparties any facilities that have Category 1 violations. North Carolina also followsthis procedure. Regulatory policies also require that penalties for noncompliancebe large enough to offset any economic gain from noncompliance. Owners orstockholders are directly affected since penalty expenses for violations are not taxdeductible.
The Need for Change and the Change Process
Success and Change
The global marketplace has created the need for companieshorizons in defining their markets for their products as well-
to expand theiras assessing the
capabilities of the competition. Companies that don’t respond to theseopportunities and threats may find their business becoming less viable. Industryleaders and the press typically have blamed the high wages paid to Americanworkers for the loss of business to foreign firms. However, many domesticcompanies have found that they can compete effectively if they are able toprovide products of good quality and value. Successful companies have foundthat providing competitive products means that they must continually assesstheir operations and be committed to ongoing change. Consequently, changebecomes an integral part of doing business. Managing change is not a one-timeor occasional thing but is one of the essential ongoing functions of management.The process of assessment and change followed by competitive companies is alsoeffective for developing profitable waste reduction strategies.
Starting the Change Process
In carrying out change you need to know four things:
1.) Current performance (present status),
2.) A standard of performance (benchmark or regulation),
3.) The proposed goal (new level of performance),
4.) How to get from here to there (a strategy).
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To start the process you must establish your present status. This assessmentrequires a careful analysis of current performance. Once this is done, a standardof performance must be obtained for comparison. Next, establish a goal to correctthe perceived deficiencies. A deficiency exists when there is a difference betweencurrent status and some standard of performance. These standards are’based on abenchmark (an internal or external standard) or statutory regulations.
In plain terms, current status states levels of performance in units of measure(like delivery time in days, cost of scrap in percent of sales, tons of VOCemissions per year, cubic yards of waste sent to the landfill per month, and soforth). For example, current status for the XYZ Company for styrene emissionsmay be 12 tons per year (TPY). A regulatory standard may state, “A permit isrequired if you exceed 10 tons per year of any one VOC.” A goal would state “ W eare going to reduce styrene emissions from our curre?l:t status of twelve tons peryear to nine tons per year.” Goals result from identifying good manufacturingpractice which you believe can be applied to your situation. For instance, youmay know of a company that changed from external mix spray guns to resinrollers for applying resin to open molds. After the changeover their emissions of
’ styrene went down 25%. Therefore, you establish your goal for the reduction ofstyrene emissions based on their performance since you believe this technologycan also be applied in your business. This method of comparison and goalsetting is frequently referred to as benchmarking on good manufacturingpractice. In each case the goals resulting from these comparisons should be statedas explicitly as possible and must be clearly communicated to all concerned. Ifgoals are not clear, the probability of successful change is diminished.
Determining the Starting Point for Change
To determine your company’s current status, the identity and magnitude of thewaste streams must be resolved. This can be done by analyzing the amount ofmaterials used and the manufacturing methods currently employed. Forexample, if a company is using a dicyclopentadiene (DCPD) polyester resin with45% styrene as a material and is applying it to a mold using an external mix highpressure spray gun, it’s likely that nearly 10% of the styrene by weight would belost to the atmosphere. This is approximately 4.5% of the total weight of theresin being used. Therefore, one waste stream could be identified as styrene loss,and an entry to a data sheet would show that 4.5 pounds of styrene would be lostfor 100 pounds of polyester resin used. The total purchases of polyester resin in ayear less adjustments for inventory would provide an indication of the amountof styrene lost to the atmosphere.
Deciding exactly what data to collect and how to tabulate it is the key todetermining your current status. A comprehensive approach is needed. Inessence, you will need to account for all the material the company buys and howit is used. This may seem to be a daunting task, but the work involved is notoverwhelming. If your company has made some studies on waste and scrap, youcan use those factors. Otherwise, you’ll have to start weighing your product,dumpster, and barrels that you may be shipping off for disposal. The styrene lost
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to the atmosphere can be estimated using information the EPA has collected oncommon laminating processes. These factors are shown in Table 2-2.
TABLE 2-2. Toxic Air Pollution Emission Factors Taken From A CornDilationFor Selected Air Toxic Compounds And Sources, Second Edition, EPA-450/2-90-011, October 1990.
Process *Emission Factor -
“Styrene Lost PerPound of Resin Used
Resin Characteristic
Closed Molding .Ol - .02 lb. Vapor-suppressed resin
Closed Molding .Ol - .03 lb. Non-vapor-suppressed resinContinuous Lamination .Ol - .05 lb. Vapor-suppressed resinContinuous Lamination .04 - .07 lb. Non-vapor-suppressed resin
Hand Lay-up .02 - .07 lb. Vapor-suppressed resin
‘ Hand Lay-up .05 - JO lb. Non-vapor-suppressed resin
Pul trusion .Ol - .05 lb. Vapor-suppressed resin
Pultrusion .04 - .07 lb. Non-vapor-suppressed resin
Spray Lay-up .C3 - .09 lb. Vapor-suppressed resin
Spray Lay-up .09 - .13 lb. Non-vapor-suppressed resin
TABLE 2-3. Estimating styrene loss from gel coat spraying.
Calculating an Estimate of Styrene Losses from Gel Coat Spraying
Styrene loss Percent Styrene Styrene LossFactor* In Your Mat’1 Per 100 Lbs.
Gel Coat Sprayed
External mix air sprayLow range .054 X =- - - - ----___High range s45 X =- - - - - - - - - - -
Airless sprayLow range .032 X =- - - - - - - - - - -High range .llO X =- - - - - - - - - - -
*Based on information from the Polvester Products ADDlications Manual, 7thEdition, 1990, Cook Composite and Polymers Co., Kansas City, MO.
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Cook Composites and Polymers Company has also conducted tests to determinethe amount of styrene loss during gel coat spraying. The results indicate thatstyrene loss from gel coating using conventional air spray equipment rangesfrom 5.4% to 14.5 %. With airless spray equipment the range is from 3.2% to11%. In both cases higher levels of styrene loss occur as the distance between thespray gun and the sprayed surface increases. The spraying distance in the testsranged from 1.5 feet to 6 feet. A method for using these factors for estimatingstyrene loss is shown in Table 2-3. To complete the calculation you will need tochoose the appropriate type of spray equipment and determine the percentstyrene in the gel coat material you are buying. If you don’t know the percentage,ask your gel coat supplier for the styrene content in percent by weight. Whenyou have determined the styrene percentage, multiply the appropriate factor bythe percent styrene to obtain an estimate of the styrene loss in pounds per 100pounds of gel coat sprayed. The amount of styrene lost from gel coat spraying isjust one source of waste.
Other losses need to be estimated in order to get a complete understanding of thewastes coming from the manufacturing system. This number can be obtained
‘ through the use of a sources and uses analysis. An example of the categoriesincluded in a sources and uses analysis are shown in Figure 2-4. To carry out theanalysis requires that the weight of all materials be accounted for during aspecific time period. The analysis has three major sections:
1. Total material purchases in pounds -- Sources
2. Total material weight in pounds in completed product -- Profitable Uses
3. Total material weight converted to waste -- Unprofitable Uses
An interesting number to calculate is the eff ic iency factor for yourmanufacturing system in terms of its ability to convert purchased materials intofinished product. Developing a profitable strategy for waste reduction hinges onhow close this factor can be brought to one. The calculation is made as follows.
Profitable UsesEfficiency Factor =
Total Sources
To calculate this factor you need to obtain the weight of laminating materialsused during a specific time period and the weight of the laminate produced.
One manufacturer of fiberglass bathtubs and shower stalls obtains these numberson a shift by shift basis. The weight of resin used is obtained by measuring howmuch the resin level has dropped in the storage tank during the shift. Theinches of resin used is converted to gallons which in turn is converted topounds. A similar method is followed to calculate the amount of gel coat used.Solid materials like glass fiber are tracked by counting the number of rolls usedduring the shift and then calculating the weight. Partial rolls are weighed onscales. The weight of reinforcing materials used are also totaled and recorded.
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TABLE 2-4. An example of a sources and uses data sheet.
SOURCES AND USES
DATA COLLECTION SHEET
Lamination ProcessTime period for the StudyBeginning Date Ending Date
SourcesMaterials Used during the Period less inventory Adjustments1. Gel Coat Lbs.
2. Polyester Resin Lbs.
3. Fiber Glass Lbs.
4. Reinforcement Materials Lbs.
5. Acetone Lbs.
6. Other Solvents Lbs.
7. Masking and Covering Materials Lbs.
Total Sources Lbs.
Profitable Uses -- Weight of all product produced in the period1. Your Product -- Boat Hulls, Decks, and
Other Components (no hardware) Lbs.
Unprofitable Uses1. Solid Waste, Dumpster Lbs.
l Trimmings Lbs.
. c u t o u t s Lbs.
l Over spray, walls & floors Lbs.
2. Acetone Drummed for Disposal or Distillation Lbs.
3. Acetone Loss (Acetone used - Acetone Drummed) Lbs.
4. Styrene Loss to the AtmosphereGel Coat loss from Figure 3.
Factor X 100 Lbs. of Gel coat = Lbs.Polyester resin used during the period.
Factor X Lbs. of Resin = Lbs.
Total Unprofitable Uses Lbs.
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I
And finally, all the weights are added together to obtain the Total Sources weight-- the weight of materials used. To obtain the weight for Profitable Uses thismanufacturer totals the weight of each completed tub and stall.
The result gives the manufacturer a means to gauge the efficiency of themanufacturing process. The difference between the two numbers provides agood estimate of the magnitude of the total waste being generated by thelamination process.
The plant manager described his job as being a material converter. He pointedout that his operation is profitable when just the right amount of materials areplaced in each product without waste. If material is wasted, it either comes out ofthe product (harming quality) or out of the company’s profit because morematerial has to be used to replace the waste. Regardless, the company suffers aloss from either reduced product quality or reduced profitability. An additionalloss also occurs from the increased costs of dealing with waste management.
The Change Process
I The sources and uses analysis provides a way to estimate the identity andmagnitude of waste steams which reduces quality or profits. This establishes thecurrent status of the business which can then be compared to appropriatebenchmarks. The desired benchmark or standard of performance is no waste.However, some other intermediate standard maybe chosen to establish a goal forimprovement. Once a goal is established, the company can move ahead in thechange process. The process can be broken down into just a few steps.
1. DiagnosisEstablishing present statusComparing present status to benchmarksGoal setting
2. PrescriptionEstablishing a strategy to achieve the goalDeveloping a plan to implement the strategy
3. ActionExecution of the planEvaluation of resultsAdjustment and then returning to the first step
The diagnostic step is key to the success of the entire change process. Knowingwhere your company stands relative to industry and regulatory standards putsyou in position to evaluate the amount of change needed. In most situationschange is readily accomplished if there is a good understanding of what needs tobe done.
In the next chapter you will find a description of the rules and regulations thatinfluence many of the standards of performance for composites industry. When
Chapter II Page 18
comparing your current level of performance against these standards you willundoubtedly find some deficiencies. The remaining chapters describe variousmethods and technologies that hopefully will help you to identify goodmanufacturing practices to resolve some of these deficiencies.
Chapter II Page 19
Chapter II Page 20
CHAPTERIII
Strategies for Working with Hazardous and Toxic Materials
Introduction
Developing strategies for working with hazardous and toxic materials raise anumber of issues for composite manufacturers. First, to form an effectivestrategy you must understand the terms and laws covering the materials it isusing. Therefore, this chapter will first examine some of the terminologycommonly used in the regulations and then describe the regulations whichtypically govern hazardous and toxic materials and their disposal. Next, theelements of an employee training program for dealing with hazardous andtoxic materials will be listed. The factors detailing a safety and healthprogram are also included. Finally, the regulatory requirements forinforming your employees and the community about hazardous and toxicwastes are listed.
Definition of Terms
According to 40 CFR 261 Subpart A, a hazardous waste is defined as any solidwaste that exhibits any of the characteristics of a hazardous waste or is a listedwaste. These waste materials are considered dangerous to human life andhealth or to the environment. Some common types of hazardous waste are:
l Flammables,l Corrosives,l Chlorinated Solvents.
There are two ways of identifying hazardous wastes. One method is bychecking to see if a material is a listed waste. A listed waste is any materialthat is classified as hazardous by the EPA or by a state or local code. These listscan be found in the document, EPA Notification of Hazardous WasteActivity. If a material you use is included on any of these lists, then it mustbe considered a hazardous waste (Traverse, 1991).
Based on 40 CFR 261 Subpart C, Characteristic wastes are those materialswhich are not included in any of the EPA lists but may meet one of thefollowing criteria:
--4 Ignitability
These are solid waste materials (waste ID number DOOl) which havethe following characteristics:0 it is a liquid, other than an aqueous solution containing less than
24 percent alcohol by volume and has a flashpoint less than 60” C(140” F), as determined by a Pensky-Martens Closed Cup Tester, aSetaflash Closed Cup Tester, or equivalent test methods approvedby the Administrator;
Chapter III Page 21
l it is not a liquid and is capable, under standard temperature andpressure, of causing fire through friction, absorption of moistureor spontaneous chemical changes and, when ignited, bums sovigorously and persistently that it creates a hazard;
l it is an ignitable compressed gas as defined by 49 CFR 173.300 andas determined by the test methods described in that regulation orequivalent test methods approved by the Administrator;
l it is an oxidizer as defined in 49 CFR 173.151.
a Corrosivity
These are solid waste materials (waste ID number D002) which havethe following characteristics:
it is aqueous and has a pH less than or equal to 2 or greater thanor equal to 12.5 as determined by a pH meter using either an EPAtest method or an equivalent test method approved by theAdministrator;it is a liquid and corrodes steel (SAE 1020) at a rate greater than6.35 mm (0.250 inch) per year at a test temperature of 55” C (130”F) as determined by the test method specified in NationalAssociation of Corrosion Engineers (NACE) Standard TM-01-69as standardized in Test Methods for the Evaluation of SolidWaste, Physical / Chemical Methods or an equivalent testapproved by the Administrator.
* Reactivity
These are solid waste materials (waste ID number D003) which havethe following characteristics:0 it is normally unstable and readily undergoes violent change
without detonating;0 it reacts violently with water;0 it forms potentially explosive mixtures with water;0 when mixed with water, it generates toxic gases, vapors or
fumes in a quantity sufficient to present a danger to humanhealth or the environment;
l it is a cyanide or sulfide bearing waste which, when exposed topH conditions between 2 and 12.5 can generate toxic gases,vapors or fumes in a quantity sufficient to present a danger tohuman health or the environment;
l it is capable of detonation or explosive reaction if it is subjectedto a strong initiating source or if heated under confinement;
0 it is readily capable of detonation or explosive decompositionor reaction at standard temperature and pressure
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l it is a forbidden explosive as defined in 49 CFR 173.51 or a ClassA explosive as defined in 49 CFR 173.53 or a Class B explosiveas defined in 49 CFR 173.88.
---4 Toxicity
If the extract of a representative sample of the waste stream containsany of the contaminates at levels above those indicated in Table 3-1,then it is considered toxic. As a generator you have two options fordetermining whether you are discharging toxic materials. First, havethe waste stream tested using the Toxicity Characteristic LeachingProcedure (TCLP). Second, if none of the contaminates listed inTable 1 are used or generated by your processes, you can opt not toperform the testing. Waste ID numbers for toxicity are DO04 - D043.
Regulations
The Resource Conservation and Recovery Act (RCRA)
This act was passed in 1976. It was the first major piece of legislation thatcovered hazardous waste activities. RCRA controls the generation,transportation, storage, management, and disposal of hazardous wastes. Itestablished “cradle to grave” liability for the hazardous waste generator. Thismeans that the generator must know where the waste is being transported, aswell as how and where it will be disposed (Traverse, 1991).
RCRA divides waste generators into three categories:
0 Conditionally exemptGenerators producing less than 220 lbs./month of hazardous waste
l Small quantity generatorsProducing between 220 and 2200 lbs./ month of hazardous wasteProducing no more than 2.2 lbs./ month of acutely hazardous waste(“l? list)Producing less than 220 lbs. of waste resulting from cleanup of spillsand residues of acutely hazardous waste
0 Large quantity generatorsProducing over 2200 lbs./ month of hazardous wasteProducing over 2.2 lbs./ month of acutely hazardous waste
RCRA specifies a number of requirements that need to be met for each levelof generation. Prior to storing, treating, disposing of, or transportinghazardous waste, small and large quantity generators must obtain an EPAidentification number. EPA form 870042, Notification of Hazardous WasteActivitv, is used to begin this process. This form specifically asks a companyto name both the listed and characteristic wastes they will be generating. Oncea company has received its EPA identification number, it will only need tonotify EPA if there is a change in the materials generated at that site or if theyno longer generate hazardous materials at that location. Even though
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I
c o n d i t i o n a l l y e x e m p t g e n e r a t o r s a r e n o t r e q u i r e d t o h a v e a n E P Aidentification number, many waste transporters and treatment, storage, anddisposal (TSD) facilities may require a company to have an identificationnumber before they will handle any hazardous wastes.
TABLE 3-l. Toxicity characteristic chemicals and regulatory levels.
EPA HazardousWaste Number
DO04DO05DO18DO06DO19DO20DO21DO22DO07DO23DO24DO25DO26DO16DO27DO28DO29DO30DO12DO31DO32DO33DO34DO08DO13DO09DO14DO35DO36DO37DO38DO10DO11DO39DO15DO40DO41DO42DO17DO43
Chemical
ArsenicBariumBenzeneCadmiumCarbon tetrachlorideChlordaneChlorobenzeneChloroformChromiumo-Cresolm-Cresolp-CresolCresol2,4-D1,4-Dichlorobenzenel,&Dichloroethanel,l-Dichloroethylene2,4-DinitrotolueneEndrinHeptachlor (and hydroxide)HexachlorobenzeneHexachloro-1,3-butadieneHexachloroethaneLeadLindaneMercuryMethoxychlorMethyl ethyl ketoneNitrobenzenePentachlorophenolPyridineSeleniumSilverTetrachloroethyleneToxapheneTrichloroethylene2,4,5-Trichlorophenol2,4,6-Trichlorophenol2,4,5-TP (Silvex)Vinyl chloride
Regulatory Level(mg/L)
5.0100.0
0.51.00.5
0.03100.0
6.05.0
200.0200.0200.0200.0
10.07.50.50.7
0.130.02
0.0080.13
0.53.05.00.40.2
10.0200.0
2.0100.0
5.01 .oS.O0.70.50.5
400.02.01.00.2
Storage Of Waste Materials On Site -- A second regulation for generatorsinvolves the storage of waste materials on site. Under this regulationconditionally exempt companies may continually store hazardous waste on-
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site unless the quantity exceeds 2200 pounds. Small quantity generators areallowed to store up to 13, 200 pounds for 180 days. Large quantity generatorscan only hold hazardous waste for 90 days. This 90 days begins as soon as acompany starts to collect the waste.
Manifesting Of The Hazardous Materials -- Manifesting of the hazardousmaterials being transported to a TSD is another requirement for generators.As with the EPA identification number, RCRA excludes conditionally exemptcompanies from having to manifest their hazardous waste, but a majority oftransporters still require a manifest. The manifest, (EPA form 8700-22), is amultiple part form which includes the generators name, transporter’s name,and list of the materials that are being carried.
Waste Minimization -- In addition to the information discussed above, themanifest also contains a statement regarding the company’s efforts in wasteminimization. RCRA requires large and small quantity generators to sign astatement which says that they are trying to decrease the amount ofhazardous waste being produced. Large and small quantity generators mustalso submit an annual report detailing their waste reduction efforts.
Large and small quantity generators are required to comply with training andemergency and contingency plan requirements outlined by RCRA. It isrecommended that conditionally exempt generators also train theiremployees and develop emergency and contingency plans. Theserequirements will be covered in more detail in the next section.
Table 3-2 shows a comparison of the RCRA requirements for each of the threelevels of hazardous waste generators.
National Pollution and Discharge Elimination System (NPDES)
There are other laws which also govern the generation of hazardous wastes.The NPDES is a permit program that covers the discharge of hazardous andtoxic wastes into the nation’s water system. Companies using public sewagetreatment systems must meet certain pretreatment standards in order tocontrol the discharge of pollutants which could negatively affect or simpl)pass through that treatment system.
Storm Water -- Included in NPDES are the requirements regarding thepermitting of storm-water discharges (“Storm-water permits,” 1993).Companies must submit an individual permit application which involveswriting a narrative “giving descriptions of the facility and materialsmanagement practices, mapping of the facility, certification that the out-charges do not contain non-storm discharges, and quantitative testing of astorm water discharges” (p. 2). Typically, EPA forms 1 and 2F have been usedfor this purpose. It is required that all new facilities apply for a storm-waterpermit at least 180 days before storm-water discharge. In addition, eachcompany that has submitted an individual permit must develop andimplement a Storm Water Pollution Prevention Plan (SPPI’) within 12
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months after receiving their permit. This plan must include the followingelements (“Outline for action,” 1993):
l Site plan,l Storm water management plan,l Spill prevention and response plan,l Preventative maintenance and good housekeeping program,l Training schedule.
TABLE 3-2. Requirements for hazardous waste generators.
A m o u n tGenerated
Manifest
~~AnnualReport
~ ~~Training
Emergency /ContingencyPlans
CertificationofMinimization
Storage onSite
EPA ID #
ConditionallyExempt
c 220 lbs./mo.
Usuallyrequired by
I1
t r a n s p o r t e r
Not required
Not requiredbutrecommended
Not requiredbutrecommended
Not required
Indefinitely,unlessquantityexceeds 2200lbs.
Not requiredby RCRA butoften requiredby transporteror TSD facility
Small QuantityGenerator
2202200lbs. / mo.c 2.2 lbs./mo. ofacutely toxic
Full manifestrequired byRCRA
Large QuantityGenerator
> 2200 lbs. / mo.> 2.2 lbs. / mo. ofacutely toxic
Full manifestrequired byRCRA
Required I Required
Required Required
Required Required
Required Required
180 days*cannotaccumulatemore than13,200 lbs.
Required
90 days
Required
* 270 days if transportation distance is over 200 miles.
Ch =Ipter III Page 26
The use of sanitary sewer for hazardous waste disposal covers any industrialuser that discharges more than 15 kilograms per calendar year of any listed orcharacteristic waste or any quantity of acutely hazardous waste into publictreatment works. These users must submit a notification of hazardous wastesmeeting those requirements.
The Federal Water Pollution Control Act
The Federal Water Pollution Control Act lists pretreatment standards forwaste water discharged into streams, rivers, lakes, and other water sources.These standards prevent the discharge of pollutants that create a fire orexplosion hazard, cause corrosive damage, cause obstruction to water flow,have a high biological demand, or inhibit biological activity because oftemperature (> 100” F) (Industrial Extension Service, College of Engineering,North Carolina State University, 1993).
The Clean Air Act
The Clean Air Act deals with the burning of solid waste. Section 305 of TitleIII details the Hazardous Air Pollutants program. This section includesdetails on performance standards and other requirements for all categories ofsolid waste incinerators. In addition, 40 CFR 266.100 through 112 details theregulations regarding hazardous wastes that are either burned or processed ina boiler or industrial furnace. Burning, as defined by this regulation, is eitherburning for energy recovery or destruction or processing for materialsrecovery or as an ingredient. There are four limitations that must be met inorder to bum hazardous wastes on-site. These are:
l The hazardous waste burned in a month must not exceed the limits inTable 3-3 that are based on the terrain-adjusted effective stack height(TESH) defined by the equation
TESH=H,+H1-TRwhere: H, = actual physical stack height,
HI = plume rise as a function of stack flow rate and stackgas exhaust temperature,
TR= terrain rise within five kilometers of the stack;
l Hazardous waste cannot contain and cannot be derived from EPAwastes numbered F020, F021, F022, F023, F026, or F027. The F series ofnumbers denote generic process wastes;
l Generator must notify the EPA of intent to operate as a small burner ofhazardous waste;
l Generator must keep sufficient records at the facility for at least threeyears concerning compliance with the requirements of 40 CFR 266.100 -266.112.
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..’ - --- ----.--1
TABLE 3-3. Terrain adjusted effective stack heights (TESH) and hazardouswaste burning rates.
TESH Allowable hazardous waste TESH (meters) Allowable hazardous(meters) burning rate (gal/ma.) waste burning rate
(gal/ma.)0 - 3.9 0 40.0 - 44.9 2104.0 -5.9 13 45.0 - 49.9 2606.0 - 7.9 18 50.0 - 54.9 3308.0 - 9.9 27 55.0 - 59.9 400
10.0 - 11.9 40 60.0 - 64.9 49012.0 - 13.9 48 65.0 - 69.9 61014.0 - 15.9 59 70.0 - 74.9 68016.0 - 17.9 69 75.0 - 79.9 76018.0 - 19.9 76 80.0 - 64.9 85020.0 - 21.9 84 85.5 - 89.9 96022.0 - 23.9 93 90.0 - 94.9 110024.0 - 25.9 100 95.0 - 99.9 120026.0 - 27.9 110 100.0-104.9 130028.0 - 29.9 130 105.0 - 109.9 150030.0 - 34.9 140 110.0 - 114.9 170035.0 - 39.9 170 115.0'or more 1900
The Clean Air Act Amendments are just now beginning to have an impacton the composites industry. A significant aspect of the Clean Air Act and itsincorporated amendments is the Title V permit program. Title V requireseach of the fifty states to implement the program. North Carolina is expectedto start in 1995. Each state will establish its own fee structure, options, andfiling deadlines. Specific information relating to Title V requirements for thecomposites industry can be obtained from the Composites FabricatorsAssociation (CFA) with headquarters in Arlington Virginia, (703) 524-3332.CFA has prepared a guidebook for each state to help members comply withthe provisions of the clean air act.
Title V establishes a permit system for those industries that release or mayrelease any regulated air pollutant in the following amounts:
l 100 tons or more a year;l 10 tons or more per year of any one hazardous air pollutant orl 25 tons or more per year of any combination of hazardous air
pollutants;l Any lesser quantity of a hazardous air pollutant, as established by EPA
rule-making.
In addition to the above amounts, a manufacturing source will also berequired to have a permit if one or more of its emissions units are regulatedunder the New Source Performance Standards (NSPS) or National EmissionsStandards for Hazardous Air Pollutants (NESHAP). If the source is within anozone moderate or marginal non-attainment area, it will also need a permit if
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it has the potential to release 100 tons per year of VOCs or N&. Otherclassifications have more restrictive limits:
l 2 50 tons per year (seriously hazardous),l 2 25 tons per year (severely hazardous),l 2 10 tons per year (extremely hazardous).
Another reason a source may need to obtain a permit is if it releases or hasthe potential to release 5 tons per year of lead or lead compounds.
The permit process varies from state to state but will likely include thefollowing elements:
l general facility information,0 summary information on emissions,l emission unit data,l supplemental data on source control.
An application fee is required for all permits based on the amount ofemissions for that facility. In addition, the generator is required to submitannual reports regarding emission reduction efforts for that year. Title V alsorequires that an annual fee be charged based on the emission level of afacility.
The Hazardous Materials Transportation Act (HMTA)
This act details the requirements for hazardous wastes (Traverse, 1991).According to Department of Transportation (DOT) rules, a label must beplaced on a container before shipment. These labels must be visible, placedon a background of a* highly contrasting color, and should contain thefollowing information about the chemical:
l the proper shipping name,l the United Nations (UN) number for the material,l the name of the shipper,l the name of the receiver.
Although the EPA does not require this level of labeling for materials storedon site, it is often much easier to label these materials as required by the DOTthan to do so while a transporter waits to take these materials off site.
Employee Training
In Title I of the Superfund Amendments and Reauthorization Act (SARA),OSHA was mandated to develop training requirements for workers handlinghazardous waste. In response, OSHA developed standard 29 CFR 1910.120 orHazardous Waste Operations and Emergency Response (Hazwoper).According to this standard, hazardous waste site workers must complete aminimum 40 hour off-site training course with at least three days of on thejob training before they are allowed to handle hazardous waste. The
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following areas must to be covered in this training (North CarolinaDepartment of Labor, 1993):
l Names of personnel and alternates responsible for site safety andhealth;
l Safety, health, and other hazards present on the site;
l Use of personal protective devices;
l Work practices by which the employee can minimize risks fromhazards;
l Medical surveillance requirements including recognition of symptomsand signs which might indicate overexposure to hazards;
l Types of procedures used for decontamination;
l Understanding of an emergency response plan which meets therequirements for safe and effective responses to emergencies;
l Types of procedures used for confined space entry;
l Understanding of spill confinement programs.
Supervisors of those employees directly involved in hazardous wasteactivities must also receive 40 hours of off-site training. Workers who onlyoccasionally work on site or those who are not exposed over the permissiblelimits need to undergo only 24 hours of off-site training and at least one dayof on the job training. Every person successfully completing this trainingshould be issued a training certificate. Each year, following the completion ofthis initial training, an eight hour refresher course is required for all theseemployees.
In addition to the training requirements ofrequired in the safety and health programof hazardous waste:
Hazwoper, the following items areof a company involved in the use
l Site characterization and analysis to identify hazards and make plansfor worker protection;
l Development of site control measures to minimize the potential foremployee contamination;
l Implementation of a medical surveillance program for all new,current, and terminated employees;
l Development and implementation of engineering controls to protectemployees;
Chapter III Page 30
I. ..T.. -
1
. -^..-L...L^.-.,.--. -_---- .__. .
l Selection of appropriate personal protective equipment based on thesite hazards;
l Implementation of a monitoring procedure for hazardous materialexposures;
l Use of information programs to inform all employees includingcontractors of environmental hazards;
l Development of a program for the proper handling of drums and othercontainers to prevent injuries;
l Development and implementation of decontamination proceduresbefore anyone enters a hazardous area;
.l Development of a written emergency response plan;
l Implementation of new technology programs to increase employeeawareness of new equipment, processes, and procedures that maycontribute to their safety and health on the job.
Hazard Communication
Although Hazwoper covers many of the issues of working with and aroundhazardous wastes, OSHA requires that all employees understand the types ofhazards which are found in a facility. The Hazardous Communication(Hazcom) standard or 29 CFR 1910.1200 (North Carolina Department of Labor,1993) covers the requirements entailed in the workers’ right to know rule.The items an employer must comply within this rule include:
l Conducting a hazard determination of the site;
l Developing a written hazard communication program which includesthe methods an employer will use to get the proper informationregarding hazardous materials to their employees;
l Using labels and other forms of warning properly;
l Having material safety data sheets available that contain all therequired information;
l Developing and implementing an employee training program whichincludes the following elements:
1. The methods and observations that may be used to detect thepresence of release of a hazardous chemical in the work area;
2. The physical and health hazards of the chemicals in the work area;
3. The measures an employee can take to protect themselves formthese hazards, including specific procedures the employer hasimplemented to protect employees from exposure to hazardous
Chapter III Page 31
chemicals, such as appropriate work practices, emergencyprocedures, and personal protective equipment to be used;
4. The details of the hazardous communication program developed bythe employer, including an explanation of the labeling system andthe material safety data sheet, and how employees can obtain anduse the appropriate hazard information;
l Applying for and detailing the use of trade secrets.
Emergency Planning and the Community Right to Know
Title III of the Superfund Amendments and Reauthorization Act (SARA)requires industries to notify the community of toxic chemicals which may bereleased either routinely or accidentally. Industries must submit EPA FormR, the Toxic Release Inventory (TRI) Reporting form, if they are classifiedunder the Standard Industrial Classification (SIC) codes 20-39 andmanufacture, process, or otherwise use any listed chemical or chemicalcategory in the quantities prescribed by the EPA. Industries that manufactureand process any listed chemical must use over 25,000 pounds in a calendaryear before they are required to file. Companies that do not manufacture ofprocess but use any listed chemical must file if they use 10,000 pounds ormore in a year. Companies that do not fall into any of these categories do notneed to file (Environmental Protection Agency, 1993).
Conclusion
There are many issues surrounding the generation of hazardous and/ or toxicwastes. They range from initial identification through off-site transportationand final disposal. The legislation covering these different areas, as well astraining requirements, are complicated and often confusing. It is hoped thatthe information in this chapter will assist you in dealing with the wastesfound at your facility.
Chapter III Page 32
:
References
Environmental Protection Agency. (1993). Toxic chemical release inventorvreoortine Form R and instructions (EPA Publication No. 745-K-94-0010).Washington, DC: U.S. Government Printing Office.
Industrial Extension Service, College of Engineering, North Carolina StateUniversity. (1993, September 1). Hazardous waste management for smallouantitv generators. (available from the Industrial Extensive Service,College of Engineering, North Carolina State University, Box 7902,Raleigh, NC 27695-7902).
North Carolina Department of Labor. (1993). North Carolina occunationalsafetv and health standards. Chicago: Commerce Clearing House, Inc.
Outline for action: Storm-water pollution prevention plans. (1993, Summer).Focus: Waste Minimization, 2,4.
Storm-water permits: Applications options. (1993, Summer). Focus: WasteMinimization, 2,2.
Traverse, L. H. (1991). The generator’s guide to hazardous materials/wastemanagement. New York: Van Nostrand Reinhold.
Chapter III Page 33
Chapter III Page 34
/CHAPTER IV
.< Pollution Reduction StrategiesProduction-Based
Introduction
Before your company formulates a strategy for pollution and waste reduction,you have some choices to make. There are two approaches to the task ofpollution and waste reduction. One is containment and compliance, and theother is waste reduction and compliance. The first approach focuses on filtering,trapping, or treating pollution and waste streams. This approach means peoplespraying resin will wear respirators, install expensive ventilation/ make-up airsystems, and properly drum and dispose of toxic and hazardous waste. Thesecond strategy relies heavily on engineering and technology to avoid, remove,or reduce waste streams from the manufacturing system. The “engineered”approach can also be cost effective.
The opportunities available for companies to reduce or avoid waste andpollution streams are dictated by the product type, volume, and the resources acompany has available. Consequently, a company must evaluate theappropriateness of the technologies available to create a strategy that they candevelop and implement. These opportunities can be found in four major areas:
l Product Design,l Materials,l Manufacturing Technology & Methods,l Work-force Ability.
The strategy developed will undoubtedly involve changes in more than onearea. A profitable strategy will probably require a company to make changes inall four areas. Nevertheless, it’s unlikely that a company’s strategy to con+will be purely containment or avoidance. It will probably be a blend of bothapproaches with one setting the theme for the resulting strategy. Consequently,this chapter focuses on various manufacturing technologies and methods forapplying resins to create laminates. Although materials are included in thechapter, this part of the discussion focuses on resins since they are probably themost significant materials in terms of impact on waste and pollution streams.The selection of a resin type and application technologies are the foundation of awaste and pollution reduction strategy.
The methods for applying resin can be classified into two major categories:
1. Spraying wet-out methods,
2. Liquid wet-out methods.
The first category, spraying wet-out methods, includes four types of spray guns,The methods for liquid wet-out are more diverse and include several groups oftechnologies. Examples from these groups include flow coaters, resin rollers,infusion systems, and resin transfer molding (RTM).
Chapter IV Page 35
II_- -_____ ___-_-- Ad- .-._- -- ____ _--._ - . ,
Resin Application TechnologiesRelative Cost Comparisons .
Spray Coat
Spraying Wet-Out Liquid Wet-OutHigh Atomkatlon No Atomization
II Tooling Cost
El Equipment Cost1 Waste and Scrap Cost
cf Workplace and Environmental Control Cost
*With Reusable Bagging
FIGURE 4-1. Comparison of costs for resin application technologies.
When evaluating the suitability of these methods, a manufacturer shouldconsider four categories of cost as they apply to each method. These costs are:
Tooling cost -- The cost to provide a mold suitable for the resin applicationtechnology. RTM has a high tooling cost because it requires both a female andmale mold. Several of the other methods require only one mold.
Chapter IV Page 36
I;r
__ -.__ ---- ------I .-- A-- ----pYY_--
Equipment cost -- The cost of the resin application equipment and the necessarysupport equipment. As an example the resin roller is a relatively inexpensiveapplicator, however, to use it productively requires an overhead trolley tosupport the hoses and static mixer to give the operator complete freedom ofmovement in the work area.
Waste and scrap cost -- Each method of application has an inherent system ofwaste. For example, conventional spray equipment creates overspray and asignificant amount of styrene loss to the atmosphere.
Workplace and environmental cost -- Dealing with waste and scrap generated byeach technology creates a second set of costs. Consider conventional spray as anexample. To use this inexpensive resin application equipment, a fabricator mustalso pay the costs for ventilation equipment, protective clothing and respirators,make-up air, and overspray clean-up.
Figure 4-l shows the relationship of these costs for each of these technologies.The relative cost comparisons between technologies also indicates some of thepotential for improvement in waste reduction. However, factors such as partdesign and volume must also be considered before including one of thesemethods in a waste reduction strategy. These factors and others are included inthe discussion on each of these methods of application in the next sections of thischapter.
Wet-Out Methods Using Spray
This section describes four types of spray systems used to apply gel coat and resinto the laminate. Of the two materials, gel coat is by far the most critical in termsof selecting a spray method because the gel coat must be applied in a denseuniform f i lm th ickness to provide protec t ion to the laminate f romenvironmental stress and furnish the necessary appearance characteristicsdemanded by the customer. Resin application, however, is far less demandingsince most laminators will use rollers, brushes, or pressure to redistribute excessresin in the laminate. Consequently, most of the comments on the followingspray systems reflect the critical application requirements demanded by gelcoating.
Conventional spray guns
The use of conventional spray guns to apply resin and gel coat to open molds isone of the most popular methods in use by fabricators of fiberglass products.Conventional spray application systems pump the gel coat through a fluidnozzle. Once the resin exits the nozzle, it is caught in the turbulence created byair streams exiting the air cap. The atomizing air pressure is typically around 60psi. Most conventional guns spray the catalyst into this steam so that it can bemixed by the turbulence created by the air cap. This type of gun is called anexternal mix spray gun. These systems have been in use for many years.
Chapter IV Page 37
1 ..r-“....v- ___ .._ -_
f:
FIGURE 4-2. Air Atomization nozzle.
The atomization nozzle for a conventional spray gun is shown in Figure 4-2.These systems offer good control over spray patterns but are not well suited for
’ efficient delivery of thick resins such as the newer low styrene resins (~35%styrene) .
Airless Spray Guns
These guns are designed so that resins are atomized by being pumped atextremely high fluid pressure through an atomizing nozzle. Airless spray gunsare considered to be more efficient in delivering resins to the work surface. Largequantities of gel coat and other resins can be rapidly transferred with thesesystems. For efficient atomization and delivery, pressures in the range of 1000 -3000 psi may be required. These high pressures, while necessary for atomizationand spray pattern development, contribute to excessive fogging, overspray, andbounce-back during the spray-up process. Recent developments in spray gundesign have resulted in new systems which blend positive characteristics of bothair and airless spray guns into one unit.
Air Assisted Airless Guns
Like airless guns, these units use fluid pressure to atomize resins through a spraynozzle. However the fluid pressure utilized is considerably lower (400 - 1000 psi)than airless guns and therefore must be augmented by introducing pressurizedair into the resin spray pattern as it exits the pressure nozzle. An example of thenozzle system is pictured in Figure 4-3.
Unlike conventional air spray guns, air assisted airless systems require a verylow compressed air pressure at the nozzle (3 - 30 psi). This low air pressureproduces an envelope which picks up material dispensed from the pressurenozzle tip. The envelope can be regulated to assist in developing a refinedcontrollable spray pattern.
Chapter IV Page 38
sP’=Ynozzle
FIGURE 4-3. Air assisted airless spray nozzle.
Potential Benefits of Air Assisted Airless Spray Guns -- Air assisted airless sprayguns for resin application can not match the high volumes of material transferattainable with airless systems or conventional spray guns. However, thereduction in material losses due to excessive fogging, overspray, turbulence, andbounce-back are significant. The gentle air and pressure atomization allows forthe development of spray patterns that offer a high degree of control whilegreatly reducing the velocity of particles. Lower pressures may help reducematerial waste, maintenance of pressure lines and fittings, and wear on pumps.Reduced delivery pressures can help in providing a cleaner, safer, and morecomfortable work area. External emissions and the need for high levels of make-up air may also be reduced.
Economic Factors -- For gel coating the air assisted airless method does notprovide high material delivery rates and good atomization like airless spraysystems. The lower pressure can result in a coarse orange peel when spraying gelcoat. This can result in a higher than desired variability in the mil thickness ofthe gel coat. When spraying lower viscosity resins these problems are notapparent.
Installation of air assisted airless spray systems does not require extensivemodification of the physical facility or the production techniques already inplace. Spray guns can frequently be adapted to make use of existing pressurepump and control svstems. High capacity air compressors are not required.Attention to nozzle’ cleaning is essential. Other maintenance and repairprocedures differ little from the requirements of other systems. Units areavailable from a number of suppliers (see Appendix C).
Initial expense may be returned quickly in many applications when convertingfrom conventional spray equipment. More of the product will get to and remainon the working area rather than mixing with plant or exhaust air or coming torest on the floor, walls, and other nearby surfaces.
Chapter I\’ Page 39
c ,L&-eA+...---.. -- ___wA-11*11----- - -_ _ _ . .--_--.---A--. ., 1
High Volume Low Pressure (HVLP) Spray
This is the most recent development of the four types of spray equipmentcommonly in use in the composites industry. HVLP is often compared withconventional air spray guns since both use compressed air for atomization.However, HVLP is limited to 10 psi, while conventional air spray is frequentlyoperated at pressures of 60 psi or greater. The higher pressure used byconventional guns creates the fogging, bounce-back and overspray thatcharacterize air atomized spray. All of this results in transfer efficiencies forconventional spray guns of less than 40%. HVLP spray guns, however, can attaintransfer efficiencies of 65% or more (according to one manufacturer). Toaccomplish this transfer efficiency HVLP guns require a high volume of air (10 -20 CFM) delivered at a pressure of approximately 10 psi to atomize the material.Material pressure (hydraulic pressure) coming to the gun falls between 200 to
’ 2000 psi. Once the gel coat leaves the orifice, the low pressure air completes theatomization and encapsulates the resin fan on its way to the mold surface. Thiscreates a soft low velocity spray which accounts for the high transfer efficiency of
, this method.
Potential Benefits -- HVLP spray guns have been evaluated by Hatteras Yachts inHigh Point, North Carolina. In this evaluation Hatteras sprayed small parts aswell as large parts (such as hulls and superstructures). The operators reportedthat the spray from the gun was “soft” and provided a more uniform coat thanthey obtain from their airless spray equipment. They reported that the gel coatflowed more evenly and the surface finish was flatter and smoother. Operatorscompared the finish to a painted surface. The operators also commented thatthey got far less gel coat on them and the odor of styrene and catalysts wasreduced.
Economics -- Hatteras Yachts ran a comparison test between airless sprayequipment and HVLP equipment. In these tests they measured the overspray inpounds of gel coat for two sizes of boats. The overspray from airless equipmentis shown in the Table 4-l.
TABLE 4-1. Overspray from airless spray equipment.
Component Gel Amount of Overspray inCoated Pounds
39’ Hull 11.7
Superstructure 21.5
54’ Hull 16.2
Sunerstructure 29.7
Overspray in PoundsPer Foot
.30
.55
.30
.55
The HVLP spray equipment (based on the operators estimates) reduced theoverspray by 25%. This means that on a 54’ hull and superstructure there was areduction of 11.5 pounds of gel coat overspray. Hatteras estimates that HVLP
Chapter IV Page 40
spray equipment in their application would provide an annualized materialsavings in gel coat of just over $900.
Case Study No 1
Type: High Volume Low Pressure (I-IVLP) spray guns
Company:Location:Contact:Phone:
Hatteras YachtsHigh Point, NCRobert C. Arthur, Engineering(910)~889-6621
Purpose: Reduce overspray of gel coatReduce Material UsageReduce clean-up requirementsImprove gel coat quality
Motivation:
Equipment:
Supplier:
PaybackPeriod:
Comments:
Source:
Reduce wasteImprove product quality
Binks HVLP spray gun
Binks Manufacturing Company9201 Belmont Ave.Franklin Park, IL 60131-2887
Not available
Reduction of waste from overspray compared to airlessspray equipment was estimated at 25%.
North Carolina Pollution Prevention Challenge GrantReport submitted 6 / 16/ 94 by Hatteras Yachts.
combining Reinforcement With Resin Spraying, Spray Lay-Up
The spraying systems described so far can apply gel coat to a mold or resin to wet-*out dry fiberglass. Spraying resin and placing fiberglass in dry sheets m a mold isa common practice termed hand lay-up. However, using spray lay-up, (chopperguns) is an equally common practice for building a laminate. This methodcombines spraying and reinforcement material application into one system. Thesystem consists of a gun-type resin applicator combined with a feeder whichpropels chopped roving into the fan of atomized resin. The gun usescompressed air to atomize the resin, create turbulence to mix the catalyst, andpropel the chopped fiber to the mold surface. (see Figure 4-4).
Chapter IV Page 4 1
glass chopper
s-T lay-up ofresin and
reinforcment
FIGURE 4-4. Fiberglass spray lay-up.
This combined form of resin and material application can build up a laminatevery quickly. However, the extremely high atomization and delivery pressuresin older chopper guns caused high levels of styrene emissions and waste due tooverspray. NOW HVLP spray guns are being adapted to work with a glass fibercutter assembly to create a HVLP chopper gun. Although this means of buildinga laminate is inherently “messier” than hand-lay-up, the use of HVLP spray canreduce overspray and styrene loss through atomization. Manufacturers of sprayequipment can provide additional information on the features andcharacteristics of this equipment. Appendix C lists these suppliers.
Liquid Wet-Out Methods
Prepreg Fiber Reinforcing
For a number of years fabricators of composite aircraft structures have relied onthe use of fiber reinforcements that are presaturated with resins. Thesematerials, referred to as “prepregs,” offer a number of advantages overconventional spray techniques. Resin to fiber ratios can be closely controlled;atomization of pollutants is practically eliminated; and clean-up and disposalproblems are greatly reduced. These advantages are, however, not enough tomake prepregs widely accepted by most fiberglass fabricators.
Prepregs are generally formulated with more expensive epoxy based resins whichrequire placing the mold in an oven or autoclave to complete the cure cycle.These more expensive resins are normally combined with exotic, high strengthreinforcing materials, such as graphite fibers. Storage is also a problem since thematerials must remain refrigerated until the lay-up process is begun. Prepregs
Chapter IV Page 42
appear to be best suited for applications where extremely high strength-to-weightratios are required and cost factors are secondary.
In-House Resin Impregnation
Equipment is now available to provide the fabricator with some of theadvantages offered by epoxy prepregs while using lower cost polyester resins andfiberglass materials. Impregnators can be placed within the lamination area of aplant and mounted in such a manner as to feed resin saturated reinforcingmaterials directly to the molding operation. A static mixer can be incorporatedwith conventional resin pumps and a catalyst metering device to provide theproper mix to a roller-reservoir system. Woven fiberglass is impregnated as itpasses through this reservoir system. A schematic of the system is pictured inFigure 4-5.
Impregnators can be designed to fit a variety of potential applications. The unitscan be mounted for convenience to lift systems, over conveyor fed lines, onbridge cranes, or on portable carts. Conventional resins and roll fiber materialsare used. Machine size and capacity can be engineered to provide a variety ofoutput feed rates and to accommodate a number of roll widths. Units currentlyavailable can produce as much as 20 linear feet per minute with resin-to-glassratios controllable to within ~2%. Larger units have an output capacity whichcan exceed 1,000 pounds of laminate per hour with a 50% glass content.
Potential Benefits -- Impregnators would appear to have considerable potentialfor the reduction of pollution associated with open molding operations.Delivery of the resin to the reinforcing laminate by means of an impregnatorwould help insure that a cleaner, safer, and more comfortable work area wouldbe maintained. Since there would be no spray atomization of resins, the levels ofin-plant and external emissions would be minimized. At the same time,requirements for high levels of make-up air and elaborate air handling systemswould be minimized.
Application potential for impregnators appears to be highest for users of roll typematerials who are either large volume producers or fabricators of largecomponents. Facilities whose molds are widely scattered throughout the plantand are used to produce only one product per day will have difficulty inproviding expensive units for a variety of areas or in moving units to a numberof locations. Fabricators who can consolidate production lay-up facilities can usea single machine to feed operations on a number of smaller molds, whilefabricators of large components can use a single machine to rapidly deliver largequantities of materials.
Quality and productivity may be improved through the use o f res inimpregnation systems. High volume delivery rates can speed lay-up of largecomponents and lead to the development of an assembly line approach tomolding smaller components. Impregnators insure a high degree of control offiber-to-resin ratios and catalyst-to-resin ratios. Worker productivity may also be
-~Chapter IV Page 43
expected to improve because strenuous rolling operations are reduced and airwithin the working environment will be less contaminated from styrene.
reinforcing fiberroll stock
FIGURE 4-5. Impregnator system for fiberglass.
Economic Factors -- For many fabricators, installation of impregnator systemsmay require extensive modification in the plant layout and productiontechniques. The units are more expensive than existing spray applicators, buttheir per unit output can be considerably higher. Use of impregnators by buildersof small boats would appear to be economically feasible only if the facility couldbe arranged so that the molds are handled in an assembly line manner, orsituated so that one machine could be easily positioned to feed a number ofmolds. Impregnators merit attention from any company planning new facilitiesor major changes to existing facilities. Builders of larger components, such aslarge boat hulls or tanks, may be able to use impregnators with little change inplant facilities. Maintenance and repair requirements would appear to differlittle from the requirements of conventional spray systems. Units are availablefrom suppliers identified in Appendix C.
The potential for savings is greatest where operations demand the production oflarge volumes of resin saturated roll stock. Small volume producers are not
Chapter IV Page 44
likely to find great use for currently available systems. Payback potential lies infive areas:
1. Increased output of saturated laminates,
2. More efficient use of materials,
3. Improvement of existing processing strategies,
4. Improvement of laminate quality,
5. Reduction of the need for elaborate air filtration and other pollutioncontrol sys terns.
Units in Use -- Impregnators are in use at Bell Halter Marine in New Orleans,Renaissance Creations in Atlanta, and Syntechnics Inc. in Paducah, Kentucky.Typical applications include the construction of hulls of Navy mine sweepers,production of barge covers, and fabrication of large architectural panels. Mostimpregnator units are used in the production of large components, includingsome structures with weights of several tons each.
Case Study No 2
Type:
Company:
Location:
Contact:
Phone:
Purpose:
Motivation:
EquipmentSupplier:
PaybackPeriod:
Venus Impregnator
Syntechnics Inc.
700 Terrace LanePaducah, KY 42003
Teddy Hold, Plant Manager
Reduce spray-up requirementsReduce plant clean-up requirementsReduce material consumptionImprove production of large components
Maintenance of air quality ’Production improvement
Venus-Gusmer, Inc.1862 Ives AveKent, WA 98032
Not available
Chapter IV Page 45
Case Study No 2 Continued
Comments: Three units are used in the production of large barge andtank covers. In November, 1994 the plant manager, Mr.Hold indicated that the impregnators continue to providethe service and performance expected of them in 1987.
Source: Phone conversations with plant manager (May, 1987 andNovember, 1994) and with the equipment supplier(December, 1986 and March, 1987).
Resin Rollers -- Spray-less Application Systems
Roller dispensing of resin is receiving a considerable amount of attention as apossible method for reducing styrene emissions without requiring majormodifications in molds and materials. Like spraying systems, resin roller
, dispenser units utilize a fluid pumping system to draw resins from drums orbulk distribution lines. This pumping system also includes a separate, fullyadjustable catalyst pump. These two pumps supply the resin and catalyst to astatic mixer. Since atomization is not required, resin delivery pressures are wellbelow 100 psi. Pressures are normally regulated for the purpose of controllingthe rate of resin delivery. Catalyst flow rates are precisely tied to resin flow toinsure a high level of control over catalyst-to-resin ratios and cure rates.Delivery rates for catalyzed resins may be as high as 20 pounds per minute.
A flexible material hose is attached to the mixer and carries the catalyzed resin tothe roller applicator. Units can be mounted to wall fixtures or portable carts.However, a more effective method is to mount the static mixing unit on anoverhead traveler that looks like a lightweight gantry crane. This arrangementgives the operator complete X-Y freedom of movement without having to holdor drag a hose around the work area. This set-up also reduces the volume ofcatalyzed resin and reduces the chance of resin gelling in the wand and roller.The roller handles are normally adjustable in length to allow for a variety ofworking requirements. As the operator rolls out the reinforcing materials, he orshe can control the flow of resin as needed through a trigger mechanism.
The resin flow is distributed by a manifold within the roller. A typical rollercover is about 9” wide by 1 l/2” in diameter and has about 150 holes that areabout l/32” in diameter. This arrangement distributes the resin uniformlyaround the circumference of the roller. In operation the roller is in continuoususe throughout the shift so the catalyzed resin is always being flushed throughthe roller cover until it is discarded at the conclusion of the shift. After the rollercover is discarded, the mixing unit, hose assembly, wand, and roller manifold areflushed using a small amount of solvent recirculated in a closed system.Another advantage inherent in the roller system is the combining of tasks -- theoperator does not need to change tools as often when switching from resin
Chapter IV Page 46
r, h
application to roll out operations. An example of a roller system is pictured inFigure 4-6.
Potential Benefits -- Resin roller dispensers can transfer catalyzed resins to themolding surface totally eliminating material losses due to spray vaporization,fogging, overspray, turbulence, and bounce-back. External emissions and theneed for high levels of make-up air can be reduced. A reduction in unneeded airmovement within the plant can further reduce styrene emissions. The lowdelivery pressures required also help to reduce maintenance while providing acleaner, safer, and more comfortable work area.
Instal lat ion of resin rol ler dispenser systems does not require majormodifications of the production facility or the tooling already in place. Highcapacity air compressors are not required. These units are beneficial in facilitiesthat are not equipped to exhaust and make-up large quantities of air in theworking environment. Since overspray is eliminated the need for protectiveclothing other than gloves is not required with this type of equipment. Otherthan replacing roller covers, routine maintenance and repair will be less than therequirements of conventional spray systems. Although the amount of resinbeing dispensed per minute is less than spray guns, the actual pounds oflaminate produced per hour of labor is very competitive with other forms ofhand lay-up methods. The issue of productivity is addressed in a case study onwaste reduction and profitability found in Appendix A. In the study this methodof resin application was used as part of an overall approach to significantl!reduce costs as well as waste. Units of this type are frequently used in Swedenand Norway because of highly demanding emission regulations. If yourapplication involves hand lay-up then you should consider method of resinapplication. A list of suppliers of roller dispenser units are listed in Appendix C.
Economic Factors -- Resin rollers are available through most companies thatmanufacture spray equipment. In general a laminator can eliminate virtually alloverspray when switching from spray to roller distribution of resin.Manufacturers of the equipment claim that a resin roller will save a laminator ,“1-10% in resin usage. Hatteras Yachts in their study comparing resin rollers toexternal mix spray equipment, found that overspray was completely eliminatedresulting in a 204.8 pound savings in resin on a 54’ hull and superstructure. Theannualized savings generated by one roller would amount to $10,178.’ However,the study noted that productivity was adversely affected and reduced the savingsrealized. Other laminators have noted that the switch to resin rollers requiressome additional investment in work area design and handling equipment to
’ ru’orth Carolina Pollution Prevention Challenge Grant report, Evaluation of Direct ResinAtwlicator and HVLP Gel Coat EcluiDment in Large Fibewlass Boat Construction, Robert C.Arthur, Hatteras Yachts, 6/‘16/94.
Chapter IV Page 47
Resin Feed Hose
/
Handles
Roller Frame Rez
Roller Cover\
Roller Cover CoreDrilled For Resin
Distribution I
;in Tube
FIGURE 4-6. Resin roller and wand.
Chapter IV Page 48
--. - ---_.__- - .-.- ---_ ---- -_ _ __
support the static mixer and supply lines. Changing work methods so that resinapplication is being done continuously using a smaller laminating crew is alsonecessary to achieve the needed productivity and to retain all the materialsavings.
AppIications -- Arjay Technologies in Largo, Florida, has used resin rolling in themanufacture of yachts for many years. In North Carolina several companies areactively studying the application of resin rolling and the changes needed tointroduce the method successfully into their laminating operation. Grady-Whitein Greenville, North Carolina has one unit and is planning to put it into serviceduring 1995. Hatteras Yachts in High Point North Carolina has tested resinrollers and has reported on its use in large yacht construction. The units arewidely available, and most manufacturers of resin dispensing equipment canprovide performance and application information for most open mold products(See Appendix C).
Case Study No 3
Type:
Company:Location:
Resin Roller
Arjay Technologies2020 Wild Acres RoadLargo, FL 34641
Contact:
Phone:
Purpose:
Robert L. Cottrell, President
(813)-538-0600
Reduce overspray of resins and clean-up requirementsReduce styrene emissions
Motivation: Improvement of air qualityImprovement of product quality
EquipmentSupplier: Binks Manufacturing Company
9201 Belmont Ave.Franklin Park, IL 60131-2887
PaybackPeriod: Not available
Chapter IV Page 49
Case Study No 3 Continued
Comments:
Source:
Remarkably clean work area in the laminating room.Noticeable reduction of overspray. Styrene odor was veryslight while one team was working on laying up a deck for alarge sailboat.Plant visit in August, 1994 and phone conversations inSeptember, 1994
Case Study No 4
Type: Comparison of Styrene EmissionsResin Spray vs. Resin Roller
Company:
Location:
Grady-White Boats, Inc.
Greenville Blvd. NEGreenville, NC 27834
Contact:
Phone:
Purpose:
Motivation:
Doug Hoffman, Plant Engineering Manager
(919)-752-2111
Reduce styrene emissions
Improvement of air qualityReduce waste
EquipmentSupplier: Resin Roller
Binks Manufacturing Company9201 Belmont Ave.Franklin Park, IL 60131-2887
Test Conditions: Styrene levels are from the lay-up of a 17’ hull in a 34’ x 58’ bayenclosed on three sides in a larger resin laminating building.Temperature was 76 - 80 degrees with a relative humidity of 40 -45%. The polyester resin was non-surpressed with a 42 - 43 %styrene content. .
Styrene Levels, Time Weighted AverageTest Location Resin Spray Gun Resin Roller
12’ - 15’ from the hull 28.5 PPM 15.0 PPM
Comments: Measurements were taken using low flow pumps calibrated betweer20 - 200 cc / minute using charcoal sorbent detector tubes. Testingconducted during November and December, 1994.
Chapter IV Page 50
Vacuum Bag Molding
The basic methods used in open molding fabrication have changed little duringthe past 30 years. Open molding spray-up and hand lay-up productiontechniques offer a number of advantages for firms that require a limited numberof units from each mold, need a rapid start up, and have limited capital fortooling. Open molding unit costs are high due to the labor intensive methodsand limited daily output. Because of limited production requirements and / orunique product designs, many fabricators will continue to rely on open moldfabrication. However, efforts to improve open molding processing techniquesappear to have gamed momentum during recent years. Some of the advantagesof closed molding technologies, notably higher glass to resin ratios and reducedwaste and emissions, are being sought.
Firms engaged in the manufacture of high performance composites, such asaircraft components, have been forced to develop many new approaches to openmolding. Use of specialized materials such as carbon fiber reinforced epoxyprepregs, exotic core materials, and unique reinforcing fiber combinations has ledto the development of innovative tooling, lay-up strategies, and curingapproaches. While most fabricators will have little use for the autoclavesrequired to work with exotic high strength material, other processing strategies,such as vacuum bagging, appear to have potential for bringing some of theadvantages of closed molding to open molding.
Vacuum Bag Molding Processes
Vacuum bag molding processes can be set up to replace many conventional openmolding operations. Molds are built from the same materials using the sametechniques required for creating open molds. Resins and filler materials differlittle from those used to produce components in open molding. Conventionalgel coating operations can also be utilized.
The vacuum bagging process begins with the application of a gel coat to thesurface of the mold. When a high quality finish is desired, a surfacing layer ofglass is carefully placed over the gel coat. Glass reinforcing and other materials,such as core stock, are cut to fit and placed in the mold. Catalyzed resin can besprayed, pumped, or poured over the lay-up. Where multiple layers ofreinforcing and/or core materials are used, the resin should be applied so thatproper distribution to all parts of the lay-up can be assured. Once the lay-upmaterials are in place, the exposed area’ is covered by special layers of plasticswhich are sealed to the edges of the mold. Before the resin begins to cure, avacuum is drawn through one or more strategically located ports in the mold orthe plastic cover. A cross section of a vacuum bag molding set-up is pictured inFigure 4-7.
A number of benefits can be derived through the use of vacuum bag lay-up.With the exception of the gel coat, resin delivery can be accomplished withoutatomization. Labor involved in rolling out air bubbles and distributing the resinis reduced since the vacuum can be used to insure full distribution of resin to all
Chapter IV Page 5 1
parts of the lay-up. A high degree of control of resin-to-glass ratios can bemaintained by carefully controlling the vacuum and by placing a release film(peel ply) and bleeder material between the laminate and the vacuum bag toabsorb excess resin. Complicated lay-ups with reinforcing core stock can beaccomplished in one operation instead of in steps that require curing before newlayers are added. Product quality and strength are improved since the vacuumremoves trapped air and serves as a clamp to insure tight bonding of allmaterials in the lay-up. The release film, or ply, applied over the lay-up can besmooth or textured to Produce a rough, smooth, or patterned surface.
Vacuum Bag Lay-Up l Step 1Reinforcement materials placed in mold by hand.Resin applied by spray or flow coater.
Fiber Reinforcement & Resin
Core ’
W Mold
Vacuum Bag: Lav-Up l Step 2Apply release ply, bleeder, and vacuum bag to cover wet lay-up.Controlled vacuum applied to eliminate voids and excess resin.
Release Vacuum
Fiber Reinforcement & ResinFilm Bag
I Bleeder ITo Vacuum
I ICore
I
PlY
I I I
SealantTape
Mold
FIGURE 4-7. Diagram of a vacuum bag molding set-up.
Chapter IV Page 52
Since vacuum requirements are typically low and curing takes place at ambienttemperatures, molds can be made of conventional tooling resins andreinforcements. Molds are laid-up over a pattern in the same manner as thoseused for open molding. Some specialized tooling may be required in the form ofvacuum lines, fittings, and ports. A substantial vacuum pump and manifoldsystem are also required.
Potential Benefits -- When spray guns are not used to deliver resin to the mold,styrene emissions can be greatly reduced. Since final distribution of the resin toall areas of the lay-up is largely controlled by the vacuum, gel coating is the onlystep in vacuum bag molding that requires atomization of resin. Pumping orpouring premixed catalyst and resin into a closed mold eliminates fogging,bounce-back, and overspray. Vapor emissions and odor are further reduced byconfining the resins in the covered mold until curing is complete. Excess resincan be trapped by ,bleeder material placed under the vacuum bag. Even dustproducing secondary grinding operations are reduced because the closed moldingsystem eliminates most flash removal and edge smoothing requirements.
Quality and productivity may be improved through the use of vacuum bagmolding. The molding system produces parts with smooth surfaces and internalstructures which are free of voids and excess resin. Open molding may requiretwo or more operations to produce parts with high performance core stock, whilevacuum bagging allows the lay-up to be accomplished in one operation. Start upand tooling can be accomplished quickly and economically. Direct lay-up laborcosts may be reduced, and rate of production from a mold may be improved.Resins used in some vacuum bagging operations may have to be designed for theprocess. With large or complex structures, gel times will need to be extended,and thick lay-ups should use resin systems that will not produce excessive heat.When the application of material can be accomplished within a relatively shortperiod of time, conventional resins may be used.
Economic Factors -- Vacuum bag molding is probably best suited for intermediatevolume production of small to midsize components. Items such as large boathulls and aircraft wing structures have been produced using vacuum baggingtechniques, but large surface areas may be difficult to cover with lay-up materialsbefore resins begin to gel. Products such as seats, boat hatches, boat deckstructures, cored bulkheads, and other items with relatively shallow draft moldsare ideal for this type of processing. The release film can also impart a fair finishon the second surface that may eliminate a need for secondary operations toimprove the inside finish.
Initial investments in vacuum bagging may be returned quickly in someapplications. In comparison to open molding, potential payback is greatest whereproduction rates are moderate, high strength and low weight are essential, andthe shape of the product is not overly complex. Payback potential is limitedwhen the mold design features deep drafts or complex shapes and demands ofquality and strength are only average. A cost that must be considered is the extrasolid waste that this method generates. Although some molders are able to reuse
Chapter IV Page 53
the fittings and even the bagging material, the bleeder material and the release filmare all waste. The amount of cured resin that is thrown away in the bleedermaterial can be minimized by careful application of just the right amount of resin tothe laminate. If this is not controlled, vacuum bagging can be an expensive sourceof solid waste.
Since most fiberglass processors have limited financing for research anddevelopment of new production processes, vacuum bagging with good resin controlis an attractive production alternative. Suppliers of vacuum bagging materials arelisted in Appendix C.
Applications - Vacuum bag molding has been successfully used by Hatteras Yachtsin New Bern, North Carolina, and by Fountain Powerboats in Washington, NorthCarolina. Hatteras uses the process in the production of a number of small partsand for production of floor units and bulkheads for larger yachts. The process isused almost exclusively with high strength-to-weight ratio components which arecored with high performance structural foam. The units produced exhibitedoutstanding structural integrity and good surface quality.
Floor and deck systems produced by Hatteras are essentially large flat shapes thatsandwich several inches of core stock between outer skins of fiberglass reinforcedpolyester. Many of these units are well over 250 sq. ft. in area. Lay-up of the unitsis accomplished in one operation, with resin applied both above and below the corestock. Once all materials are in place, they are covered by a release film, a bleedermaterial, and a vacuum bag which is sealed to the edges of the mold. No gel coat isused on the floor systems since they are covered by finishing materials afterinstallation. For most small parts, molds are gel coated before lay-up is started.
Fountain Powerboats has used vacuum bagging to produce a number of small partsincluding engine compartment hatch covers. Currently they use the technique onlyfor boats produced for the military.
Case Study No. 5
Type: Vacuum Bag MoldingPowerboat Engine Compartment Hatches
Company:
Location:
Fountain Powerboats
P. 0. Drawer 457Washington, NC 27889
Contact: Mike Good, Design Engineering
Phone: (919)-975-2000
Purpose: Improve product performanceReduce number of operations,
Chapter IV Page 54
Case Study No. 5 Continued
Motivation: Quality improvementIncreased production
EquipmentSupplier:
PaybackPeriod:
Comments:
Rimcraft Technologies
Not available
In 1987 vacuum bag molding was thought to be beneficialfor one step lay-up of the high performance materials beingused. In follow-up conversations seven years later,
.’ vacuum bagging is seldom used due to the large amount ofsolid waste generated from the peel ply and bleedermaterial. Builder indicated that use of vacuum baggingapplications would be increased if this waste factor could besubstantially reduced.
Source: Plant visit (May, 1987) and phone conversations (October,1994).
hfusion
Infusion shares many of the characteristics of vacuum bag molding and resintransfer molding (RTM). Like RTM, infusion reduces styrene emissions bywetting out and curing the laminate in a closed system. The use of air pressureto squeeze the resin into the reinforcement fibers is a benefit that infusion has incommon with the vacuum bagging process. One form of the infusion process,known as the SCRIMP (an acronym for Seemann Composite Resin InfusionMolding Process), provides many structural benefits that the developers of theprocess say rival the material and mechanical properties obtained in a highlycontrolled autoclave process. The infusion process creates a high performancelaminate in one “shot” eliminating secondary bonding problems. The processalso provides opportunities to achieve fiber to resin ratios as high as 70:30 alongwith the virtual elimination of air entrapment and voids. The key to the processis the resin distribution system patented by Seemann Composite Systems, Inc. ofGulfport, Mississippi. In general, the patents center on a flexible coverincorporating a medium for resin distribution along with several importanttechnical features that enable a builder to get repeatable properties from a closedmolding system suitable for low volume production.
The process requires a mold similar to any open molding process and a unitaryvacuum bag (see Figure 4-8). The process, as described in the patents, begins withthe fabrication of a bag from silicone rubber to conform to the mold. The siliconerubber compound starts out as a brushable liquid. The bag is made up by
Chapter IV Page 55
ComparisonVacuum Bagging and Infusion
7acuum Bag Lay-UpReinforcement materials placed in mold by handResin applied by spray or flow coater with some hand rolling and tuckingApply release ply, bleeder, and vacuum bag to cover wet lay-upApplied controlled vacuum to eliminate voids and remove excess resinAfter cure, remove and dispose of bag materials, bleeder, and release film
Release Vacuum
nfusion Process - SimplifiedSpecialized fiber reinforcements and core materials placed in mold by handApply special bag to cover lay-upDraw a vacuum and introduce resinControl uniform distribution of resin by use of vacuum*After cure, remove and dispose of bag material**
l-0
3
Vacuum
SpecializedentFiber Reirforce
TTo Vacuum
Mold I*Some infusion processes also make use of a combination
of vacuum and pressure feeding of resin 4 1
“Alternative tooling designs may provide for reusablesoft bags or semi rigid covers
FIGURE 4-8. A comparison of vacuum bagging and infusion processes.
Chapter IV Page 56
applying several coats of silicone rubber over a completed lay-up that has beenleft in the mold. Once the silicone rubber is cured, it can be peeled from themold providing a tough temperature resistant tailored form that can be reusedmany times. The bag or form also incorporates some other features such* as opensided resin distribution ducts with branch conduits to provide paths to flow theresin to all parts of the laminate. At the periphery of the bag are vacuumconduits. Each of the major vacuum and resin conduits is provided with aninlet tube for connecting to a vacuum manifold lead or a resin supply tube. Inaddition, the bag can include a pattern of small pillars, cones, or pyramid shapesformed on the inner surface to hold the bag off the laminate. This provides localpaths for the resin to flow to the laminate and covers most of the fiber lay-upexcept for the perimeter where resin flow is directed into the fiber instead ofacross it. An alternative to this approach is the inclusion of a mesh or resindistribution media which serves to hold the bag off the laminate. Some of thecurrent applications of this process use disposable bags which are used only once.This approach provides a significant amount of solid waste and is probablyjustified only for very low volume production. It’s apparent that the reusablebag makes sense in terms of economics and waste reduction for sustainedproduction.
The sequence of operation for the process begins with laying up the dry fiberglassagainst the mold in the desired amount and orientation. Coring material is alsoplaced in a similar manner. Some builders use a spray adhesive compatible withthe resin to hold the dry fiberglass in place. The vacuum bag with the resindistribution medium is put in place over the dry laminate. Once the system issealed, a vacuum is then applied and the enclosed mold checked for leaks. Afterthe system has been evacuated, the resin is introduced until runoff in the resinchannels indicates that the laminate has been totally impregnated. The moldremains sealed until the resin is cured. After curing, the bag is carefully peeledaway and cleaned for reuse.
The key objective in the infusion process is to create a conforming bag structurefor a specific mold that can be reused without the necessity of laying-inindividual distribution media, resin channels, and vacuum conduits each time apart is made in the mold. This reduces waste and minimizes the variability thatoccurs when a new resin and vacuum distribution system has to be constructedeach time the mold is used.
Potential Benefits -- The reduction of styrene emissions has been widely reportedas a the major benefit from the infusion process. The Hinckley Company locatedin Southwest Harbor, Maine, was able to reduce its styrene emissions to less than200/O of previous levels through the adoption of the infusion process. This,coupled with the company’s acetone reduction program, earned it an“Environmental Merit Award” from the U.S. Environmental Protection Agencyin 1994. The infusion process provides additional benefits for companiesproducing highly engineered laminates that require excellent mechanicalproperties. Mechanical properties in terms of tensile, compressive, and bending
Chapter IV Page 57
strength from the infusion process are comparable to autoclave processing. Voidcontent is virtually undetectable with this process.
Economic Factors -- To use the process laminators must acquire a license to usethe patents and pay for training covering some proprietary techniques developedby TPI (formerly known as Tillotson-Pearson, Inc.) in Warren, Rhode Island. TPIhas collaborated with Seemann Composites to commercialize the process. Eachlaminator will have to evaluate costs and benefits of the process to determine ifthis approach to composite construction is economically feasible for theircircumstances.
Infusion With a Semi-Rigid Cover
Structural Composites in Melbourne, Florida, has developed a molding process. called the Resin Infusion Recirculation Method (RIRM). The process is similar
to the vacuum bag infusion process but with some significant differences. Thismolding process begins by placing dry reinforcement material in an open mold.Next a semi-rigid cover containing ports for vacuum and resin connections is
. paced over the dry laminate and sealed around the edges of the mold. Once allthe appropriate connections are made to the ports the infusion process begins. Avacuum is drawn on the mold to evacuate the air from the laminate. When thisphase is complete, the resin is introduced. The supply tank for the resin has aslight over pressure (2 - 5 psi, gauge pressure) which causes the semi-rigid coverto flex. This flexing opens a gap between the cover and the laminate. The gapprovides a pathway for the resin to move across the laminate to insure itscomplete impregnation with resin. Once the laminate is completely wet-out, theresin inlet is closed and the atmospheric pressure squeezes the cover against thelaminate as in the vacuum bag process. The semi-rigid cover, however, providesa smooth surface giving the completed part a second finished surface verysimilar to Resin Transfer Molding (RTM).
The actual difference between vacuum bagging and this process is the use of asemi-rigid cover. This cover can be fabricated from a thermoplastic sheet andvacuum formed using the open mold with a finished laminate left in place. Thevacuum formed cover should be transparent so that an operator can visuallymonitor’ the progress of the wet-out during infusion. The thickness of the coveris critical since it has to be able to flex at the interface between the resin and thedry laminate while still maintaining its basic form.
Potential Benefits -- The infusion process using a semi-rigid cover provides aclosed molding system that will eliminate nearly all styrene emissions duringthe transfer of resin to the laminate. The process also reduces solid wastes sincethere is no overspray and limited trimming. A significant source of waste inmost bagging processes is the disposal of the bag after molding. In this processthe cover is not perishable.
The elimination of secondary bonding problems is a benefit with this processsince the laminate is created in one “shot.” The process also creates a second sidethat will have a good finish which in most cases will not require any secondary
Chapter IV Page 58
finishing operations. And, if the fabrication of the cover is carefully done, theprocess can furnish a high glass-to-resin ratio providing parts with good,uniform mechanical characteristics.
Economics -- This process provides a middle ground between vacuum *baggingand RTM which is discussed in the next section. The advantage this processoffers laminators is the opportunity to make and modify their own toolingwithout having to go to outside sources. This gives the laminator control oftooling costs and more importantly the ability to make changes quickly andeconomically. This flexibility is not available in RTM and compression molding.The elimination of overspray and bagging material waste provides anotherreason for considering this process.
Type:
Company:Location:
Contact: Scott M. Lewit, PresidentPhone: (407) 951-9464
Purpose:
Motivation:
Supplier:
PaybackPeriod:
Comments:
source:
Case Study No 6
Resin Infusion Recirculation Method (RIRM), Infusionwith a Semi-Rigid Cover
Structural Composites, Inc.7705 Technology DriveW. Melbourne, FL 32904
Reduce styrene emissionsReduce solid wasteProvide laminates with improved mechanical propertiesEase fabrication
Improvement of air qualityImprovement of product quality
Structural Composites, Inc.
Not available
The part being fabricated with this process was a battery trayfor a commercial vehicle. The tray size was approximately3’ by 5’. The tray was a complicated part with severalcompartments. Part weight, strength, finish, and wastereduction were all factors in applying this process to theproduction of this part. Structural Composites providestraining and assistance in technical transfer to companies irthe composites industry.
Plant visit in August, 1994 and phone conversations.
Chapter IV Page 59
. I.. . .,, ._ ._ :
.._,_ 2‘.<’.*_ ‘..
-.
Resin Transfer Molding (RTM)
Fabricators who make fiberglass products can choose from a wide choice ofproduction methods. Open molding spray-up and hand lay-up productiontechniques are frequently employed by smaller firms or those who producelimited numbers of units from each mold. Open molding carries a high perpiece cost due to the labor intensive methods inherent in the process, limiteddaily output from each mold, and waste. Closed mold technologies may offer apractical alternative to reduce these costs if volume and part design areappropriate. Closed molding operations practically eliminate requirements foratomization of resins and may offer a number of production advantages overconventional approaches to molding. The closed molding technologies mostfrequently applied to production of fiberglass components are compressionmolding and resin transfer molding.
-
moldingcompound
FltiUKk 4-Y. Compression molding.
Compression molding can reduce high per unit cost, but only if productionvolume is high enough to sufficiently spread out the high cost of the matchedmetal dies. Special molding compounds of resin and reinforcing materials arenormally required. The molding compounds are compressed between heatedmatched mold surfaces (see Figure 4-9). Output is high because the moldingcompounds cure rapidly in the heated mold. Some materials yield a good finishwithout application of a gel coat. Both surfaces of the molded product will be assmooth as the mold. Compression molding processes have been usedsuccessfully in the automotive industry for more than 25 years. Productionoutput requirements for this type of molding will need to approach 150 parts-per-
Chapter IV Page 60
mold-per-shift to provide a reasonable base to spread out the costs of molds andtooling.
Another closed mold process known as resin transfer molding (RTM) has alsobeen in use for several years. Like compression molding, RTM utilizes matchedmolds. However, the matched molds do not have to be made of metal, and highpressure mold closing systems are not required. RTM appears to offer manyadvantages to firms that seek production volumes of 500 to 10,000 parts per year.
Resin Transfer Molding Processes -- RTM production systems can be set up toreplace many conventional open molding processes. Molds can be producedfrom the same materials and with the same techniques required for productionof conventional molds. The molding resins and filler materials differ little frommaterials used to produce similar components in open molds. Even the gel coatfinishes are the same as those produced in open molding.
RTM is carried out in a closed mold at room temperature. Processing beginswith the application of a gel coat to one or both sides of the mold, depending onrequirements. Glass reinforcing and other materials, such as core stock, areplaced in the bottom half of the mold. The mold halves are closed and securelyclamped. After the mold is closed, catalyzed resin is injected through one ormore strategically located ports. Inlet ports and vents are normally located in thetop half of the mold. A diagram of the RTM process is pictured in Figure 4-10.
Resin injection pressures are typically between 30 and 75 psi.. The matchedmolds are laid-up over a pattern in the same manner and with the same types ofmaterials used to produce molds for open molding. Some specialized tooling isrequired to insure that alignment and clamping pressure are maintained whenthe molds are closed. The molds must also be properly reinforced to avoidflexing during the injection and curing cycles. Inlet ports and vents must beproperly located so that resin is pumped into all parts of the mold. Mold andtooling quality determine the quality of the part.
Potential Benefits -- Pollution output is greatly reduced since application of thegel coat is the only step in RTM that requires atomization of resin. Pumpingcatalyzed resin into a closed mold virtually eliminates vapor emissions and odorby confining the resins in the mold until curing is complete. There is little, ifany, waste of resin. Even dust producing secondary grinding operations arereduced because the closed molding system eliminates most flash removal andedge smoothing requirements.
Quality and productivity may be improved through the use of RTM. Themolding system produces parts that can have an excellent finish on both sides.Open molding requires at least two molding operations and secondary assemblywork to produce parts with two finished surfaces. Since conventional moldmaking practices can be employed, start-up and tooling can be accomplishedquickly and economically once experience with this technology is gained. Withcomplex parts, the lay-up of reinforcing materials, core stock, inserts, and resincan be accomplished in one step.
Chapter IV Page 6 1
Resin Transfer Molding SequenceSpecialized fiber reinforcements and core materials placed in mold by hand.Mold halves closed and clamped shut.Specially formulated resin pumped into the closed mold.Mold remains closed during cure cycle.After cure, part is removed with little or no waste.
Upper Air&.Mold \ / En;
b
SpecializedFiber Reinforcement
LowerMold
f;lG UKL: 4-10. Resin transfer molding.
Low molding pressures required for RTM help reduce many expenses associatedwith other molding approaches. Less energy is required to operate materialdelivery units. Lower operating pressures reduce the cost and maintenance ofpressure lines and fittings. Wear on pumps, accessories, and controls is alsoreduced. Routine clean-up of the working environment should be needed lessfrequently.
Economic Factors -- RTM applications seem best suited for intermediate volumeproduction of small to midsize components. Large items, such as boat hulls, canbe produced using RTM techniques, but tooling costs per unit would be quitehigh. Items such as restaurant seats, hatches, doors, recycling bins, automotiveparts, tubs, and shower units are much better suited to this type of processing.Molds for products of this size can produce parts that require a minimum oftrimming, assembly, and secondary finishing. Initial investments in RTM maybe returned quickly if there is sufficient volume. In comparison to openmolding, potential savings are greatest when production rates are moderatelyhigh and both sides of the component must be finished. In situations whereproduct demands are high enough to require increases in productivity, RTMshould be explored. Some guidelines in the form of questions are shown inTable 4-2.
Chapter IV Page 62
TABLE 4-2. Factors for choosing resin transfer molding.
If you can answer yes to most of these questions, then you may need RTM.
l Production requirements1. Is the part high volume?2. Need two good sides?3. Is wall thickness tolerance important?4. Are delivery dates critical?5. Need a way to reduce styrene levels?6. Is floor space limited for high volume production?
l Secondary operations1. Are size tolerances critical?2. Need good fit and match-up?
l Can you amortize tooling that may be more than ten times as expensive asopen mold tooling?
Since most intermediate volume processors have limited research anddevelopment money, RTM applications have increased at a slow pace. Interestin the technique has remained high as more processors seek ways to improveproductivity and reduce waste and pollution. Economies can be obtained bydesigning the mold used computer aided design software and then turning thedesign into a mold using a computer controlled machining center. Othereconomies can be realized by using customized glass fabric made to size for RTMapplications. Suppliers of RTM equipment are listed in Appendix C.
Units in Use -- RTM has been used on a limited basis by Hatteras Yachts in HighPoint, North Carolina. The process was applied originally in Hatteras’ NewBern, North Carolina plant in the production of a rudder assembly for thecompany’s 65 foot sailing yacht. The rudder assembly has curved surfaces onboth sides and is cored with a high strength structural foam. The units producedexhibited good structural integrity and surface finish and required little in theway of secondary finishing and no assembly operations.
Hatteras Yachts also uses RTM in the production of other products includingtransom door units for large motor yachts. These 4 inch thick curved doorsweigh approximately 15 pounds and have a surface area of almost seven squarefeet on each side. They must fit uniformly in the openings which are moldedinto the transom. To insure high strength the units are reinforced with rollfiberglass stock and are cored with structural foams. The units are finished on allsurfaces so that both mold sides are gel coated.
Chapter IV Page 63
Type:
Company:Location:
Contact:
Phone:
Purpose:
Motivation:
EquipmentSupplier:
PaybackPeriod:
Comments:
Source:
Case Study No 7
Resin transfer moldingYacht door and hatch structures
Hatteras YachtsHigh Point, North Carolina
Robert Arthur
(910)-889-6621
Reduce material consumptionInsure qualityImprove productivity
Reduction of steps required in lay-upReduction in finishing operations
Rimcraft Technologies1914 English RoadHigh Point, NC 27260
One year
In 1986 RTM was introduced to reduce labor for assemblyof components, fairing operations, and finishing. Eightyears later Hatteras Yachts is still using RTM but on alimited scale. They are currently producing a “hingecoaming” and a fish (transom) door using RTM. Otherparts once considered for RTM are being made withvacuum bagging and thermoforming. These processes wititheir less expensive tooling can be justified for low volumeproduction while still providing good fit and finish.
Plant visits during November, 1986 and April, 1987.Phone conversation October, 1994
Rotational Molding, Examining Thermoplastic Options
Products will likely continue to be made by open molding of thermosettingplastics because no other process can meet the design constraints requiringlow volume, large part size, critical mechanical performance, and high styleand finish. Materials such as polyester resins and fiberglass can be combinedin a simple manufacturing system to produce products profitably to meet these
Chapter IV Page 64
constraints. Molds and tooling are simple, and investments in specialtyequipment are considerably smaller than investments associated with othermanufacturing processes. Product lead time can be very short, and the process iswell suited to the production of prototypes and short product runs. Productionrelated drawbacks of the process, however, include high labor content, longproduction cycle times, limited daily output per mold, and high pollutionpotential. Consequently, laminators should consider other materials andmethods that may meet the design constraints without the drawbacks.
The plastic industry as a whole uses far more thermoplastics than thermosettingplastics. Thermoplastics processing offers faster curing cycles, lower emissionsduring processing, lower costs per pound of raw material, ease of recycling, andlower labor intensity. Advances in processing technologies and thermoplasticresin systems are causing many in the industry to examine alternativeapproaches to the molding process. New engineering grades of thermoplasticscan be reinforced with fiberglass or other fibers. These materials can rival thestrength of many of the strongest thermosets. Production machinery and toolingcosts however are still high for thermoplastics forming processes such asinjection molding, extrusion, and blow molding. Often thousands of productsmust be produced in order to provide a reasonable amortization for mold costsalone (large chrome plated steel molds may cost more than $100,000 to produce apart with only a few square feet of surface area). Molds for processes such asrotational molding, however, can be produced at costs low enough to warrantthe interest of some open molders.
Rotational Molding of Small Tanks
Rotational molding is a manufacturing process that produces a rigid or semi-rigid hollow part by charging a hollow mold with a measured amount ofpowdered thermoplastic resin. The process begins by charging a mold which isthen rotated simultaneously around two perpendicular axes. While beingrotated, the mold is subjected to a two phase cycle. During the heating phase themold is brought to the resin melt point and held at that temperature to melt theresin and coat the interior of the mold. Next, the mold rotation is continuedthrough a controlled cooling cycle. After cooling, the mold halves are openedand the part is removed. Cycle times may be as low as five minutes for smallproducts. Times for larger products with thick walls will be considerably longer.Figure 4-U depicts the basic rotational molding process.
Rotational molding provides an attractive alternative to in-plant production ofopen molded assemblies. Tooling costs for molds are considered to becompatible with tooling costs for conventional molds. Rotation molds for thetanks are produced from inexpensive aluminum castings. Because openmolding fabrication and curing cycles are lengthy, a number of conventionalmolds are required to insure adequate daily output of tanks. Only one rotationalmold is required to maintain production. Several companies have replacedfiberglass tanks with thermoplastic tanks using this process. Indications are thatthe thermoplastic units meet design and performance requirements for strength
Chapter IV Page 65
and durability. Per unit costs are compatible with open molding on low volumeruns and less expensive per unit on high volume runs.
FIGURE 4-11. Rotational molding.
Changing from in-plant open molding to rotational molding requires carefulstudy and planning. Changing processes are best done when product redesignsand/or new product designs create a need for new tooling and molds. Chemicaland physical properties of thermoplastic tanks are significantly different thanthose of fiberglass tanks. For this reason basic tank designs will need to be alteredalong with assembly and installation techniques.
Rotational molding is not an answer for all producers of open moldedcomponents. The process is best suited to items which are hollow in structureand require uniform wall thickness. Items which are open, relatively shallow inprofile, or require inserts and internal structural features are difficult to producethrough rotational molding. Replacing in-plant open molding with in-plantrotational molding requires major investments in ovens, materials handlingequipment, and specialized processing equipment. Strength and durabilityproperties of many of the plastic materials used for rotational molding may notmatch properties of materials used in open molding. Appendix C has anequipment supplier listed for this process.
Combining Subassemblies to Minimize Waste
An effective strategy for waste reduction in the composites industry is combiningtwo different functional components into one thus eliminating the source of onewaste stream. A good example of this approach is a patent pending processdeveloped by Structural Composites in West Melbourne, Florida. StructuralComposites has created a means to combine flotation foam with a tailored to fithull stringer system. The product called the PRISMA Composite PreformSystem replaces the traditional wood stringers that manufacturers glass into thehull of motor boats. Typically these wood stringers serve to stiffen t: w hull andprovide mounting points for tanks, engines, and flooring in the boat. The
~~~Chapter IV Page 66
. ..,- ._ _-_ .---_i__-------_ _-_ ._-
Composite Preform System provides a dry fiber-reinforced outer surface that iscast to shape using a two-part self-rising non-CFC urethane foam core. Thecomposite preforms are custom manufactured ready for lamination and can beused in either an open or closed molding system.
Stitch-BondedGlass Fabric
Hull Conforming Box Mold
\ Flotation Foam CavityFilled With- ------ -_-.
Urethane Non-CECIntegral Bonding Tabs
FIGURE 4-12. Integral stringer and flotation system.
To start the process the boat builder has to provide Structural Composites with aboat hull and stringer system (loose). Once received, the first step is to create a setof box molds that accurately conform to the hull, stiffening grid, and the locationpoints for mounting components in the boat. The size of the box molds mustalso be designed to provide the proper buoyancy for the boat. Once the molds arebuilt Structural Composites is ready to begin production of the replacementstringer system. The original hull and stringer system are returned along withthe first preformed system for the boat builder’s approval.
The production sequence for the stringer system is as follows. First, a customstitch-bonded glass fabric is laid out on all sides of the box mold. Next a polyesterfabric (Trevira) is placed over the layers of glass. This provides a liner of materialto which the foam can adhere. Once the box is fully lined, it is closed andclamped in preparation for the foaming operation. The hose delivering thefoam is attached, and the foam is injected into the box molds (see Figure 4-12).The heat and pressure developed by the foam that could distort or mar the boathull is easily handled by the mold. Once the foam is cured, the mold is openedand the glass encased foam stringer is removed. A stringer system is actually a
Chapter IV Page 67
set of interlocking components. Each component is molded separately andplaced in separate plastic sheaths for shipment to the boat builder. Once thefoamed core stringer system has been received by the builder, it is ready to bewetted-out with resin and attached to the hull. One of the unique aspects of thesystem is the extra glass that is provided for attachment to the hull. There is noneed to tape the stringer since the glass extends 4” - 5” from the stringer.Indentations and channels to locate and hold other components are all moldedin as part of the process to facilitate the building process.
Potential Benefits -- Fabricators can simplify their construction processsubstantially by adopting this system. The stringer system provides boat builderswith a well engineered floatation and reinforcing system that speeds theinstallation of interior components. The system also provides a reinforcing
. system that spreads loads out over wide areas of the hull and can substantiallyimprove hull stiffness. The uniformity of the flotation system and its placementalso provides the builder with predictable results. Supplemental blocks can alsobe provided to precisely fit in areas under a deck to provide needed stability.
Economic Factors -- To determine if this approach for creating a moldedstringer/flotation system for your boats is profitable; you will have to carry out acomprehensive review of your manufacturing costs. In general, builders of highperformance boats ascribe the following for benefits to this system:
l Provides a well engineered hull reinforcement system that is less laborintensive to install;
l Creates an integral floatation system;
l Eliminates foaming operations in the plant;
l The structural grid serves as an accurate jig to speed the mounting, locating,and attaching other interior components;
l Eliminates wood as a reinforcement material.
These advantages reduce labor costs and provides a means to substantiallyincrease rate of production without increasing the number of hull molds or floorspace required. The system also reduces scrap.
Case Study No 8
Type: Composite Preform System
Company:Location:
Contact:Phone:
Structural Composites7705 Technology DriveWest Melbourne, FL 32904Scott M. Lewit, President(407) 951-9464
Chapter IV Page 68
Case Study No 8 Continued
Purpose: Improve product performanceEliminate in-plant foamingReduce solid wasteEase fabrication
Motivation: Improvement of air qualityImprovement of product quality
MaterialSupplier: Urethane foam - Non-CFC
BASF and Polyfoam Products
PaybackPeriod: Not available
Comments: The application won Regal Boats a 3rd place ACE Award atthe 1994 Composites Fabricators Association nationalconvention. Structural Composites is currently supplyingstringer systems to five different boat builders
Source: Plant visit in August, 1994 and meeting at the CFAconvention in October 1994.
Materials
Low Emission Resins -- Additives
Low emission resins also referred to as “vapor suppressed resins” are chemicallyengineered to reduce emissions, primarily styrene, which occur while the resinsare curing. There is a sizable difference in performance between suppressed andnon-suppressed resins in styrene loss per pound of resin used in variousprocesses (Chapter II, Figure 2-2). Currently the styrene monomer makes upapproximately 45% of the composition of most general purpose and DCPDpolyester resins. High exposure levels to styrene can occur during the course ofspray-up, lay-up, and curing. Before the cure cycle is completed, up to 10% of thestyrene can be expected to evaporate in as hand lay-up process. The amount ofstyrene evolved is dependent on surface area, laminate thickness, ratio of resinto reinforcement, temperature, and duration of processing. Vapor suppressedresins will do little to limit emissions created during atomization processes,however, they can make a significant difference in reducing emissions duringthe curing cycle.
In concept, suppressed styrene resins are designed to limit the outward migrationof styrene due to normal evaporation and the exothermic process associated withthe reaction of catalysts and resins. Resin producers have experimented with
Chapter IV Page 69
wax type additives which quickly migrate to the surface of the resin and form abarrier to seal in the styrene. Results in terms of emission reduction werepositive. Results related to product quality were less than positive. The waxy
residue contributed to delamination and separation of the composite lay-up.Current research emphasis has been directed at development of chemicaladditives which can block excessive styrene migration without interrupting thebonding structure between resin and reinforcing material or various layers of thelaminated structure. There are some additives being sold which claim to reducestyrene emissions significantly. One source claims both styrene suppression andfreedom from secondary bonding problems.’
Fabricators should work closely with their resin suppliers to keep abreast of newdevelopments related to improved resins and additives for styrene suppression.
Catalysts
Benzoyl Peroxide (BPO) - BP0 has been reported to have a beneficial effect insuppressing styrene emissions. Part of this effect has been attributed to a
e reduction in gel time and a lower peak exotherm (temperature) while curing atroom temperature. This catalyst can replace methyl ethyl ketone peroxide(MEKP) for room temperature curing providing the proper accelerator is used inthe polyester resin. Normally cobalt is included as an accelerator for polyesterresin catalyzed with MEKP. Cobalt however, is not an effective accelerator forBP0 Therefore if you are considering using BP0 as a catalyst, your resin suppliershould be consulted first.
UV Curing Resins -- These resins derive their benefits from a photo sensitivecuring mechanism. UV light serves as the catalyst for this curing mechanismwhich was developed over fourteen years ago by BASF, a large multi-nationalchemical producer. This curing agent or initiator can be used in either vinylesteror polyester resins. The curing process “involves the decomposition of a photo-initiator” by exposure to a particular wavelength of light. Once exposed, thedecomposition produces free radicals which trigger the polymerization reactionof the resin. BASF indicates in their technical literature that laminates up to 20mm in thickness can be cured in one lay-up using this curing mechanism. BASFwill license any resin producer to use their initiator.
Advantages
l The resin requires no mixing with catalysts or promoters.
l There are no limits on processing time hence no “pot life” concerns.
l The resin is not temperature dependent for curing.
l Once the resin is exposed to the proper wave length of light, the resin exhibitsfast gelling and short curing times.
’ An example of this type of product is Styrid. Additional information can be obtained from:Specialty Products Company, 75 Montgomery Street, Jersey City, New Jersey 07303, (201) 434-4700
Gapter IV Page 70
l The cure moves through the laminate starting at the surface and thenmoving inward. The result is limited exotherm and laminate stress.
l Evaporation of styrene is reduced because the laminate is “sealed from theoutside in.”
l Resin not exposed to UV can be returned to storage for re-use.
l Cleaning costs are less since the material will not cure on tools.
Disadvantages
l The resin can not be pigmented.
l Only transparent fillers can be added and then only in limited quantities
l The geometry of the part must allow direct exposure to UV light in order forcuring to take place.
Laminating with UV Resin - The laminating process can be carried out innormal shop conditions using fluorescent lights. Exposure to direct sunlight,however, will cause the resin to begin curing. Other than that precaution, theprocess can be carried out as you would any other lay-up method. The laminatewill not begin to gel until it is moved outside for exposure to direct sunlight orplaced in a room containing UV lighting.
The flexibility of being able to place and roll out a laminate without concern forgel time provides manufacturers with a great deal of flexibility in adjusting crewsize. The entire part can be laid up and then cured as a complete unit. Largerwork can be left “wet” during a break or interrupted for a short period of timewithout any adverse effects. Tools and dispensing equipment do not have to becleaned since the resin is not gelling. Since the resin does not need to be mixedwith a catalyst, the resin can be applied effectively with a flow coater or rollerwithout a mixing and metering system.
Case Study No 9
Type: UV Cured Resins
Company:Location:
International Marine8895 South West 129th StreetMiami, FL 33176
Contact:P h o n e :
Purpose:
Ray Russell, Owner(305)-255-3939Reduce styrene emissionsEase fabrication
Chapter Iv Page 7 1
Case Study No 9 Continued
Motivation: Improvement of air qualityImprovement of product quality
MaterialSupplier: SunRez Corporation
1374 Merritt DriveEl Cajon, CA 92020(619) 442-3353
Agent: Bill GallopRelated TechnologiesPO Box 585038
PaybackPeriod:
Comments:
Orlando, FL 328585038(407)297-7195
Not available
Noticeable reduction of styrene odor. The curing systemprovides total operator control on GEL time. Exotherm isalso well controlled even on thick sections.
Source: Plant visit in August, 1994 and conversations with resinsupplier agent (September, 1994)
Economic Factors -- The cost for including a UV curing mechanism in a polyesteror polyvinyl resin is about $50 per pound of resin. For high volume polyesterresin users this nearly doubles the cost of the resin. The savings that can berealized from improved manufacturing flexibility and reduced styrene emissionsin some circumstances may justify the additional cost. For large volume usersother alternatives may prove to be more profitable in gaining similar benefits.
Low Styrene Resins
“Traditional” general purpose (GP) othro type polyester resins were widely usedby the industry into the early eighties. These resins had approximately 44 - 48 %styrene content by weight. By the mid eighties DCPD (dicyclopentadiene) resinsbecame popular because of improved cosmetics due to reduced shrinkage andtheir cost competitiveness. DCPD blends currently have a slightly lower styrenecontent. However, in 1988, rule 1162 (A South Coast Air Quality ManagementDistrict VOC regulation) required composite manufacturers located in a fourcounty area in Southern California to adopt resins with a styrene content nogreater than 35%. The tough low profile (TLP) resins which are available to meetrule 1162 have a 33.5 to 35% styrene content. Reichhold Chemical, a producer of
Chapter IT.’ Page 72
r /
resins for the marine industry, indicates that the flexural fatigue propertiesdeteriorate quickly when styrene levels drop below 33.5 %. Nevertheless, thefuture according to one resin supplier is “no styrene.” The styrene monomerwill probably be replaced in the resin by a more environmentally acceptablemonomer. The replacement, however, will likely to be more expensive andrequire laminators to develop new techniques to handle the styrene free resins.
Laminating with Low Styrene Resins - Currently, low styrene resins are readilyavailable and in use in Southern California. The most notable characteristic ofthese resins is the higher viscosity. This makes it more difficult for the resin towet a surface and saturate glass fiber. Reichhold indicates that the moldingsurface and glass fiber should be coated with resin and allowed to wet-out 45seconds before roll-out to give the resin a chance to interact with the binders andsurface. Achieving good secondary bonding has also been mentioned as aproblem because of reduced styrene levels. This is due in part because the lowstyrene resin is less forgiving of dust and contaminates on the laminate surface.Therefore, more attention has to be paid to surface preparation as well asfollowing good wet-out procedures.
Resin Storage
A number of approaches are utilized for purchasing resins for moldingoperations. Many processors elect to purchase all materials in 55 gallon drums,while others prefer to purchase resins in bulk quantities. Large firms, such asbath fixture manufacturers, purchase practically all their resins in bulk and storethese materials in large storage tanks. Smaller companies, however, usuallypurchase their laminating resins in drums. Specialty resins such as gel coatcolors, tooling resins, and fire retardant resins are almost always purchased indrums.
When large quantities of resins are consumed, bulk systems offer companiesseveral advantages, particularly lower prices. Lower prices are possible because ofquantities purchased, elimination of packaging in the form of barrels, and ease ofhandling in terms of loading and unloading. Bulk systems are well suited fordelivering large quantities of resins to vats for mixing with fillers or otheradditives. The purchase of drums, however, offers smaller users flexibility tomeet seasonal demand in terms of quantities purchased which enable them tomaintain fresh stocks. Furthermore, drums do not require installation ofexpensive storage tanks, resin delivery pumps and piping, and the need periodicstorage tank clean-up.
Drums do create some problems. A systematic approach to inventory, control,and disposal must be established in order to assure that resins are used beforetheir storage life expires. To maintain uniform properties agitation is needed toprevent stratification particularly if the material has been on hand over twoweeks. Even small FRP operations will collect drums at a rapid rate, and it maybe difficult to dispose of them. Many landfills refuse to accept drums andparticularly drums containing liquids. Disposal of drums containing liquidresidue may require handling the drum as a hazardous material. Storage of full
Chapter IV Page 73
drums and empty ones is also a problem. Considerable floor space is required forstoring large quantities. Again to maintain consistent properties the resin drumsshould be stored at a constant temperature between 72 - 78OF, and should neverexceed 80 OF. Use of drums normally implies a commitment of labor to materialshandling. Drums must be transported from the delivery truck to the storagearea, from the storage area to the point of use, and then from the point of use tothe storage area.
Breather Vent &Clama Armc+nr Agitator
Return Linem1Manholes
Blowout.
II I A I I SUPPlY Linel-l
Valve
-
Containment Dike ’
l Mild steel Underwriters Laboratories (U.L. 142) approved storage tank withepoxy liner or steel tote tank.
l Bottom and top entry manholes (24”) for tank inspection and agitatormaintenance.
l Return lines direct to bottom of tank to avoid static buildup.l Electrically ground all lines and tank.l Temperature controlled enclosure or insulated tank and temperature
controlling medium required.
FIGURE 4-13. Resin storage and delivery system.
Chapter IV Page 74
c
Mini-Bulk Resin Storage - Fabricators can choose an intermediate approach toresin storage that offers some of the advantages of both the bulk and barrelstrategies. This method uses special containers which are large enough to supplyseveral hundred gallons of resin, but small enough to be handled by a smallforklift. These containers form the heart of what is referred to as a mini-bulkresin system. The mini-bulk system uses reusable stainless steel containers ordisposable (fiber box exterior with a polyethylene bladder) containers which areshipped to the user by truck. Since the units can be stacked, floor space dedicatedto resin storage can be reduced significantly. When new shipments of resinarrive, the empty reusable containers are returned to the supplier. The tanks arethen steam cleaned and refilled for delivery. The disposable tanks offer somewaste disposal problems but not to the extent posed by barrels.
This form of resin storage has some disadvantages as well. The problems areprimarily in maintaining the uniformity of the stored resin. These containers donot offer a practical means for agitation. In the case of the disposable tote, thehead opening does not allow a normal drum agitator to be used. In the caseswhere agitators can be fitted, the configuration of the tote prevents the mixers‘from adequately stirring the contents. Therefore, a recirculation system isessential even for mini-bulk storage. Tote users should inspect the tote contentsprior to use to insure that stratification of the contents has not taken place.
Bulk Storage Systems - Fixed storage tanks are very useful and economical forlarge volume users. These tanks can be either vertical or horizontal. Verticaltanks have some advantages since they are easier to agitate and provide lesssurface area exposed to the atmosphere. Stainless steel (type 304) is therecommended material, and it should be phenolic or epoxy lined if promotedpolyester resins are being stored. Do not use copper or brass fittings because thesemetals react with polyester resin and create compounds which may effect thecure, color or shelf life characteristics of the resin. Aluminum and stainless steelfittings are preferred. Figure 4-13 shows an outline of the basic components of abulk storage system.
Resin Circulation System
The bulk resin systems offer a number of positive features. Inventory, productcontrol, and record keeping are easier to manage. Products can be tied directly tothe resin batch used in their lay-up without resorting to extensive record keepingand drum labeling. There is no mixing of different batches from different barrelsor including a barrel of out-of-date material with good resin. There are also nopartially used barrels to dispose of or store. However, a bulk storage systemrequires agitation and a means to circulate the resin from the storage room to thelaminating area. The resin distribution system typically consists of a closed loopplumbing system which is used to circulate resin to all areas of the facility. Acirculation loop is required to prevent resin from solidifying in piping servingareas where resin is used infrequently. During plant operating hours resin iscontinually circulated and returned to the storage tank. This action helps keepthe resins mixed and maintains temperature control of the resin. A positive
Chapter IV Page 75
I -___; ---- ------_III I
displacement pump is ideal for resin delivery. A diagram of a bulk storagedelivery system is shown in Figure 4-14. It should be noted that regardless of thetype of resin distribution system, barrels or storage tanks, the resin should bestirred and temperature controlled. Many resin suppliers also recommend aninert atmosphere be established inside the tank. With good temperature controlthis inert blanket can inhibit color degradation and polystyrene buildup.
Resin circulates in aResin circulates in acontinuous flow to allcontinuous flow to all
I I
plant lay-up areasplant lay-up areas
FIGURE 4-14. Kesin storage and delivery system.
A mini-bulk system was installed at Privateer Manufacturing, in Chocowinity,North Carolina, in 1986. This system has functioned efficiently in this facility.The stainless steel tanks measure 42 inches X 42 inches X 55 inches and have acapacity of 300 gallons. The resin tanks and resin are supplied and shipped byInland Leidy, Inc.. Tanks are unloaded with a small forklift and stored inside themain production area. One central resin supply loop and pump are used todistribute resin to a number of outlets in the adjacent lay-up area. On a perpound basis resin prices are the same as for drum shipments. Other cost savingfactors have emerged. Since less floor space is required, inside storage of resin ispossible. This approach helps keep resins warm in winter and promotes fasterand better curing. Time lost to handling resin drums has been greatly reduced,and production interruptions due to empty resin drums are eliminated. Thecompany owner indicated that installation costs for the resin distribution systemwere recovered in less than a year.
Chapter IV Page 76
_------ -v--I _-------Ad-..- -. -- --A- _ __ _- __ __ ..-- L_I-L-,l;_I ___- >A
Type:Case Study No 10
Mini-Bulk resin storage system
Company: Privateer Manufacturing, Inc.Location: I? 0.69Chocowinity, NC 27817
Contact:Phone:Purpose:
Warren Wilkerson, President(919) 9467772Reduce barrel storage of resinsImprove worker productivity
Motivation: Fewer barrels to dispose ofSimplification of record keepingReduction of operating expenses
EquipmentSupplier: Resin tanks and resin
Inland Leidy, Inc.900 S. Eutaw StreetBaltimore, MD 21230
Resin distribution equipmentRimcraft Technologies, Inc.1914 English RoadHigh Point, NC 27260
PaybackPeriod: Less than one year
Comments: Drum disposal problems were greatly reduced. Productivitywas improved significantly. The labor required for materialhandling was reduced.
Source: Plant visits in August, 1986 and April, 1987 and phoneconversations with plant manager and equipment supplier:(March, 1987). Several years later the plant was closed andpartially relocated. Mr. Wilkerson indicated in follow-upconversations in December of 1994 that the mini-bulk resinstorage system was a worthwhile investment and providedall the benefits anticipated.
Chapter IV Page 77
- . .- ,,“..a .> 9 d _ _ .
I I
. ._.; ._w-- ---. -.---.--‘-.---_;_---..I
Chapter IV Page 78
CHAPTER V
Managing Contaminated SolventsSolvent Use
Acetone and other similar solvents for general cleaning are being replaced inmost open mold fabricating plants. These solvents were widely used to removeuncured resins from spray equipment, rollers, brushes, tools, finished surfaces,and the hands of employees involved in lay-up operations. Since these solventsbecome contaminated with residue from resins and catalysts, they fall understrict governmental regulations (see Chapter 3). Precise records must bemaintained on the delivery, storage, and disposal of these solvents. Disposal ofcontaminated solvents represents a major expense in payments for hazardouswaste removal and disposal. Prices for transportation and storage can exceed$400 per barrel for moderately contaminated waste. Given the RCRA “cradle-to-grave” philosophy regarding waste generation, the expenses may not end with‘payment of invoices for shipping and disposal. Long-term liabilities andresponsibilities for problems that might evolve from storage of contaminatedsolvents must also be considered.
Recent findings supported by the EPA indicate that acetone has negligiblephotochemical reactivity. Consequently, acetone may be redefined as a non-volatile organic compound (VOC) and deleted from the list of toxic chemicalssubject to reporting under the Toxic Release Inventory (TRI). However, acetonewould continue to be treated as a hazardous chemical under RCRA and theClean Water Regulations. Deleting acetone from the list of toxic chemicalssubject to section 313 of the toxic release inventory reporting requirements underthe Emergency Planning and Community Right to Know Act (EPCRA) of 1986would in many cases significantly reduce the reported amount of toxic pollutantsbeing discharged from fiberglass plants.
Nevertheless given the status of current regulations and rising solvent costs,alternative solvent systems should still be considered. There are severalapproaches that are proving effective for the fiberglass industry. The mostpopular approach is adopting a replacement cleaner that can be safely disposed ofin municipal sewers. However, solvents can not be handled in this manner.Therefore, in the case of solvents, recycling is the most viable option since iteffectively concentrates wastes and returns usable solvent to the laminator.
Alternatives to Acetone
There are two groups of acetone replacements that have emerged as effectivealternatives for laminators. Unfortunately, most laminators will probably haveto use both while still retaining the use of a small amount of acetone for specialcleaning problems. The first group consists of high flash point solvents whichon the whole significantly reduce the risk of fire when compared to acetone.Some of the most popular solvents in this group are:
l Diacetone Alcohol (DAA),
Chapter V Page 79
l Dibasic Ester (DBE),l N-methyl Pyrrolidone (NMP),l Propylene carbonate (dioxolanone).
These solvents are more expensive than acetone. But because they are lessvolatile, they have a longer usable life. Also, most of these solvents can beeffectively recycled. Consequently, many of the solvent suppliers are able toprovide recycling services or can recommend a source for recycling.
The second group of acetone replacements is water-based resin emulsifiers ordetergent cleaners. These cleaners are good for washing hand tools, brushes, andequipment. To use these cleaners effectively, a company will have to providewash tanks (heated tanks improve cleaning action) and fixtures to facilitatesoaking and scrubbing tools. These tanks can be quite inexpensive and are easilyfabricated in a maintenance shop. One plant used five gallon buckets with eachone fitted with two scrub brushes permanently mounted on a rack suspended inthe bucket. This arrangement provided a means for soaking tools and using themounted brushes for scrubbing off the residue that remained after soaking. Once.the tools are clean, they can be dried by dipping the tool or brush in a small pailof acetone. Because the primary cleaning is done by the resin emulsifier, thissmall quantity of acetone is changed very infrequently. Although this cleaningprocess is more complex than using acetone alone, it has some significant safetyand cost advantages. One of the major advantages is disposing of waste. Whenthe tanks are emptied, the liquid (the solids in the bottom of the tank are trappedand disposed of separately), can be discharged into a sanitary sewer. However,before this is done a company must notify the municipal authorities and receivetheir permission to do this. Your municipality may require some testing, butthis is neither difficult to do nor prohibitively expensive. The cost of thematerial is also a factor for switching away from acetone. Most resin emulsifiersare very economical when diluted with water to their working strength.
Case Study No 11
Type:
Company:
Location:
Acetone Replacement in a Fiberglass Laminating Operation
Carolina Classic Manufacturing Co.
510 East Jones StreetWilson, NC 27893
Contact: J. N. Eason, Vice President of Manufacturing
Phone: (919) 237-9105
Chapter V Page 80
Case Study No 11 Continued
Purpose: Replace acetoneReduce fire hazardReduce storage of wasteReduce consumption of solvents
Motivation: Eliminate emissions and fire hazard
EquipmentSupplier: Water-based resin emulsifier
Insco195 Cleaner(800) 849-l 133
Solvent replacementSuperiorS-280Indianapolis, IN(317) 7814448
PaybackPeriod: NA
Comments: Carolina Classic reduced their acetone usage by switching toa high boiling point solvent and a water-based resinemulsifier in 1990. As a result, acetone emissions decreased50%, and hazardous waste generation dropped more than70% during the first year. The reduction in acetone usagestill continues. In 1991 the plant used .0148 pounds ofacetone per square foot of product laminated. In 1994 thisrate decreased to .0071 pounds per square foot of productproduced.
Source: Plant visit on November 2, 1994
In-Plant Solvent Recovery
Small Batch Solvent Distillation Equipment -- Some fiberglass fabricators inNorth Carolina are finding in-plant batch type distillation systems to be a costefficient approach for dealing with contaminated solvents. Batch type units haveproven to be successful in meeting the needs of firms producing small tomoderate quantities of contaminated solvents such as acetone. Unit sizescommonly available range from 5 to 55 gallon units.
,
A basic batch type system consists of four major components: a contaminatedsolvent collection tank, a heated boiling chamber, a condenser, and a clean
Chapter V Page 8 I
solvent collection container. A typical low cost system is diagrammed in Figure5-l. The operating systems for these units are typically contained within a singlecompact cabinet. Space required to house a unit is generally less than the spacerequired for storage of virgin solvents and contaminated waste.
COOlbIg
water
JII -1
valveboiling
chamber
FIGURE 5-l. Basic batch solvent distillation system.
Small quantities of contaminated solvents are poured into the solvent collectiontank during normal employee clean-up operations. The contaminated solventcollection tank should have an inlet that can be properly sealed to preventevaporation. A filtering screen should also be placed in the inlet collectionsystem to prevent solids and sludge from clogging pumps and/or feed pipeswhich deliver contaminated resins to the heat chamber. If the collection tank issituated higher than the top of the heat chamber, piping and valves can bepermanently installed so that solvent can be gravity fed into the heat chamber. Ifthe collection tank is not located above the heat chamber, a pumping system maybe required to transfer solvents for processing.
The heat chamber is designed so that a vapor tight seal can be maintained duringheating and cooling cycles. In the chamber contaminated solvents are heated to apredetermined vaporization temperature, and these vapors are channeled out ofthe container to an external condenser. Heat can be supplied by means of electricelements or by steam coils. Steam units offer some advantages in terms of speedand safety. If the plant does not have steam available, a boiler can be supplied bythe manufacturer of the still. The heat chamber will also be equipped with ameans to collect the unusable residue which has been separated from thereclaimed solvent. This residue is referred to as “distilled bottoms” or “stillbottoms”.
Chapter V Page 82
Depending on design requirements, condenser units may be water cooled or aircooled. Water cooled units are generally more compact and more efficient butrequire connection of external water inlets and drains. In the condenser, vaporsare cooled rapidly in order to promote condensation. This condensate is cleansolvent and is drained off and collected in appropriate containers. Thesecollection containers may be either a permanently piped in bulk storage unit orsimply conventional barrels. The solvents collected in this manner are generallyready for use without further treatment or additives. The distillation recoveryoption seems particularly appealing since Federal EPA regulations (Regulation 40Part 261.6) do not require a permit for this type of solvent treatment. However,the North Carolina Solid and Hazardous Waste Management Branch must benotified when a solvent distillation unit is installed.
There are a number of cost factors affected by the use of batch distillation units. Incomparison to conventional disposal techniques, the quantities of solventswhich must be disposed of by hazardous waste handlers may be reduced by asmuch as 90%. Since usable solvents are produced, the outside purchase of virginsolvents can be dramatically reduced. Long-term liabilities for waste disposal arealso significantly reduced. The units do require a considerable initialinvestment. Prices may vary from approximately $5,000 for a basic 5 gallon perbatch unit to more than $40,000 for a relatively sophisticated 55 gallon unit withlabor saving automatic control systems and pumps. Stills also require energy forheat, some labor for operation, and water for the condenser. These operatingcosts will generally be less than 50~ per gallon, with some manufacturersclaiming costs under 204 per gallon. Other expenses include disposal of stillbottoms, bags, and maintenance.
Batch type distillation systems do not require full-time operators or extensiveoperator training. With the most basic design an attendant is normally assignedthe duty of filling the heat chamber with contaminated solvents, sealing theunit, activating appropriate controls, deactivating the controls after the cycle iscompleted, and removing the residue distilled bottoms from the heat chamber.The complete cycle time normally ranges from six to eight hours, but theoperator need only be present during start-up, shutdown, and clean-up. Suppliesconsumed in the processing of solvents are usually limited to disposal bags.
The addition of automatic controls and pumping systems to load waste solventscan greatly reduce labor demands and prove greater assurance that the unit willbe shut down if an operational problem occurs. A diagram of a larger unit withautomated controls is shown in Figure 5-2. Fountain Powerboats inWashington, North Carolina, has used a Recyclene model RX-35, supplied bySouthern Recovery Company, for several years. The unit features a number ofautomatic control systems for materials handling, cycle control, and safety. Linerbags are used to collect still bottoms and keep the boiling chamber clean. Totaloperator time required for each cycle is only 12 minutes.
Selection and installation of a batch type distillation system requires careful studyand planning. Suppliers listed in Appendix C will normally provide expert
Chapter V Page 83
advice about the systems they carry. Demonstrations of equipment should becarried out using representative samples of contaminated solvents from yourfacility. Insurance requirements, safety, and fire codes should be taken intoconsideration before a system is selected and installed. Vapors produced duringdistillation can be highly flammable, so units and surrounding equipmentshould be of an explosion proof design. Results may be disappointing onsolvents which have been heavily contaminated with water or other elementswith high vaporization temperatures.
/ condenserC(Dntaminated recovered
recovered solvent
/ I aitoma tic heat andautomatic distilled bottoms water controlsfill system collector
FIGURE 5-2. High efficiency batch distillation system.
Case Study No. 12
Type: In-plant batch distillation unit
Company:Location:
Contact:Phone:Purpose:
Fountain PowerboatsP. 0. Drawer 457Washington, NC 27889
(9 19) 975-2000Reduction of waste disposal costsReduction of solvent costs
Motivation: Reduced hazardous waste storage and disposalReduction of expenses
Chapter V Page 84
- ,. _.a.. .*.<,.. \,\,- . . . . . . . :* -;... _ r -:.,-.- -;-:.- -. : ‘.*; “L 2’;. -em,:: ‘.->: - . . . .*,-~. ---L---.-L.-----------.--.---.-.------L-AriLi-------. .
Case Study No. 12 Continued
EquipmentSupplier:
PaybackPeriod:
Southern Recovery Co.P. 0. Box 3279Fort Mill, SC 29715(803) 5485740
Less than one year
Comments: Unit is cycled at least once per work day.Approximately 90% of the contaminated acetone is
recovered. Operator time required is less than 15minutes per cycle. Hazardous waste shipments andsolvent purchases have been reduced by at least75%.
Source: Plant visit (May, 1987)
Continuous Feed Distillation Equipment
While batch type solvent recovery units may prove to be successful in meetingthe needs of many North Carolina f irms, large volume producers ofcontaminated solvents may find continuous feed distillation equipment bettersuited to their requirements. Recovery output for continuous feed systemswhich are commonly available can range from 250 gallons per shift to as much as200 gallons per hour.
A continuous feed distillation system requires all of the major componentsincluded in a batch type distillation unit plus more elaborate controls andmaterials handling equipment. An automatic pumping system is required totransfer contaminated solvents from the collection tanks or drums to the boilingchamber. Condensers may be either water or air cooled. The clean solventcollection system must be equipped with a monitoring system to avoiddangerous spills created by overflows.
With continuous feed systems contaminated solvents should be collected in acentralized solvent collection tank as a part of normal operational activities.Contaminated solvent collection systems should be equipped with a device toprefilter solids and heavy gels. The collection system should be properly sealedto prevent evaporation and made of conductive materials to insure propergrounding.
The heat chamber of a continuous feed system will normally be loaded by anautomatic pump system. Some designs allow for overriding of automaticloading systems so that batch processing can be carried out. Heat is normally
Chapter V Page 85
supplied by means of electric heating elements or steam coils. As with batch typedistillation equipment, the heat chamber will also be equipped with a means tofacilitate collection of the unusable residue which has been separated from thereclaimed solvent. The units can also be equipped with vacuum attachmentswhich allow for recovery of a higher boiling point solvents which are taking theplace of acetone.
Just as with batch type units, there are a number of cost factors to be considered inthe selection of continuous feed distillation units. In comparison toconventional disposal techniques, the quantities of materials which must bedisposed of by hazardous waste handlers may be greatly reduced. Since usablesolvents are produced, the outside purchase of materials can be dramaticallyreduced. Long-term liabilities for waste disposal are also reduced. The units dorequire an initial investment that is much larger than that for smaller batch typeunits. Installatidn costs for large units are likely to exceed $50,000. These types ofunits are not likely to be justifiable for firms with recovery needs of less than 100gallons per day.
Because of the major capital investment required, selection and installation ofcontinuous feed distillation systems requires careful analysis and planning.Suppliers listed in Appendix C will normally provide expert advice about themerits of the systems they carry. Merits of the units available should beevaluated on the basis of compatibility with company needs. Demonstrations ofequipment should be requested and carried out using actual samples ofcontaminated solvents taken from the facility. Insurance requirements, safety,and fire codes should be taken into consideration before a system is selected.Because acetone vapors produced during distillation can be highly flammable,the units and surrounding equipment should be of an explosion proof designand well ventilated. Your solvent supplier can provide additional informationon distillation processes particularly if you are planning to reclaim an acetonereplacement solvent.
Ongoing Developments -- Solvent distillation processes are steadily improving.Equipment manufacturers are highly competitive in research and developmentas well ,as marketing approaches. Firms that have experienced poor results witholder in-plant distillation processes will find that the newer designs offerefficient processing, reliable control systems, improved materials handlingsystems, and less operator involvement. These units also feature manyimproved safety features.
Out-of-Plant Solvent Recovery
Recycling Agreements -- Some North Carolina fiberglass fabricators aresuccessfully using supplier based solvent recovery as a cost efficient means ofdealing with contaminated solvents. In firms where in-plant-recycling has notproved feasible or gained favor with management, successful arrangements havebeen made for outside recovery of solvents. Often these arrangements are madewith solvent suppliers who can reclaim the contaminated solvents at a cost
Chapter V Page 86
considerably lower than the cost of producing virgin materials. Contracts andarrangements for these services take a variety of forms.
In some cases “toll” arrangements are made to insure that the waste generator’ssolvents are handled separately. The reclaimed solvents are then returned to thegenerator along with virgin stock. This arrangement helps reduce the likelihoodof solvents becoming contaminated by undesirable substances produced by otherwaste generators. Some firms have developed service agreements which do notplace restrictions on the source of the reclaimed solvents which they purchase.Other companies may elect to specify the purchase of virgin materials only.Separate arrangements, whereby new solvents are purchased from one sourceand contaminated solvents shipped to another firm, are also common
Features of Out-of-Plant Recycling -- As with in-plant recovery techniques, out-of-plant recycling requires an efficient management and control system.Contaminated solvents must be collected in tanks or drums as a part of normalemployee clean-up operations. The contaminated solvent collection systemmust be carefully monitored. A filtering screen should be placed in the inletcollection system to separate solids and sludge. The collection tank, or drums,should be sealed to prevent evaporation and contamination. Water and trashwill drive up the cost of recovery.
Where more than one type of solvent is used, special care must be taken toprevent mixing of dissimilar materials. Each container should be clearly markedwith a chemical identification label and a permanent tag. The label on the wastecontainer should include composition and the method by which the waste wasgenerated. A record of this information should be maintained for each containerand kept in a central location. Containers should not be labeled as waste unlessthe materials they contain are no longer in use. In order to avoid requirementsfor special permits, a management system should be developed to assure thatcontainers are not kept in storage for more than 90 days. Drums should also bestored in a manner that protects them from the weather and physical damage.Leaking drums are a major source of contamination of storm water run off froma plant site. Drums must be in good physical condition or they will not beaccepted by the waste hauler.
Out-of-plant recovery has a number of drawbacks. Shipment of solvent wastemust be carried out by a licensed transportation firm. The waste generator’sresponsibility for the contaminated solvent does not end when it is loaded onthe truck. The RCRA “cradle-to-grave philosophy” places ultimate liability forproper handling and disposal of waste with the generator of that waste. For thisreason short-term transportation liabilities and long-term disposal liabilitieshave driven up insurance costs.
Selection of a recycler and transportation firm should be done with care. Anumber of waste management companies have ceased operations due to legalactions against them or bankruptcy. Failures of this type frequently result inclean-up and dump site management costs being passed on to the wastegenerator. This may occur years after the waste has been shipped. The waste
Chapter V Page 87
management firm’s financial status and approaches to handling incineration,still bottoms, and storage should be thoroughly investigated before any businessagreements are reached.
Hatteras Yachts in New Bern, North Carolina, has elected to use supplier basedsolvent recovery as the primary means of managing and disposing ofcontaminated solvents. Hatteras buys acetone in bulk and a proprietary non-flammable chlorinated solvent in 55 gallon drums from The PrillamanCompany in Martinsville, Virginia. The company also purchases clean drumsfrom Prillaman for the purpose of collecting and shipping contaminated acetone.Contaminated chlorinated solvents are also collected and shipped back toPrillaman in drums.
Prillaman charges Hatteras $10.00 for each clean barrel and issues a credit of $6.00when the solvents are returned for recycling. The net cost to Hatteras fordisposal of each drum of contaminated solvent is $4.00. The company does notpurchase reclaimed solvents from Prillaman but does have an agreement for
Hatteras feels that this arrangement provides for’
purchase of virgin solvents.satisfactory disposal of waste at a reasonable cost and insures delivery of a goodSUDD~V of high oualitv solvents.
Case Study No 13
Type: Supplier based solvent recoveryAcetone and high boiling point solvents
Company:Location:
Contact:Phone:
Purpose:
Motivation:
ServiceSupplier:
PaybackPeriod:
Hatteras Yachts110 N. Glenburnie RoadNew Bern, NC 28560
Andy Misky, Jr., Manager, Facilities Engineering(919) 633-3101
Reduction of waste disposal costs
Limiting ion,o-term liability for waste disposal
The Prillaman Company(703) 638-8829P. 0. Box 4024Martinsville, VA 24115
Immediate in comparison to other out-of-plantmethods.
Chapter V Page 88
Comments:
Source:
Case Study No 13, Continued
The Prillaman Company will take contaminated non-chlorinated solvents for distillation at their facility.The distilled solvent is sold for reuse under name of“Rock” solvent.
Plant visits during November, 1986 and April, 19 8 7and phone conversations with the PrillamanCompany in December, 1994.
Incineration of Contaminated Solvents
Incineration is also an option for disposing of contaminated solvents, such asacetone. Acetone can serve as a fuel source for heat recovery because of its highBTU value and low halogen content. In some industries, companies haveinstalled in-plant incinerators to bum waste solvents. Chapter 3 discusses someof the regulatory issues that a manufacturer must deal with in order to lawfullyincinerate waste. Generally in-plant incineration is too expensive in bothequipment and administrative costs to be profitable for most open molders.Therefore, out-of-plant incineration may be more attractive to molders.
Waste solvents may be sent to cement or light aggregate plants for use as a fuel.This option may be particularly attractive to small producers. Companies, suchas Oldover Corporation, can send their trucks to the customer’s facility, to pickup waste solvents. These waste solvents must be pumpable. Collection can bemade from large tanks or drums. Cost per gallon for the service is somewhatdependent on the nature of the waste collected. When high BTU value ismaintained, costs are reduced. Some contaminants, such as halogen, canprevent the solvents from being disposed of by incineration.
Still bottoms may also be disposed of by incineration. Burning contaminatedsolvents and/or still bottoms in an aggregate or cement kiln produces no ash.This effectively relieves the generator from further liability, since no solid orliquid waste remains.
Just as with out-of-plant recycling, out-of-plant incineration requires an efficientmanagement and control system. Contaminated solvents must be collected intanks or drums as a part of normal employee clean-up operations. Thecontaminated solvent collection system must be carefully monitored. A filteringscreen should be placed in the inlet collection system to separate solids andsludge. The collection tank or drums should be sealed to prevent loss of BTUvalue through evaporation and contamination. Water and trash will also driveup the cost of the service.
Record keeping obligations are not relieved simply because solvents are beingcollected for incineration. Each container of solvent purchased should beaccounted for. Containers should be clearly marked with a chemical
Chapter V Page 89
identification label and a permanent tag. The label on the waste containershould include composition and the method by which the waste was generated.A record of this information should be produced for each container andmaintained in a central location. Containers should not be labeled as wasteunless the materials they contain are no longer in use. In order to avoidrequirements for special permits, a management system should be developed toassure that containers are not kept in storage for more than 90 days. If drums areused for shipment of waste, they must be in good physical condition or they willnot be accepted by the waste hauler.
Transportation remains a drawback of out-of-plant incineration. Shipment ofsolvent waste must be carried out by a licensed transportation firm. The wastegenerator’s responsibility for the contaminated solvent does not end when it isloaded on the truck. The RCRA “cradle-to-grave philosophy” places ultimateliability for proper handling and disposal of waste with the generator of thatwaste. For this reason short-term transportation liabilities are not relieved.
Selection of a waste management or transportation firm should be done withLcare. A number of waste management companies have ceased operations due tolegal actions or bankruptcy. Failures of this type frequently result in clean-upand dump site management costs being passed on to the waste generator. Thismay occur years after the waste has been shipped. The waste management firm’sfinancial status and approaches to handling incineration, still bottom, andstorage should be thoroughly investigated before any business agreements arereached. Ideally, the waste generator should inspect the incineration facility andobserve the operations carried out there. A system for either reclaiming allbarrels shipped or insuring their absolute disposal is desirable. This step mayhelp assure that the waste generator does not bear the expense cleaning up wasteplaced in these containers, at a later date, by another generator. Records relatedto collection and disposal of the waste should be maintained forever. A formthat would be useful for internal record keeping and tracking of solvents ispictured in Figure 5-3.
Chapter V Page 90
c 4
FIGURE 5-3 Internal record for tracking waste solvents and disposal.
Chapter V Page 9 1
Chapter V Page 92
CHAPTER VI
Management and Facility Based Pollution Reduction
StrategiesProcess Control Strategies
An effective approach to waste reduction is process control. Although processcontrol focuses on hardware, it is in reality a management technique forcontrolling variability. Variability is the most common cause for waste andrework in manufacturing. In many cases excessive variability can be caused by alack of operator knowledge or experience. However, many processes are difficultto control because there is no direct feedback to the operator. Consequently aprocess that relies heavily on the skill and experience of the operator is thereforeinherently variable unless there is some feedback to guide the operator.
The process of driving a car on a highway has been used to illustrate how processcontrol works in these situations. Consider a driver keeping an automobile in itslane on a two-lane highway. If the car is in good shape mechanically, the driveris experienced, the day is clear and bright, and the road is straight, then staying inthe right lane is easy. However, if the road begins to twist and turn and visibilitydecreases it becomes more difficult to stay in the lane. To maintain speed(production) the driver needs more road width or well lighted markers showingwhere the road is going.
Now consider one of the most critical production processes in laminating -- gelcoating. In gel coat spraying getting the proper thickness is difficult to achieve.Consequently, many laminators spray on more gel coat than is needed to insurethere are no thin spots. This approach is adding more material than needed(increasing waste and reducing profits) to prevent the customer from beingshort-changed on quality.
In gel coating, once the bright base color of the mold is covered with 5 or 6 milsof gel coat the visual guides are gone for the gel coat sprayer. The operator isnow spraying “blind.” Consequently, to keep the process in control the operatorlike the driver, needs to have some markers or guides. For a particular mold theoperator can use a wet film gauge to measure the thickness of the gel coat. Thisis useful in gaining experience, but in a production setting stopping to measurewet film thickness is awkward. Therefore, a marker or running guide is needed.
Most gel coat spraying is done using a positive displacement piston pump whichmakes a distinct sound when it reaches the end of a stroke. Each stroke indicatesthat a precise amount of gel coat has been sprayed. Consequently, there are aspecific number of pump strokes needed to-provide a definite mil thickness on aparticular portion of a mold. If this volume is known, the operator can countthe strokes of the pump while spraying that section of the mold and bereasonably confident that the right thickness has been obtained. Another way to
Chapter VI Page 93
MARINE MANUFACTURING INC.Gel Coat Control: Hull Application
Z o n e - A 1 Zone - B I Zone - C
I I
Model #
Serial #
Date
Operators
Gel PumpStrokes/TimeStandard Strokes
Zone A Zone B Zone C
Actual Strokes
Standard Time
Ac tuai Time
Gel Zone A Zone B Zone CMils 1 2 3 1 Range 4 5 6 Range 7 8 1 9 Range
Standard 10 10 10 +1 10 10 10 +l 10 10 10 +l
Actual
/
NOTES
FIGURE 6-1. Gel coat control form for a hull application.
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-- _ - -- .-__ _ _-__-_.-_.- .-A.L.~L-.~ - _-. -- _- ._------
MARINE MANUFACTURING INC.
Gel Coat Control: Deck Application
Z o n e - A 1 Zone-B i Zone - C
I I
Model #
Serial #
Date
Operators
Gel PumpStrokes/TimeStandard Strokes
Zone A Zone B Zone C
Actual StrokesI I I
Standard TimeI I I
Actual TimeI ’ I I
GelMils
Standard
Actual
Zone A Zone B Zone C1 2 3 ( Range 4 5 6 / Range 7 8 9 Range
10 10 10 fl 10 10 10 ,+l 10 10 10 zkl
NOTES
FIGURE 6-2. Gel coat control form for a deck application.
Chapter VI Page 95
MARINE MANUFACTURING INC.
Gel Coat Control: Small Part Application
Part name
Model #
Serial #
Date
operators
II
Zone-A i Zone - B
Gel PumpStrokes/Time
Zone A Zone B
I Standard StrokesI I
I Actual StrokesI I
I
Standard Time
Actual Time
NOTES
FIGURE 6-3. Gel coat control form for a small part application.
Chapter VI Page 96
look at this is to consider the sound of the pump stroke as the rate or tempo forapplying the gel coat.
To create these guides or rates an operator is going to have to record the pumpstrokes and the resulting wet film thickness on a worksheet for the first partsbeing made from the mold. An important part of the recording process isassociating the pump strokes with zones on the mold. Therefore, it’s importantto sketch the mold outline and the zones on the worksheet to develop theinformation needed. A key part of this technique is identifying zones that matchup with good spraying practice. Filling out the worksheet initially may seemtedious, but it is a one time set-up to learn how to spray (“drive”) the mold.After the worksheet is filled out it becomes the process guide for providing moreuniform gel coating and less waste.
Examples of worksheets with sketches of boat shapes are shown in Figures 6-1, 6-2, and 6-3. These worksheets indicate how a boat builder might divide thecomponents of a boat into areas. In practice it does not matter what the productis, but the surface being sprayed should have two or more defined areas to serveas guides. Once the areas are established, the person spraying the gel coat willmark these as spray zones and note the pump strokes needed to properly coateach zone. Then, as the mold is being sprayed the operator counts the pumpstokes -- pacing the spray application to use all the allotted pump strokes in thezone. Since most companies have a wide variety of molds, an appropriateworksheet should be developed for each one so the guides are availablewhenever that mold is being gel coated.
Carolina Classic, a manufacturer of bathtubs and related fixtures, has taken thisapproach and simplified it through the use of a programmable logic controller(PLC). The PLC is an industrial computer which can be programmed to control asequence of events in an industrial process. At Carolina Classic they createdseveral short programs that contain the spray time it takes for each model of tubor fixture and loaded the programs into a PLC. In this application the company iscontrolling the amount of glass chop and resin being applied to the mold.When an operator is ready to spray chop onto the mold, he or she presses thebutton on the PLC for the appropriate model and begins spraying. Just as soon asthe trigger on the gun is depressed, the PLC counts time. When the trigger isreleased, counting stops. At the instant the spray time is 3/4 elapsed, a hornsounds and the operator continues to complete the mold. After all the time haselapsed, the horn sounds continuously. The operator can spray even when thehorn is on, but the horn is intended to pace the work and give the operator andthose working in the area confirmation that the amount of material beingapplied is in control. A schematic of the PLC system is shown in Figure 6-4.
Control of Materials -- Material consistency is also an integral part of processcontrol. For a laminator the most critical materials are the gel coat and resin.The complex chemistry that takes place in a laminate is determined largely bythese materials. Consequently, if the process is to be controlled, the laminatormust kno\v beforehand if the materials to be used are going to perform as
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expected. Therefore, a performance test of the materials should be done onreceipt of materials and periodically over time if the resin batch is not used up intwo weeks. The importance of this type of testing became clear to the authorswhen the owner of a small boat building company related an experience he had.His company purchases resin by the barrel and usually only two barrels at a time.On receipt of an order of resin he samples the resin and performs some simpletests which include time to gel. On one particular order he found the resin didnot gel. After rechecking his results, he called the resin supplier and explainedthe problem. The resin supplier got back to him later and reported that his testresults were correct -- the resin he received was shipped mistakenly without anypromoter. The resin supplier also volunteered, that the same batch consisting ofhundreds of barrels, had been shipped to another builder who was using theresin unaware of the problem.
Programmable LogicController
Control Panel
button for eachmold unit loadspreset program
l PLC is connected to resin application system and operator control panel.@Operator selects control button for the established program for the mold beinglaminated.l PLC loads the program and monitors quantity of resin applied and/or time requiredto complete operation.
.PLC can provide operator with immediate feedback as well as record as well asrecord and download data for analysis.
FIGURE 6-4. A schematic of a PLC control system for gel coat application.
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A company’s size does not determine its level of sophistication nor its ability tocontrol its manufacturing processes. Small companies can adopt elementsprocess control as easily as large corporations. The incoming tests for resins donot have to be time consuming or expensive. The value of these tests will showup in two ways. First the tests establish a history of performance for eachsupplier. Next, they provide confirmation to you that the material behaves asexpected. When problems do occur, you will be able to quickly rule out thosefactors which you know are correct. This helps to quickly identify the source ofthe problem.
An example of the basic information and tests needed to begin a material controlprogram for resin is shown in Figure 6-4. For companies wishing to movebeyond this basic level, there are several sophisticated approaches that can beadopted. Specific tests and recommendations can generally be obtained fromyour material supplier. Also, companies looking for a more general andcomprehensive approach to manufacturing control should look at the guidelinesfor the North Carolina Quality Leadership Award. Information about this awardcan be found in Appendix D.
Material Record
Purchase Order. #
Date Rec’d -/-/-
Supplier Name
Lot Number
Product Designation
Amount
Catalyst indicator -yes -no
Comments:
lncominn Tests I Value I comment
Item
Gel Time
Peak Exotherm I I
Time to Peak I ITemperature
Humiditv
I Approved by:-
FIGURE 6-4 Resin material record and incoming tests.
Plant Layout -- Localizing And Isolating Problem Operations
Plant layout is an art and science. The art requires skill and creativity to blendfinancial resources, technology, existing structures, and a sense of future needsinto an efficient productive factory. Science prescribes the application oftechnology to create the product. A well run plant is going to properly usetechnology consistently to be a profitable factory. Unfortunately many plantsstart-up without the benefits of good art or science. Some plants begin well butover time slip into becoming a workshop. A workshop is a general purpose areathat is not well suited for any particular technology or product. A factoryhowever is an organized facility that is able to efficiently replicate one or severalproducts profitably. A profitable factory is able to control waste and
Chapter VI Page 99
systematically reduce waste over time. In the preceding chapters severaltechnologies for producing composites were discussed. In the following sectionsin this chapter the discussion changes to the arrangement and housing ofproduction equipment in a factory for open molding.
Pollution Sources -- Use of spray guns for applying resin to a laminate iscommon practice for most open mold fabricators of fiberglass products. Gun-typeresin application systems use either compressed air or high fluid pressures orcombinations of both to atomize resin materials for efficient delivery to the worksurface. As discussed in Chapter 4, HVLP spray systems are considered to behighly effective in delivering resins to the work surface. Gel coat and otherresins can easily be transferred in the quantities needed to maintain high levelsof productivity. Even the most effective spray systems produce some oversprayand styrene vapors while older conventional guns can produce large amounts ofoverspray making surrounding areas unfit for any other activity.
Factors other than spraying also contribute to pollutants entering the workplace.Even if resins are applied by processes not requiring spraying, the very nature of
’ their chemical curing process will still produce considerable vapor and odor.There are always other environmental and physical dangers such as chemicalspills involving resins, catalysts, or solvents. Because of the nature of thesechemicals, there is always considerable risk of fire and explosion. Pollution inthe form of airborne dust particles is also a potential problem since mostproducts require post-molding grinding and finishing operations.
In the course of preparing the original manual and this revision more than fortyvisits were made to plants where open molding accounted for a sizable part ofproduction activities. All of these processors expressed concern aboutmaintaining a safe plant environment and minimizing pollution. Many hadundertaken effective measures for implementing pollution reduction strategies.Some approaches to reduction involved innovative changes in plant layoutand/or major mechanical systems. Just as with some of the production-basedapproaches to pollution reduction, a number of the facility-based pollutionreduction strategies involved relatively simple measures with extremely highpayback potential. Other approaches involved equipment outlays and facilitydevelopments with very high capital outlays which would be difficult to recoverthrough increased productivity.
Isolating Problem Areas
Many firms are producing open molded products in physical facilities that arepoorly designed for the production techniques used. Fabricators often performspray-up in large open structures. This approach normally results incontamination of air throughout the entire facility and necessitates rapidturnover of plant air in order to reduce airborne vapors and solids. Because ofthis turnover, expenses involved in heating make-up air are increasedsignificantly. When incompatible activities are carried out in these openfacilities, there is also considerable potential for cross contamination, such asdust in gel coat finishes or airborne trash falling in the lay-up. Figure 6-5
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provides a diagram depicting typical facility problems. A number of benefits canbe derived from segregating or isolating some production operations.
Confining Gel Coat Applications
Confining spray application of gel coats is not an uncommon practice in theindustry. Gel coats carry a relatively high filler content and require highpressures for atomization. Because of these pressures, considerable aircontamination occurs in the form of overspray and bounce-back. In comparisonto other steps in the fabrication process, gel coating is normally considered to beone of the greatest producers of airborne pollutants. Some high volumefabricators, such as bathtub producers, have successfully utilized movingassembly lines to move molds in and out of enclosed spray booths for gel coatingand other spray operations. Other fabricators, such as builders of small andmedium sized boats (up to 45’), have constructed large spray booths for use in gelcoating. These builders use mobile mold fixtures and/or overhead lift systems tomove molds in and out of the spray area.
With a relatively confined working area for gel coat applications, a number ofpollution, safety, and housekeeping problems become easier to manage. In aconfined gel coat area measures to insure worker safety are simplified. Sincethese units are isolated from other parts of the facility and can be equipped withseparate climate control and ventilation systems, only the workers directlyinvolved in the application process need risk exposure to atomized vapors andsolids. Potentially explosive vapors are also prevented from entering the plant.Exhaust and make-up air are easily directed to a particular area, thus avoidingunnecessary and inefficient turnover of air throughout the plant. With thisapproach only the workers in the gel coat room need wear appropriate safetyclothing, eye protection, and breathing apparatuses. Providing “cherry pickers”to move the operator close to the spraying surface on large molds reduces thespray distance which can substantially decrease styrene loss.
Localizing the gel coat application also means that appropriate filtering systemscan be placed in the exhaust system in order to reduce the output of airbornepollutants. Where regulations, company policy, or nuisance odor problemscreate pressures on the fabricators, confining gel coat applications should meritconsiderable attention. High pollution outputs associated with gel coatapplication increases the payback potential for filtration or other treatmentprocesses, especially if the spray output can be isolated and confined.
Plant maintenance operations and housekeeping can benefit from confining gelcoat application to isolated booths or bays. Where application is carried out inthe open plant environment, some undesirable output of resins in the form ofheavy vapors and solids results. This contamination can affect air throughoutthe facility creating nuisance odors and a potential for respiratory problems. Anincrease in the risk of fire can develop because heating, air conditioning, and airhandling systems throughout the plant will become coated with a build-up offlammable solids. Walls and floors throughout the area also become coated with
Chapter 1’1 Page 101
lamination area
airinlet
1
deck and small part hull lamination area
this build-up. Efforts required to keep equipment and fixtures clean also increasein plants where gel coating applications are not confined. A well designed gelcoat application area keeps these contaminants out of the other plant areas. Suchunits can be easily equipped with disposable wall and floor coverings, filters toprotect ventilation systems, and other features which help insure safety andsimplify housekeeping chores.
Other benefits gained from isolation of gel coating activities include a number ofquality related factors. An isolated spray-up area will not be contaminated byother operations in the plant. Mold surfaces and the resulting product finishesare less likely to be damaged by dust or particles from grinding operations or byfibers and resins from nearby lay-up. The climate in a closed area can beregulated in terms of temperature and humidity in order to insure a proper andconsistent chemical cure of resins. Special lighting can also be provided toimprove visibility and eliminate shadows that might cause improperapplication. As long as the mold remains in the spray area, there will be nonearby operations to damage or contaminate the coating before it cures.
Approaches to Gel Coat Isolation
Although use of specialized booths or bays for gel coat application is not a newapproach, there has been a recent increase in the number and types of operationselecting to use this type of facility. Use of spray booths for gel coating is mostcommon with the producers of relatively small items or high volume producerswho have incorporated moving assembly lines into their processing operations.A number of firms have elected to use readily available production type spraypainting booths. This approach appears to work well when relatively smallmolds are used. Small mold fixtures are usually moved in and out of the boothby hand. Where high production is necessary, labor requirements can be reducedby using fixtures such an overhead chain conveyors or track systems to moverelatively large units like hot tubs or shower enclosures.
The. Lasco Bath Fixtures Division of Phillips Industries in South Boston,Virginia, designed their new plant to make use of an overhead chain system tomove conventional fiberglass tub molds through various production areas.These production areas include self contained gel coat and spray-up areas, heatedcuring booths, demolding, and finishing. The system allows Lasco to minimizelabor used in materials handling while allowing for easy isolation of areas whichgenerate most airborne pollution. Carolina Classic in Wilson, North Carolinahas several gel coat spray booths in a separate room devoted to gel coat sprayingand mold preparation. Each spray booth is fitted with fixtures which allow theoperator to rotate and position the mold within the booth for ease of spraying.Using spray booths has improved productivity and helped eliminate nuisanceodors in other areas of the production facility.
Builders of larger products such as boats, custom engineering fixtures, andautomotive body structures have been slower in installing self-contained gel coat
Chapter VI Page 103
facilities. Even with relatively small boats in the 18 to 25 foot range, moving amold in and out of various production areas is difficult. The task is moredifficult when mold lengths approach 40 feet or more. It becomes nearlyimpossible with mold lengths of 50 feet or more. With most of these .producersoutput per mold rarely exceeds one unit a day. This low output means thatpotential for developing highly mechanized assembly line strategies is limited.
Fountain Powerboats in Washington, North Carolina, has installed a large gelcoat spray booth in its recently expanded production facility. The companymanufactures high performance offshore speedboats up to 12 meters in length.The new spray booth is completely self-contained and is completely equippedwith explosion proof electrical systems and an elaborate lighting system. Moldsup to 50 feet in length are mounted on special fixtures which allow them to berolled to various locations in the facility. These fixtures are designed so that themolds may be rolled from side to side to permit easy worker access for sprayingand lay-up. Fountain elected to build and use an isolated booth for a number ofreasons - gel coat quality, safety, and plant air quality were major factors in the
c decision.
Since the boats produced are very specialized high performance craft with pricesthat may enter the six figure range, exterior finish quality is extremely critical forcustomer satisfaction. The company feels that the quality of the gel coat finishcan be more consistently maintained by using a spray booth rather than byspraying in the open plant environment. Trash and other contaminants arepractically eliminated. High intensity lighting, required to insure that theoperator can deliver a consistent coating, is easier to provide in the booth.Overspray and fogging are reduced since a high volume of air turnover can beeasily maintained in the spray booth. The temperature and humidity in thebooth can also be maintained at levels which promote proper curing of the gelcoat resins.
There seems to be little doubt that the use of an enclosed and environmentallyisolated area for gel coating can result in a number of benefits. A highly efficientexhaust and make-up air system can be used to remove contaminated air fromthe spray area. Odors, vapors, and solids are prevented from contaminatingother parts of the facility. Where emission outputs are high enough to requirefiltration or purification, the treatment systems will be much less expensive andmore efficient if they are not required to filter air from the entire facility. Overallrequirements for plant ventilation and make-up air will also be greatly reduced.Overall plant safety can be improved and potential fire hazards reduced.
Approaches to Isolating Other Operations
Use of conventional spray guns for resin results in contamination similar to thatproduced in gel coat application. Not only do these spray-up systems deliverlarge volumes of resin, but they may also be equipped with glass choppers tochop fiberglass roving into short lengths and spray it onto the molding surface.Some alternative production approaches and equipment are discussed inChapter 4. Many of these alternative approaches have the potential to nearly
Chapter VI Page 104
_.. _ _--e--e_ -
eliminate pollution output generated during lay-up. Although some of thesealternatives are very attractive and will be used by many companies, sprayapplicators will continue to remain popular. This is true because of theirversatility, high efficiency, and relatively low cost. The use of these applicationsystems is not likely to be discontinued in the near future.
Where spraying remains the application technology of choice, efforts should bemade to reduce pollution associated with the process. The production lineapproaches used by Lasco Bath Fixtures Division help eliminate contaminants inthe lay-up process as well as gel coating. Carolina Classic is using spray booths forboth gel coating and lay-up and both areas are separated from other parts of theplant. As with gel coat application, when filtering or treating contaminated air,the task is simplified if the sources of pollution can be isolated. Isolation of thelay-up area can be nearly as beneficial as isolation of gel coating operations.Many of the same pollution, contamination, quality assurance, and maintenancebenefits are attained through isolation.
Air Filtration and Recirculation Systems
Filtering Contaminated Air
Selective filtration of plant air should be given serious consideration by anyfiberglass fabricator who seriously wants to reduce pollution output. Heavyvapors and solids can be removed from the plant exhaust flow. Even simplepaper or fiberglass filters have some effect on the levels of nuisance odorsentering the outside environment. Overspray build-up on plant air handlingequipment is reduced along with the build-up of overspray on nearby structures,equipment, cars, vegetation, and the ground. These external deposits often makefiberglass facilities appear to be excessively dirty and high in pollution output.Even when a facility is equipped with simple, through-the-wall exhaust fansystems, filter units can be fabricated and installed.
Filtering air as it leaves the work area has benefits other than reducing certainemissions. Plant air handling equipment used for exhaust and heating canperform more efficiently when contaminants are removed from the air.Overspray from spray applications and dust from grinding operations can build-up inside ductwork, fan units, motors, and other components. This build-upbecomes a potential fire hazard when electricity or heat are involved. Fans andductwork do not function efficiently when build-up occurs. Excessive build-upreduces air flow and places excessive loads on motors and control systems. Thisextra load combined with build up on fan motor cooling vents, frequently leadsto overheating and burnout of the motor.
Some firms are left with little choice about filtering plant exhaust. For a fewhigh output facilities, emission clean-up is mandated by regulatory agencies.Where regulations are severe, elaborate filtration and purification systems arerequired. For most operations dry filtration can be used to maintain localappearance, protect ventilation equipment, and remove solids in the form of
Chapter VI Page 105
dust or overspray. In some cases dry filtration has been used to remove enoughsolid contamination to allow the air to be recirculated.
Dry Filtration and Recirculation
Many fiberglass fabricators use a dry filtration medium in the plant exhaustsystem. Protection of expensive air handling equipment is normally sufficientreason to justify expenses for purchasing and changing filters. Dry filters areeven used to protect ductwork and fans in facilities which are equipped withelaborate purification systems. Simple dry filter systems can be installed overalmost any air intake opening. A number of units, observed in the course ofpreparing this manual, are simple shop built units constructed of angle ironand/or sheet metal. Large units can also be built in as an integral part of thephysical facility.
Work Bav, I I false wall
I /\‘\* / /\ \
\\, ,\‘\
f , /\ \/ /I
FIGURE 6-6. Work bay air collector.
The air collectors are designed as an integral part of the work bays used forfiberglass production activities. Collectors consist of a false masonry wall built
Chapter VI Page 106
across the rear of the bay. The false wall is placed approximately 18 inches infront of the actual back wall. This wall extends across the width of the bay andfrom ceiling to floor. An opening extending nearly the full width of the wall isframed up to accept two layers of dry filter material (a cross section of the aircollection is pictured in Figure 6-6). Air is pulled through the filter units by anexhaust fan unit located on the mezzanine above the bay. Each bay has its ownduct system and fan.
Ductwork is provided to exhaust air through the plant roof. An alternate ductprovides an outlet for returning air to the plant. A damper system in theductwork can be regulated to allow all air to be dumped outside the plant or toallow all or part of the air to be returned to the plant environment. The designallows the operator to exhaust all air from a bay when spraying operations are inprogress and to return all or part of the air to the plant when pollution output islow.
Plants that have used this system indicate that the units have proven to beefficient in sweeping contaminated air from the workplace. On occasion anoperator will forget to switch to outside air discharge when spraying operationsare in progress. Odors are immediately noted by workers on the mezzanine,and word is passed to the operator. Using this system to filter and recirculate airfrom grinding bays has not been successful. The dust created by grindingproved to be difficult to remove using single stage filtering. Supplemental filterson the discharge side of these units should be installed.
Case Study No 14
Type:
Company:
Location:
Plant Air Recirculation System
S2 Yachts, Inc. / Tiara Yachts
725 East 40th StreetHolland, MI 49423-5392
Contact:Phone:
Purpose:
Motivation:
Leon Slikkers(616) 392-7163
Filter air exhausted from plant environmentRecirculate plant airReduce requirements for make-up air and heating
Improvement of air quality in plantReduction in utility costs
EquipmentSupplier:
PaybackPeriod:
Building contractor for new facility
Not available
Chapter VI Page 107
Comments:
Source:
Case Study No 14 Continued
All pollution intensive operations are confined to separatework bays. Each bay is equipped with an exhaust andfiltration system which allows air to be recirculated ordischarged.
Plant visit in March, 1987 and phoneconversations with company president(December, 1986)
Wet Filtration Systems
Water wash spray booths have been successfully used to control emissionsassociated with spray application of industrial finishes. Manufacturers of sprayapplication equipment frequently market conventional and “water wash spraybooths.” The typical unit features a powerful exhaust system which pullscontaminated air through a mist or spray of water. Most filtration units are
‘ designed to provide a water wash by using pumps to spray water in the airpassageway. Pumpless designs are also available. Figure 6-7 features crosssections of two water wash spray booths. Special chemicals can be added to thewater reservoir for the purpose of trapping contaminants. Chemicals added tothe water can make contaminants settle to the bottom of a collection tank or floaton the surface for collection.
Waterfall units appear to offer some advantages over conventional dry filtrationunits. Dry filters clog quickly during heavy spray-up and gel coat application.This clogging lowers the surface velocity of air sweeping the work area andreplacement of filters drives up maintenance costs. The air passages on waterfallunits do not clog, and filtration capacity remains high unless water in thereservoir becomes overloaded with solids. Potential fire hazards are also reducedby the water wash system. Most local codes accept water wash spray booths as thebest type of spray booth available. Units can be designed to fit the requirements ofalmost any production facility. Although use of these units for paint sprayoperations is widespread, there is little evidence of applications in open moldedplastics facilities.
Hatteras Yachts in New Bern, North Carolina has successfully used water washbooths in two of their production areas. A spray painting area approximately 150feet long, 40 feet high, and 40 feet wide is equipped with pumpless water washexhaust units along the full length of each side wall. The units exhaust throughthe roof and make-up air is forced in from overhead. Make-up air and exhaustair are carefully matched in order to maintain a slightly positive air pressure.These water wash units have enabled the company to efficiently reduceemissions associated with the spray application of large quantities of urethane
Chapter VI Page 108
Water Wash Systemwith Pump Supplied
Spray
entrainment plate
contaminated
outlet tostack
cleanair
PumplessWater Wash
System
FIGURE 6-7. Water wash spray booths.
paints. A smaller area of the main plant is also equipped with a water washbooth. This booth is used to filter dust from grinding and finishing operationscarried out on small fiberglass parts.
The original water wash units worked so well that Hatteras elected to incorporatewater wash filtration units in a new production that was added to the New Bernplant. The new facility was completed during the summer of 1987 and wasdesigned to accommodate production of yachts considerably larger than 75 feet.The building will house three large lay-up areas which will have all exhaust airfiltered through pump type water wash exhaust units
Chapter VI Page 109
Fume Incineration, Burning Styrene Emissions
High heat can be used to eliminate fumes and odors associated with styrene andother polymers. In situations where emissions associated with open moldingprocesses are particularly high or severely restricted by regulation, incinerationmay prove to be a viable option. Incineration of styrene requires temperaturesapproaching 1,400” F. These high temperatures mean that any system developedfor incineration of styrene must be carefully engineered to insure safety, areasonable working life, and efficient use of energy. Chapter 3 discusses theregulatory aspects of incineration and the design considerations for stack height.
Designs which provide only a gas fired heat chamber are relatively inexpensiveto design and construct. Such designs, however, will require excessive use offuel to heat all exhaust air in a relative short period of time. Commonafterburner units are designed to rapidly ignite and oxidize the volatile organiccompounds (VW) found in fumes. Efficiency of these units can be improved byadding a tube type “catalytic” converter to hold the VOC’s at a high temperaturefor a longer period of time.
c Another design concept features a number of ceramic filled recovery chambersconnected to a central bum chamber, the plant exhaust duct, and a dischargestack. These connections are made through a complex manifold system which isconnected to a modern computerized monitoring and control system. A simplediagram of a unit depicting the interaction of two recovery chambers with theburn chamber is shown in Figure 6-8. Each recovery chamber can alternatebetween being in the ‘inlet” or “outlet” mode.
Exhaust enters from work area.
ceramicfiller
to exhaust stack
’ .’ceramicfiller
tn Pyhallct
FIGURE 6-8. Fume incineration unit.
When a chamber is in “inlet” mode, plant exhaust is fed over the heated ceramicmaterial in the chamber and out into the burn chamber. As the VOC’s leave the
Chapter VI Page 110
chamber, their temperatures are very close to the incineration temperature.Oxidation is completed in the central chamber. The bum chamber is equippedwith a burner system in order to maintain a predetermined temperature. Someignition of the volatiles will occur while they are passing through the ceramicmaterials in the recovery chamber. When the content of volatiles is high, thisauto ignition may provide all of the heat required for recovery, and the burnersystem will go to the pilot mode.
Purified air is passed from the bum chamber through the ceramic bed in achamber which is in the “outlet” mode. Heat from this air is absorbed by theceramic material. As heat is withdrawn, the cooled air exits to an exhaust fanand discharge stack. Most units consist of a central bum chamber and up toseven recovery chambers. Once sufficient exhaust is passed through an ‘outlet”chamber, the ceramic bed becomes hot enough to allow the chamber to switchroles and become an “inlet” chamber. The units have to be brought up totemperature before the plant exhaust system can be placed in use.
Incineration Unit Application -- The Lasco Bath Fixtures Division of PhillipsIndustries has installed a 20,000 SCFM incineration unit in its bathtubproduction facility located in South Boston, Virginia. Because of the highvolume of resin use anticipated for the operation, installation of a treatmentsystem was required by the State of Virginia. In an effort to attract Lasco to theSouth Boston location, some local funding was used to assist in the purchase of atreatment unit. The company selected a Re-ThermTM model 20 produced byRegenerative Environmental Equipment Company (see Appendix C). The unitcost was approximately $750,000. All exhaust from the isolated gel coat andspray-up areas are exhausted to the Re-Therm unit.
Performance of the unit is electronically monitored and controlled by a system ofsensors and a computer unit. A permanent record of the unit’s operation isautomatically entered on a paper time chart. All plant equipment is tied touninterrupted operation of the unit. If the unit is not operational, all spray andresin application systems are automatically shut down. In the event of a systemfailure, the appropriate state agency must be notified, and all performance chartsmust be kept on file for review by state inspectors. In two years of operation onlyone minor failure has occurred. This failure was traced to lightning damage offuses and electronic components in the control system. The only othermaintenance required has been a topping off of the ceramic beds.
Lasco also adds another treatment to air discharged from the plant. An odormasking chemical is misted into the plant discharge vents and stacks. Thischemical has a sweet pleasant odor that helps mask the smell of styrene. Duringthe first few months of operation some complaints were received about thesmell of the masking chemical. This problem was eliminated by reducing thequantity of masking chemical released.
The company has been pleased with the performance of its incineration unit.Maintenance costs have been low and pollution output is dramatically reduced.
Chapter VI Page 11 1
There have been few interruptions to production. Neighbor complaints aboutodor and pollution from this new facility have been minimal. Fuel costs havebeen estimated to be less than $5.00 per hour. Since location incentives wereprovided and the unit was deemed essential for plant operation, paybackcalculations were not available.
Case Study No 15
Type: Incineration system for styrene emissionsRe-ThermTM model 20
Company:L o c a t i o n : .’
Contact:Phone:
Purpose:
Lasco Bath Fixturesl? 0. Box 1177South Boston, VA 24592John Davenport, Production Manager(804) 572-1200
Remove styrene emissions from plant exhaustMeet Virginia regulations
Motivation: Required by State for operating plantImprovement of air qualityLower utility costs when compared to other units
EquipmentSupplier: Regenerative Environmental Equipment Co., Inc.
Box 600520 Speedwell AvenueMorris Plains, NJ 07850
PaybackPeriod:
Comments:
Not available
All pollution intensive operations are confined toisolated work booths. Exhaust from booth is feddirectly to incinerator.
Source: Plant visit in April, 1987 and phone conversations withplant manager and equipment supplier(March, 1987).
Chapter VI Page 1 12
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Controlling Air-Flow and Exhaust
There are many codes and standards that govern the ventilation of commercialand industrial buildings. These may be expressed in terms of* naturalventilation, such as the area of window space in a facility as a percentage of itsfloor area, or in terms of mechanical ventilation, such as the number of cubicfeet per minute (CFM) of air required per occupant or unit of space. Thesestandards establish good ventilation practice which is termed dilutionventilation.
However if human or environmental safety is threatened by highly toxicsubstances, the guidelines governing acceptable levels of airborne contaminantsare embodied in exacting and comprehensive state and federal regulations. Theventilation of these contaminants may thus require special equipment alongwith administrative and technical measures to achieve compliance.
Most industrial and commercial requirements for ventilation fall somewherebetween these two extremes. That is, the waste by-product or contaminant isbeing generated at a rate that is acceptable for immediate exposure, but presents adanger in higher concentrations that cannot be dealt with adequately throughgood dilution ventilation.
Dilution ventilation can be successfully used to control vapors from someorganic liquids, such as the less toxic solvents. In general, it is not successful forthe control of dusts, fumes, gases, mists and vapors that can produce an unsafe,unhealthy, or undesirable atmosphere. The control of these substances requiresa system of exhaust ventilation designed with the basic principles of airflow inmind.
Exhaust Ventilation
The most fundamental principle of airflow is that the flow of air between twopoints is due to the occurrence of a pressure difference between the two points,with the air flowing from the area of high pressure to the area of low pressure.Simply stated, as an exhaust fan evacuates air from its intake side, it creates andarea of low, or negative pressure, causing air to move from all directions towardthe area under suction.
Maintaining Positive Pressure
Before listing some of the specific guidelines for achieving exhaust control, itshould be noted that a complete industrial ventilation system should provide asupply of fresh air to compensate for the air being exhausted from the building.If enough new air is not supplied, the pressure of the building will be negativerelative to the surrounding atmospheric pressure. This negative pressure resultsin the infiltration of air through open doors, windows, cracks, combustionequipment vents, etc. It also increases the total system resistance, makingexhaust fans consume more energy than is necessary in a balanced system. Thereare other potential problems. As little as 0.05 inches (water gauge) of negativepressure can cause workers to complain about drafts and might cause down
Chapter VI Pagp 113
drafting of combustion vents, creating a potential health hazard. If workers nearthe plant perimeter complain about cold drafts, unit heaters are often installed.Heat from these units is usually drawn into the center of the plant because of thevelocity of the infiltration air. This leads to overheating in the area and furthercomplaints.’ It is therefore recommended that a slight positive pressure bemaintained in the facility through the use of sufficient intake fans or airconditioning/heating systems.
General Guidelines -- The propose of exhaust ventilation is to entrain theairborne contaminant or nuisance in the air flow lines created by the system. It isfrequently and mistakenly assumed that, because of the specific gravity of acontaminant, it is either “heavier-than-air” or “lighter-than-air” and willeventually rise or fall of its own accord. Actually, even relatively heavy dusts,
. fumes, vapors, and gases are truly air-borne and are not subject to any appreciablemigration up or down because of their own weight. This is because thecontaminant-air mixture is usually overwhelmingly composed of air. Thebehavior of this mixture is thus virtually the same as for clean air and should be
’ considered as such when planning an exhaust system.
No two facilities ‘or production processes will be alike, but the followingguidelines cover the major points to consider in achieving effective exhaustventilation:
0 Exhaust fans or outlets should be located at or below the operator worklevel. They will then tend to pull the contaminant down and away frombreathing level.
0 The contaminant-producing process or equipment should be locatedbetween the operator and the exhaust outlet. This will pull thecontaminant away from the operator area.
0 Exhaust outlets should be placed as close as possible to the source ofcontamination. Obviously, the closer the outlet, the more rapidly thecontaminant can be entrained and exhausted before it disperses into theroom.
a Consider using a push-pull system in which the contaminant is directedtoward the exhaust outlet(s) by a low velocity airstream produced by fansor ducted inlets on the other side of the operation. It is important tokeep velocity low to avoid creating eddies and turbulence that woulddisperse the contaminant.
0 Avoid cross-contamination of “clean” work spaces by arranging thefacility so that HVAC inlets, cooling fans, or other exhaust vents do notproduce cross-currents of air at the source of contamination.
’ Note: ASHRAE HANDBOOK, 1984 SYSTEMS, p. 20
Chapter VI Page 114
0 Partitions, lowered ceilings, etc. can be used to advantage to enclose thecontaminating process as much as possible. The more complete theenclosure, the more efficiently the exhaust system will evacuate thecontaminant.
0 If cost allows, consider the use of an exhaust hood. (See Local Exhaustbelow).
0 Exterior exhaust outlets should be kept well away from open inlets to thebuilding. Ideally, an exhaust stack above roof level is used.Alternatively, outlets should be placed to take advantage of localprevailing winds and the aerodynamics of the building to avoid re-entry.
An additional recommendation would be to design the provisions for exhaustventilation with potential future regulatory changes in mind. In terms ofenvironmental safety, the trend is toward ever-greater control of hazardoussubstances. If possible, the owner should research any governmental initiativesin that direction. The facility might then be designed for compatibility with thetypes of containment equipment likely to be used. This is usually less expensivethan retrofitting the facility into compliance.
Local Exhaust
For certain applications, the most effective method of evacuating a hazardousairborne substance from the workplace is to utilize a truly localized exhaustsystem. This consists of a ducted hood and an exhaust fan or other air-movingdevice. It offers optimum contamination control with minimum air volumerequirements and therefore lowers the cost of cleaning the air.
Hoods are either enclosing or non-enclosing tvnes. The enclosing type isobviously more effective and more efficient, but it is not always practical becauseof the access requirements of the process or machinery. The non-enclosing typecan be nearly as effective when placed in very close proximity to the process.This too can be impractical in terms of access to the process or machinery.
Inasmuch as localized exhaust is the most cost-effective method of removingcontaminants, it is in the owner’s interest to investigate its use whereverpossible. The proper design and construction of a hood requires thoroughknowledge of the principles of airflow and of the specific application to which itis dedicated and may require the services of an HVAC engineer.
Chapter VI Page 115
Chapter VI Page 116
10% more per pound for gel coat;
40% more per pound for fiberglass,
7% more per pound for resin;
28% increase in the time requiredrollers;
The changes made by Arjay initially looked as if the company was going to increasecosts instead of improving profitability. Their initial efforts caused the comnanv topay on a per unit basis:
I ,
largely due to changing to knitted fabrics;
to laminate since they started using resin
* 37% higher labor rate than when they started because they cut back theirwork force. Specifically they let the least experienced people go, therebyraising the average plant wage rate.
When a company is trying to break a manufacturing paradigm and implement
APPENDIX A
A Case Study in Waste Reduction and Profitability
Ajay Technologies in Large, Florida, was a well established contract producer oflaminates that sold component parts to manufacturers in the boating industry.Currently the company is focusing on offering its expertise and laminationtechnology to others in the industry. However, before this change in emphasisoccurred, Arjay made full use of the technologies and methods it’s now helpingother companies put to use. The experience and success Ax-jay achieved beganduring the early nineties when the company made several significant changes in itsmanufacturing methods and techniques to reduce waste and to improveprofitability. Because of Arjay’s total focus on fiber reinforced plastics (FRP), thecompany is a true cost center for lamination. Arjay’s experience indicates that thetypical laminator, one that uses gel coat and sprays resin, can cut its costs by asmuch as 24%. This can be done says Bob Cottrell, the President of ArjayTechnologies by “rethinking what’s fast, what’s expensive, and what’s clean.” Thework his company did he believes will make a company more productive andcompetitive.’
change then many of the present performance indicators may show that thechanges are making things worse. Consequently it would appear that a marginallyprofitable operation may become unprofitable.
The reason this can occur is that mostthat are on a unit of measure basis andthe changes instituted resulted in thebasis.
manufacturing systems have cost indicatorsnot on a cost per product measure. At Arjayfollowing improvements on a per product
’ This case study is based on a presentation by Robert L. Cottrell to the Composite FabricatorsAssociation, Fabrication ‘93, Nashville, Tennessee, October 28, 1993
Appendix A Page 117
* Gel coat was reduced by 50% -- Gel coat usage was cut in half by spraying at 9-11mils as opposed to 18 - 20.
Resin was reduced by 54% - Resin was reduced by over half by achieving higherglass ratios and wasting less resin.
Was@ was reduced by 90% - This resulted from reduced materials usage,instituting good material handling practices, and eliminating wastefulmanufacturing methods and techniques.
Work force was reduced by 30% --The manufacturing methods allowed Arjay toreduce its manufacturing work force by 30% while it turned out the same quantityof work
Total cost of production dropped by 24% -- This was the net result from all thechanges put into effect.
Cottrell says the focus for change was waste minimization. He points out that ‘I- wetried to get rid of that trash collector. At least waste minimization was what wethought we were doing when we started our journey. As we look back today, wesee that it was far more than that. When I read the current best selling book,‘Reengineering the Corporation’ by Michael Hammer and James Champy, itoccurred to me that what we inadvertently had done was reengineer the FRPoperation.”
Prior to the change Arjay’s typical practice for hand lay-up involved a spray wet outoperation using 1 - l/2 ounce mat. After the change they used 3/4 ounce mat andknitted fabric. The resin application equipment changed too. They replaced thespray guns with roller applicators. The changeover to rollers began on the simplershaped hulls, then moved on to include complex decks and liners. The change inresin formulation, application equipment, and glass resulted in a reengineeredlamination operation.
Production Characteristics Before Reengineering
* Resin Application - Spray Gun
* Gel Coat Thickness - 18-20 MILS
* Glass to Resin Ratio - 26%
* Solvent Type Used - Volatile, Acetone
* Lamination Room Environment - Dirty, High Maintenance
Spraying resin, applying thick a gel coat, employing glass ratios below 30%, usingacetone, and operating in a dirty, high maintenance environment creates aproduction system that places a manufacturer in a financial “grid” or paradigm thatlimits the profit that can be realized from a business. This type of manufacturingsystem existed for about ten years at Ajay before the change and yielded material,labor and operating expenses that varied only slightly. A typical profit and lossstatement for that period can be characterized as follows.
Appendix A Page 118
Characteristic Profit and Loss Statement for the Old Manufacturing System
Sales $100
Material 38
Labor 18
Operating Expense 8
Prime Profit $36
As you can see, for every $100 of sales, material costs were 38%, labor costs,including workman’s compensation insurance, medical, vacations, holidays, etc.,were 18%. Opera ‘n costs, including utilities, solvents, supplies, maintenancetr gitems, etc., were about 8%, leaving a Prime Profit of 36%. Fixed costs which wouldbe subtracted from prime profit to calculate gross profit are not shown.
As a contract producer selling component parts to assemblers and marketers, Ajayis a true cost center for lamination. There are no assembly costs or other post FRPpart costs to cloud the analysis. Consequently, this analysis is useful for providing ameans for evaluating the financial impact these changes will have on a company.Since the major changes were in the materials, the biggest expense category, itsuseful to examine where the money goes.
Material
Gel
Purchased Part Weight
Lbs. Lbs. $/Unit Total Cost
5 2 $1 .oo $ 5
Glass 12 9 1.00 12
Resin 35 20 0.60 21
Total 52 Lbs. 31 Lbs. $38
Examining the left hand column in the table shows that $38 for material purchased5 pounds of gel coat, 12 pounds of glass, and 35 pounds of resin for a total of 52pounds to make a part selling for $100. However the second column shows thatonly 31 pounds (60%) of the 52 pounds purchased actually made it to the part. Theother 21 pounds (40%) that was purchased became trim scraps, emission losses,overspray, cutouts, scrap parts, and other forms of waste. Note that the gross oroverall glass ratio (excluding the gel coat) is 26% (12 / 12 + 35), although thefinished part had a 31% glass ratio (9 / 20 + 9).
All of these figures came from a material balance study of the laminationoperation. This type of analysis is also referred to as a sources and uses study. Thepurpose for this type of study is to determine what and where the material is used.It is a good first step for defining the manufacturing paradigm.
Appendix A Page 119
__ ._.________- --_- -. - -- _. -- --. _--- -
From this study it is apparent that the resin supplier is the significant vendor in- -terms of dollars. The money sent to resin companies exceeds the amount sent tothe glass suppliers by a ratio of 21 to 12. This means that if a tanker of resin costs$21,000 you would spend only $12,000 for the glass to go with it. The gel coat costsare less than one fourth the resin costs. These comparisons provide a means forestablishing priorities for changing the system.
Now, look at the labor portion of the profit and loss statement. For each $100dollars of sales at Arjay, there is $18 of labor cost. At Arjay the average hourly wageat the time of the study was $8.00 per hour. This amount includes direct labor suchas laminators and gel coaters as well as QC people, warehouse people, maintenancepeople, and supervision. The average hourly wage for the manufacturing system acan be calculated for a period by dividing the gross payroll by the total hoursworked. However, the number that is really needed is the gross wages for theperiod divided by the total sales during the period. In this P&L the number isactually the wages per each $100 of sales for the period. This provides a ratio todetermine what part of each $100 of sales is labor. In this case its $18 per each $100of sales. It is extremely important to understand that the TOTAL labor representsall people involved in manufacturing since one of the major benefits fromreengineering comes from reducing the necessity for staffing the non-value addingpositions required by the current manufacturing system.
In brief, here is what Arjay Technologies did to change their operation. Theystarted with the resin by changing the chemistry and the way it was stored anddispensed in the plant. The new resin included an extender, had a higherreactivity, and was more viscous due to reduced styrene content. Ax-jay promotedthe resin themselves instead of having the supplier do it. They also installed atemperature controlled bulk storage and recirculation system that looped the entireplant. The catalyst, MEKP, was also circulated to each mixing unit in the plant. Theresult was a resin that gave predictable performance and worked well with the newlay-up methods.
Although the changes in the resin were important, there were other factors thatcontributed to Arjay’s waste reduction and improvements in f inancialperformance. The reengineered system included:
0 A gel coat spraying operation that was brought into control through theapplication of process control techniques. This allowed Arjay to reduce theamount of gel coat sprayed in two ways. First, they were able eliminate theexcessive gel coat thickness that resulted from a highly variable process.Second, because of the reduction in variability they were able to move to thelower end of the range of gel coat thickness needed. The use of a lowpressure spray system also helped because of improved transfer efficiencies.
0 Resin spraying was eliminated with the introduction of resin rollerapplicators. These applicators apply resin more uniformly without overspray. Because the resin is not atomized, the applicators significantly reducestyrene loss to the air and maintain a much cleaner work area. Equipment
Appendix A Page 120
maintenance is reduced because of the change over to a simpler resin rollersystem. Solvent usage is also reduced and can be further reduced throughthe use of a closed system to flush and clean the roller equipment.
0 Glass ratios were increased through the use of knitted and specialized glassfabrics. The result was an increase in the gross glass ratio to 38%. Theincrease in the glass ratio was also due to some laminate engineering and thebenefits that can be realized through the application of resin with the rollersystem.
0 A high boiling point solvent is sparingly used. Acetone was eliminated andnot seriously missed because of the cleaner resin application methodsimplemented.
0 The operation is noticeably cleaner and requires significantly lessmaintenance. This can be attributed largely to the changes in resin and gelcoat application processes.
The full impact of the changes to the manufacturing system are apparent bycomparing the changes in the materials used to make the original 31 pound part.The total material cost ($38) dropped to $27, a reduction of 29%. The part weightalso went down by 16%. This reduction in weight is a the result of changes in boththe manufacturing technology and part design. Savings also showed up in laborand operating expense. The labor cost dropped slightly to $17 from $18 and theoperating expense was cut in half to $4.
Material ComparisonsBefore After
Lbs. Mat’1 $/Lbs. Total Lbs. Mat’1 $/Lbs. TotalWeight cost Weight cost
Gel 5 2 1.00 $5 3 2 1.10 3Glass 12 9 1.00 12 10 9 1.40 14Resin 35 20 0.60 21 16 15 0.64 10
1 Total 52 31 $38 29 26 $27
40 % of purchased materials wasted 10 % of purchased materials wasted
Summarizing
These changes in manufacturing resulted in making Arjay’s glass vender the majorsupplier. The dollars going towards the purchase of glass were 40% more than theamount spent with the resin supplier. The gel coat cost as a percentage of glass alsowent down significantly from 42% to 21%. Comparing costs on a unit of measurebasis to the cost per unit of production makes the point again that a total approach
Appendix P Page 121
IT,- - -
!
-I :. .-. II1 Ik
to reengineering the laminate has to be considered to achieve waste and costreduction.
. .. .;;:i .;:
* Gel coat* Glass* Resin
Cost Per -Pound Costs Per Unit of Productionup 10% Down 40%up 40% UP 17%up 7% Down 52%
Arjay’s approach to waste reduction and performance improvement appears to besuccessful. The methods and techniques used are straightforward and do notrequire disproportionate investments in time or money. They do however requirea company wide approach that will challenge everyone in the manufacturingsystem to become involved in rethinking what’s waste, what’s expensive, andwhat’s profitable.
Appendix A Page 122
APPENDIX B
Map of regional offices for the North Carolina Department of Environment,Health, and Natural Resources.
Appendix B Page 123
Appendix B Page 124
APPENDIX C
This list was developed from a review of sales literature, personal interviews,and facility visits. The preparer takes no responsibility for the. list’scompleteness or for the quality of products and services provided by thesecompanies.
Company:
Processing Equipment Suppliers
Bids Manufacturing Company9201 West Belmont AvenueFranklin Park, IL 60131-2887Mailing Address: PO. Box 66090Chicago, IL 60666(312) 671-3000
Products: Manufacturer of spray finishing equipment, resin mixingequipment, and resin applications systems including HELPspray guns and resin rollers.--..-..---.......-....-......-......-.......... . ..-...-.-..-..l.-UI-...-....-.--....................................................................................-..........-..-..---....
Company: DeVilbiss RansburgSouthern Regional Sales520-A Wharton Circle, S.W.Atlanta, GA 30336(800) 338-4448 or (404) 696-4988FAX (404) SOS-3345Tech. Assist: Roger Cedoz & John Treuschel
Products: Spray finishing equipment.. . . . . . . . . . . . . . . . . . . . . ..-...............................................................--......-........-.....................-..............-............-.....................................-..-.-......-...--..........-.-.Company: Glas-Craft
5845 West 82nd St., Suite 102Indianapolis, IN 46278(317) 875-5592FAX (317) 875-5456
Products: Fiberglass and poly-urethane dispensing equipment andresin rollers.
Company: Grace, Inc.P.O. Box 1441Minneapolis, MN 55440(800) 367-4023FAX (612) 623-6580
Products: Spray guns -- airless air spray, air assisted airless, and otherspray equipment.. . . . . . ..___.............................................-......................................-................................................-.....................................................-..-.................--...
Appendix C Page 125
Company: High Point PneumaticsP.O. Box 5802High Point, NC 27262-5802Contact: Wayne Roach(910) 889-8416
Products: Supplier of Kremlin Inc. Airmix products; Nordson sprayequipment, Chemco spray booth filtering media; and booth
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..~...“.-..-.......-...__....._.....-.-........ maintenance equipment.. .._........._...I_“-.......-.“...”-.--.-.”......-..” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Company: Kremlin, Inc.211 South LombardP 0 Box 1219Addison, IL 60101(708) 543-1177FAX (708) 543-1201
Products: “Airmix” air-assisted airless spray painting system; HVLPg-; “Airmix” electrostatic systems; coating heaters;pumps; and portable spray equipment..-............-......-.............” -._..........“........“-........................................................_.____......................-............................................-...............-...........-
Company: Magnum Industries1701-56th Court NorthClearwater, FL 34620(813) 575-2955FAX (813) 572-6895
Products: Manufacturer of spray finishing equipment, resin mixingequipment, and resin applications systems including HVLPspray guns and resin rollers.. . . . . ..__.___.._......-...........--...........-...........-......... .._..............._....-.........-.................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..-..................-......-... . . . .._.................-.........-.
Company: Nordson CorporationCustomer Service11475 Lakefield DriveDuluth, GA 30136(800) 2418777
Products: Airless spray guns for sealers, lacquers, and stains; airlesselectrostatic spray guns; automatic electro-static guns; andpowder coating application and recovery equipment.. .._._...............-................................... . . . . . . . . . . .._............................................................................-...... . . . . . . . . . . . ._..._...........................-.......-. . . . . . . . . . . . . . . . . .
Company: Production SystemsP.O. Box 5406High Point, NC 27262Contact: Bill Ball, President(919) 886-5081
Products: Supplier of DeVilbiss Ransburg, Binks, Grace ArrowProducts, and HVLP guns.. . . .._....e...................m.............. ._...._.._...______.......~...~.............~.....................~....................~..............~.................~........~...........~...~~.................~....~.....~...
Appendix C Page 126
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Company: Venus-GusmerDivision of PMC, INC.1862 Ives AvenueKent, WA 98032Contact: Ed Marquardt(206)854-2660FAX (206) 854-1666
Provides tools, dispensing equipment, spraying equipment,and plant engineering for the fiberglass industry.
Products:
Suppliers of Distillation Equipment
Company: Baron-Blakeslee1500 West 16th StreetLong Beach, CA 90813(800)548-4422Contact: Britton Roberts, North Carolina representative at(910) 997-2833
Products: Solvent recovery stills and carbon absorption systems forrecovering solvents from exhausts.-.-.-.-....-..-...-....-..-. . ..-..............-.-............-”.-........-.-....“...............-................“...................................................-.....-...-.--....-..-.--........-....
Company: Brighton Custom Fabricating Division11862 Mosteller RoadCincinnati, OH 45241(513) 771-2400FAX (513) 771-2404Contact: Harry McCarty, Sales Manager
Products: Solvent recovery systems.. . . . . . . ..“........................................-...............-.......................................... . . . . . . . . ..-........................-..--..-.........--.....-.......-........-.............-..-....................
Company: C B MillsDiv. of Chicago Boiler Co.5 Busch ParkwayBuffalo Grove, IL 60089-4517(800) 522-7343 or (708) 459-0007FAX (708) 459-0598
Products: Manufacturer of Red Head solvent recovery equipment andtank and drum cleaning systems.. . . . . . . . . . . . . ..-....................-............. . . . . . . . . . ..-........................-....................................................................-............... . . . . . . . . . . . . . . . . . . . . . . ..-...........................
Company: Detrex Corporation325-A Emmett AveBowling Green, KY 42101(800) 959-0323, ext. 283FAX (502) 781-3425
Products: Manufacturer of washing and cleaning equipment andsolvent recovery systems.
Appendix C Page 121
Company: Hoffman Air & Filtration SystemsPO. Box 5486035 Corporate DriveEast Syracuse, NY 13057Contact: G. Bagnall, Sales(800) 258-8008 or (315) 437-0311FAX (315) 432-8682
Products: Industrial Liquid filtration products and systems.. . . ..---...............................--...--.--.--.-.----.-...-.. . . ..“..“.......“.....~.“......... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..I.........“............-.....-..-..-......
Company: Jan Engineering Co.736 Indian Manor CourtStone Mountain, GA 30083(404) 292-1711Contact: H. A. Janicek
Products: Batch type solvent recovery stills (Little Stills, Finish-Thompson Engineering) ranging from 15 and 55 gallons. Avacuum option is available to distill solvents up to 500” Fboiling point.. ..-..................................................-...........-..............-............”.~.........................................................-..............................................................-.
Company: Luwa HVAC FiltersP.O. Box 7263Charlotte, NC 28241(704) 588-5220FAX (704)-588-5721Contact: J. T. Carter
Products: Manufacturer of air filtration equipment and accessoriesfabricated to customer specifications.
Hazardous Waste Services
Company: Detrex Solvents1410 ChardonI’ 0 Box 17161Euclid, OH 44117-0161(216) 692-2464FAX (216) 692-0080
Products: Solvents and waste removal..._......_.......................-.................................-....-................. . . . . . . . . . . . . . . . . . . . . . . . . ..-......-....-...............................................................-..............................
Company: Rollins Environmental Services, Inc.One Rollins PlazaP 0 Box 2349-TWilmington, DE 19899-2349(302) 429-2700Contact: Jack Homberger, VP Mktg./Sales
Appendix C Page 128
Services: All solid, liquid, and gaseous hazardous waste accepted.Available services include incineration services withcomplete emissions control equipment, a secure landfill,and complete lab facilities.
Company: S.T.A.T. INC.P.O. Box 1443Lenoir, NC 28645(704) 396-2304Contact: Gary L. Sparks
Services: Incineration and transportation of chemical wastes in bulksolid form to and from the Mitchell Systems and chemicallandfills in Pinewood, SC and Emelle, AL. Will pumpliquid from drums into bulk tankers, clean chemical storagetanks, clean up hazardous waste sites, provide emergencyspill control, test underground tanks (sonic test), andprovide bulk container rental service.
Equipment: Vacuum truck, vacuum trailers, roll of bulk sludgecontainer, drum trailers, bulk tankers, emergencyequipment. Note: No radioactive waste.. . ..“.-.-.--....-.............~-......................-.........”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..-..........-..............-.............................-..................................................--...-..-..
Company: Systech Environmental Corp.245 North Valley RoadXenia, OH 45385-9374(513) 429-2533FAX (513) 374-4133Contact: Tom McGhee
Services: Wastes Accepted: liquid sludges, with a minimum of 5,000BTU/lb.; and up to 10% chlorides. Transportationavailable for drums and bulk wastes. Facility locations arein Ohio, California, Kansas, Alabama, and Michigan.
Hazardous Waste Transporters
Company: Ashland Chemical Company3930 Glenwood DriveCharlotte, NC 28208(800) 637-7922 or (704) 392-2121
Service: Transports waste solvent.._.._._...........................................................-.............--......................................-....... . . .._......_....................................................................................
Company: Detrex Chemical Industries, Inc.P.O. Box 5287Charlotte, NC 28225-5278(704) 372-9280Contact: Ana Mathes
Service: Fully licensed TDS.
Appendix C Page 129
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Company: Detrex Environmental Services3027-I Fruitland AveLos Angeles, CA 90058 andBowling Green, KY(800) 433-8739FAX (213) 588-9216
Products: Hazardous waste management and disposal services.m......“-......... . . . . . . . . . . . . . . . . . . . . ..--............................ . . . . ..-....................................................... . . . . . ..-...........................-........................-........-...
Company: Ecoflo2750 Patterson StreetGreensboro, NC 27407(910) 855-7925Contact: Bob Davis
Services: Waste transporter..--..-..----.-.--.-......-.-.-.--.-.--.-....-..-... .-.-.........-..-....-....-..-................................-...-....................._...................................
Company: Enviro-Chem Waste Management ServicesP.O. Box 12542Apex, NC 27(919) 469-8490Contact: Jerry Deakle
Service: Transporter of waste. No radioactive, pathological, orexplosive wastes are carried.. . . . ..-....._.........---...-..........--..-...............----.-.....-.-.......... _. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..-.-...............-.....-.-... . . . . .._...............-..-.........-..-..-----...-...............
Company: Heritage Environmental Services4132 Pompano StreetCharlotte, NC 28216(704) 392-6276Contact: John Nagle
Services: Bulk liquid transporter.. . . . .._...................-.-.....----..-......--.-....-....... __...._...._..................................-..............-................................-........................................-................-........
Company: High Rise Service Company, Inc.PO Box 730Leland, NC 28451(910) 371-2325Contact: A. J. Simmons, Jr.
Services: Contracts to handle wastes in drums or in an 8000 gallontank truck. Tank cleaning is also available.. . . . . . . .._..__._...........~~..........~~~....................~............................................. _..........._._._................-....-..-..........-...........................-........-..................-.-.....
Company: Laidlaw Environmental Services208 Watlington Industries DriveReidsville, NC 27320(800) 535-5053 or (910) 342-6106Contact: Robert D. Stephens
Services: 24hour emergency response. No radioactive waste, poisongas, kepone, sodium azide over 25%, or explosives aretransported.
Appendix C Page 130
Company: Petroleum Tank Service, Inc.P.O. Box 237Newell, NC 28126(704) 597-1910
Services: Transporter of bulk or drum products. Other tank relatedservices are welding, installation of environmentalprotection systems, tank coating and lining, fiberglassing,calibrating, water-blasting, sandblasting, ultrasonic testing,and mechanical piping.. . .._......._......“................ . . . . . . . . . . . . . . ..--..-.-.......-.-.................. . . ..-.........................................-...............
Company: Photo Chemical Systems, Inc.105 Forest DriveKnightdale, NC 27545(919) 266-4463Contact: Greg Wilson or Preston Averette
Services: Transports wastes in DOT approved containers to a landdisposal site or incinerator. Offer “truck-sharing” forgenerators of less-than-truckload quantities of wastes.-.-...................................... . . . . . . . . . . . . . . . . . . . . . . . . . . . ..“._......“..........~........................~........................._.........................~.~................................................
Company: Southchem, Inc.2000 East Pettigrew StreetDurham, NC 27702(919) 596-0681Contact: John Scott
Services: Handles spent solvents, no radioactive wastes.. . . . . . . . . . . . . . . . . . . ..m........................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..--..........................................._........................................................
Company: Waste Industries, Inc.3949 T Browning PlaceP.O. Box 30966Raleigh, NC 27609(919) 782-0095Contact: Jim Perry, President or Lonnie C. Poole, Jr., CEO
Services: Company provides detachable containers for storage,completes all necessary paperwork, locates an approveddisposal site, and tests material if required. Alsotransports waste. Equipment includes straight trucks(50,000 lb. GVU class) and enclosed vans for less-than-truckload quantities. The company has twenty-fivelocations throughout North Carolina._........_.._......................................................................-...........................................-......................................................... . . . . . . . . . . . ..-.........................
Appendix C Page 131
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APPENDIX D
The North Carolina Quality Leadership Award
The North Carolina Quality Leadership Award is patterned after the MalcolmBaldrige National Quality Award. Both awards recognize outstandingachievement in quality and quality management. The awards are based on anexamination of a company’s quality processes and quality improvementmethods. The examination process serves not only as a reliable basis for makingawards but also provides a diagnosis of an applicant’s overall approach to theoperation of their business.
The Baldrige Award is administered by the National Institute of Standards andTechnology (NIST), an agency of the Department of Commerce. In North
* Carolina, the North Carolina Quality Leadership Foundation administers theQuality Leadership Award. This foundation is a cooperative industry-government-academic effort to promote quality awareness, recognize qualityachievements, and publicize successful quality strategies in North Carolinacompanies. Annual awards based on assessment are intended to stimulateeducation and training of management and work-force; to improve performanceand resource management in all areas of activity; to further the success ofparticipating companies in a competitive environment; and to apply the qualityguidelines published in the Malcolm Baldrige National Quality Award tobusiness and industry.
Since North Carolina is one of the top ten manufacturing states in the union, thisprogram can have a significant impact on improving the competitiveness of thestate’s manufacturing base. Waste elimination and improvement of the effectiveuse of resources are inherent in the quality process outlined by the awardcriteria. Consequently, companies entering into an assessment of their qualityand management processes can benefit significantly even though they may notachieve the award. Therefore, the NC Quality Leadership Foundation offerscompanies the opportunity to participate in a self assessment solely for thepurpose of getting feedback on areas needing improvement. The foundationalso has assessment teams that can make site visits to provide further input tomanagement.
The Foundation charges a fee for either the award competition or the selfassessment. The fees for the process can reach several thousand dollars,however, the benefits that can be realized make this a very attractive investment.Information packets and guidelines are available from:
Edith HicksNorth Carolina Quality Leadership Award4904 Professional Court, Suite 100Raleigh, NC 27609(919) c/ L-8198FAX (919) 872-8199
Appendix D Page 133
