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Larson Juhl, Inc.
Replacing AAAL (Air Assisted Air
Less) spray guns with HVLP (High Volume Low Pressure) spray guns |
| Standard Industrial Classification
(SIC) |
Miscellaneous Wood Products (wood picture
frame mouldings) /2499 |
| Type of Waste |
Waste paint |
| Strategy |
Process modification: use of (High Volume
Low Pressure) HVLP spray technology |
| Company Background |
Larson Juhl is one of the world's largest
manufacturer and distributor of picture frame mouldings and related supplies with
operations that span five continents. The Ashland, Wisconsin facility is the largest
manufacturing operation with more than 160 employees. This facility specializes in
manufacturing hardwood picture frame mouldings. Its product lines currently contain more
than 100 profiles on pine, oak, ash, poplar, maple, cherry, and alder. Volume through puts
range between 350,000 - 500,000 linear feet per week. |
| Original Process |
All mouldings start as rough sawn lumber of
random length and width. A computer controlled "gang-rip" saw cuts the boards
into rip-stock. The rip-stock is milled into mouldings, which are then sanded and
finished. The finish was then applied using an Air Assisted Air Less (AAAL) spraying
system. |
| Motivation |
To improve employee and plant safety,
minimize company liability, and reduce disposal and material costs. Disposal costs had
increased 400% within a 16 month period and material costs had increased by 200%-300%
during the same period. |
| Pollution Prevention Process |
The finishing operation consists of: (3)
automated staining spray machines; (2) sealing fan coaters and (4) automated top coating
spray machines. Larson Juhl is now using HVLP spray guns in seven of its nine finishing
processes. Finishing operations are the largest part of the manufacturing process. As many
as eleven finishing steps may be required for a single moulding. The finishing department
processes 7-10 million feet of moulding in a month's time. |
| Material/Energy Balance |
Original Process
Feedstock
Acrylic-based and nitrocellulose-based paintsWaste
Volatile Organic Compound (VOC) air emissions, waste paint
Disposal
Hazardous waste was removed by a hazardous waste management company.
Pollution Prevention Process
Feedstock
A 45% decrease in raw material use due to increased transfer efficiency.
Waste
Waste paint - reduction of 45-50%
Disposal
Waste paint |
| Economics |
Capital Costs
$4,700 for purchase of three HVLP guns, pump, and fittings per system. Seven systems were
converted to HVLP.Operation/Maintenance Costs
- 70% decrease in maintenance and parts inventory costs.
- 45% decrease in waste paint generation and disposal costs.
Payback Period
Immediate. Annual material, maintenance, and disposal savings of over $18,000 for one
system. Payback periods and cost savings vary for other systems. |
| Benefits |
The HVLP spray guns are easier to set up,
have less problems with tips clogging, and have better coating properties than the AAAL
guns. |
| Other Pollution Prevention
Activities |
Larson Juhl is currently using a
water-based top coat in one of its product lines and is investigating the possibility of
using it in all top coating operations. Top coating currently comprises 50% of all coating
operations in the finishing department. In addition, Larson Juhl has been researching 100%
foil coverings, UV coatings, and water-based stains. |
| Company Address |
Larson Juhl, Inc.
422 3rd St. W.
Ashland, WI 54806 |
| Contact Person |
Wayne Cameron
Manufacturing Engineer
or
John Thompson
Finishing Team Leader715/682-5257
715/682-5583 (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 |
 |
Bureau of Cooperative Environmental Assistance
Wisconsin Department of Natural Resources
P.O. Box 7921
Madison, WI 53707
608/267-9700
PUBL-TS-043 96 |
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