Pollution Prevention Case Study

.pdf fileGerry Wood
Products Company

Alternative coating to reduce volatile organic compound
(VOC) emissions from lacquer coating operations
Standard Industrial Classification (SIC) Manufacturer of wooden juvenile furniture and expansion gates; SIC 2511.
Process Finish coating for wood furniture.
Type of Waste Solid Wastes
Scrap wood and office wastes. Waste coatings which test as non-hazardous are sent for fuel-blending.

Hazardous Wastes
Spent solvents.

Air Emissions
Volatile organic compounds (VOCs) from coating operations and associated cleanup.
Strategies Material Substitution
Dry application of a formulated wax coating for selected parts in lieu of a lacquer coating.
Background Gerry Wood Products presently employs approximately 300 people and produces over 1.8 million units per year.

Many of Gerry's product components, such as wooden slots and rods, are finished by means of a tumbling process. Previously, the finishing process consisted of loading component parts into a barrel, pouring lacquer-type finishing material in the barrel and rotating it until coverage of the components was smooth and uniform.

This process had been cost-effective and efficient. However, the lacquer-type finish that had been used in the tumbler was a significant source of VOC emissions in the facility.
Motivation To reduce VOC emissions while improving the air quality of the work environment.
Changes Implemented In 1992, Gerry completed a transition to a new material that allows the facility to produce over 80% of the total tumbled production without VOC emissions. The replacement material is a formulated granular wax material that is tumbled with the parts using the original equipment. There are no known hazards associated with this material.
Problems Encountered None.
Material/Energy Balance Original Approach
Feedstock
Liquid lacquer.

Waste
VOC emissions from the curing of tumbled lacquer coated products and other hazardous wastes from daily cleanup.

Disposal
Air emissions.

Pollution Prevention Approach
Feedstock
Dry formulated wax.

Waste
VOC emissions have been reduced by 44,800 pounds per year. Also, hazardous wastes from daily cleanup have been reduced by 5,000 pounds per year.

Disposal
Air emissions. The working environment no longer requires a special air supply or exhaust to remove the VOCs.
Economics Capital Costs
No new capital costs.

Operating/Maintenance Costs
Daily cleanup, labor and waste costs have all been reduced.

Payback Period
Immediate. Annual savings of over $200,000 have been realized.
Other Waste Reduction Projects Gerry already uses ultraviolet (UV) coatings, and both electrostatic and air-assisted airless spray equipment, to reduce VOC emissions and to increase transfer efficiency.
Planned Future Waste Reduction Projects Realizing the cost savings and environmental benefits of eliminating waste, Gerry is vigorously pursuing reuse of the collected overspray from its spray coating operations. Testing is underway to facilitate possible reformulation of collected dry overspray powder into a reusable coating material.
Company Address Gerry Wood Products Company
214 Nu-Line Street
Suring, WI 54174
Contact Person Mr. Ward Longtine
Environmental Finishing Technician
Phone: 414/842-2141
Pollution Prevention Resources Free, On-site Technical Assistance
University of Wisconsin Extension
Solid and Hazardous Waste Education Center
Milwaukee area: 414/475-2845
Remainder of state: 608/262-0385

Pollution Prevention Information Clearinghouse
Wisconsin Department of Natural Resources
Hazardous Waste Minimization Program
608/264-8852, 608/267-9523 or 608/267-3763
DNR Logo


Bureau of Cooperative Environmental Assistance
Wisconsin Department of Natural Resources
P.O. Box 7921
Madison, WI   53707
608/267-9700

PUBL-SW-239