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Madison Pre-hung Doors and Pre-finishing
Converting to a Water-based Wood
Finish |
| Standard Industrial Classification
(SIC) |
Wood finishing on doors, wood trim and
molding/SIC #2431 |
| Type of Waste |
VOC's and cleaning solvents |
| Strategy |
Material Substitution and Process
Modification |
| Company Background |
Madison Pre-hung Doors & Pre-finishing
is an owner-operated small business providing finishing on doors, wood trim, and molding
for builders and commercial distributors since 1965. The business is located in Oregon,
Wisconsin and has 28 employees. |
| Original Process |
The company manually applied solvent-based
finishes on wood doors and used automated spray finishes on wood trim and molding. |
| Motivation |
A fire in 1980 forced the owner to rebuild
his facility. In order to expand capacity and continue to use solvent-based finishes, the
owner would have been required to install an after-burner (thermal oxidizer) to remain in
compliance with air regulations. Prior to the fire, the business had experimented with
water-based finishes and subsequently decided to switch to this product. |
| Pollution Prevention Process |
Water-based finishes were substituted for
the solvent-based finishes in the manual application and the automated spray application
of finishes. |
| Stage of Development |
The company now uses water-based finishes
in its entire production process. |
| Level of Commercialization |
Water-based finishes are readily available
through commercial suppliers. |
| Material/Energy Balance |
Original Process
Feedstock
Solvent-based finishes and stainsWaste
115 tons/year of evaporated Volatile Organic Compound (VOC) air emissions from solvents;
solid waste (paint filters); and waste-solvent.
Disposal
Solid waste was landfilled. Unused solvent was removed by a hazardous waste management
company and recycled.
Pollution Prevention Process
Feedstock
Water-based finishes
Waste
VOCs have been reduced to less than six tons of emissions/year while production has nearly
doubled. There are non-hazardous solid waste and wastewater discharges.
Disposal
Solid waste is landfilled. Wastewater is removed and discharged into Madison
Publicly-Owned Treatment Facility (POTW). |
| Economics |
Capital Costs
Five stainless steel spray guns were purchased to apply the water-based finishes at a cost
of » $1,200 each.Operation Maintenance Costs
No substantial costs
Payback Period
A payback period has not been computed, but the company has experienced cost savings
through:
- Reduction in insurance premium costs (reduced fire risk). The company's
premium decreased by $8,000 even though the policy coverage increased by $350,000.
- Savings from the elimination of costs associated with the installation
and maintenance of an after burner.
- Elimination of waste solvent disposal costs.
|
| Benefits |
Fire hazard has been drastically reduced.
Improved work environment and reduced employee exposure to hazardous/flammable materials.
Employees are no longer required to wear safety equipment. |
| Obstacles |
The major challenge has been to achieve a
comparable quality to that of solvent-based finishes. The company worked with their paint
supplier to design a production process that would address initial quality problems. The
manual application of water-based finishes requires more labor (extra sanding and more
coats of finish) due to some grain raising. |
| Technology Transfer |
Water-based finishes can be readily adopted
for use by others doing wood finishing. |
| Other Pollution Prevention
Activities |
The company has installed a curtain coating
system in the automated application of finish that eliminates overspray and recycles
excess finish. Madison is also using non-toxic, biodegradable hydraulic fluid and has
begun to recycle cardboard. |
| Company Address |
Madison Pre-hung Doors and Pre-Finishing
4775 Hwy CTHB
Oregon, Wisconsin 53575 |
| Contact Person |
Jim Copus, Owner
608/256-3155
608/835-8618 FAX |
| 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: 608/262-0385Pollution Prevention
Information Clearinghouse
Wisconsin Department of Natural Resources
Hazardous Waste Minimization Program
608/264-8852, 608/267-9523 or 608/267-3763 |
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Bureau of Cooperative Environmental Assistance
Wisconsin Department of Natural Resources
P.O. Box 7921
Madison, WI 53707
608/267-9700
PUBL-TS-034 95 |
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