|
3D Manufacturing, Inc
Energy Conservation and Waste
Reduction through Enhanced Process Management |
| Standard Industrial Classification
(SIC) |
Truck and Bus Bodies/3713 |
| Type of Waste |
VOC air emissions, hazardous waste from
paints and solvents, inefficient use of energy for heating and drying. |
| Strategy |
Modifications to painting and finishing
operations |
| Company Background |
3D Manufacturing has been in business for
25 years and currently has 150 employees. Located in the industrial park in Shawano,
Wisconsin, 3D manufactures fire trucks, ambulances, heavy rescue and aerial devices. 3D
operates using two facilities; Plant 1 manufactures and assembles the units, while Plant 2
performs the painting and finishing operations. 3D's niche in the market is created by
their custom manufacturing technique which is driven by a team management philosophy.
Because of this attention to quality, 3D is able to offer a 5 year warranty on all of
their products. |
| Original Process |
A conventional paint system with
conventional spray equipment was used in the original finishing operations. The paint
matching was performed by a local paint jobber. The finishing operations were conducted in
a 9800 square foot building which was not energy efficient and contained many unusable
areas. Due to the building's |
| Motivation |
3D was motivated to make pollution
prevention changes to reduce production costs and obtain higher levels of efficiency by
accelerating the through-cycle time per unit. 3D was further motivated to be pro-active in
assuring regulatory compliance and to promote a safe and healthy work environment. |
| Pollution Prevention Process |
3D changed from traditional paints to high
solids paints and began using High Volume Low Pressure paint guns. Paint matching is now
performed by a computerized paint matching system. 3D also designed a new building which
accommodates more units in less space. The new building measures approximately 7200 square
feet. The forced air for the paint booth is heated by natural gas which caused a reduction
in energy consumption. The oversized booth can be separated by a sliding wall which allows
two units to be painted at the same time. The fast bake cycle increases the production
rate while improving the quality of the finished product. |
| Stage of Development |
The pollution prevention techniques used at
3D Manufacturing are in full use. |
| Level of Commercialization |
All the new process materials are readily
available. The high solids paints are custom made for 3D Manufacturing but are not
patented. |
| Obstacles |
Changing to high solids paints required
additional training for the painters. The circulation system in the paint booth is so
efficient that the filters must be changed quite often. |
| Production |
Old Process |
New Process |
| 172 units/year |
231 units/year |
|
| Material/Energy Balance |
| |
Description |
Old Process |
New Process |
| Feedstock |
paints and solvents used in finishing process |
1717 units/mo |
1464 units/mo |
| Energy |
natural gas used in heating |
0.46 ft2/mo |
0.37 ft2/mo |
| Waste/Disposal |
filters, paints and solvents |
80,000 #/yr |
17,600 #/yr |
|
| Economics |
| Capital Costs |
Description |
Cost |
| New Equipment |
Booth, Vacuum system,HVLP guns, washer, and
misc. |
$295,000 |
| Building |
|
$158,000 |
| R&D Engineering; Start Up Training |
Booth, High Solid Paint, HVLP guns |
$6,000 |
| Initial Permits |
Air, Storm Water, Shielding permits |
$750.00 |
| Space Needs (saving) |
saved $23.25/ft2 x 2,993 ft2 |
$69,587.00 |
| Utility Connections |
|
$2,100 |
| |
Total Capital Costs |
$392,263.00 |
Capital Costs Explanation
- New building combined old paint operation and our final assembly
operation.
- Less space used to produce more units.
Operating Costs |
Description |
Cost
Old Process |
Cost
New Process |
Cost/Savings |
| Materials/Supplies |
paint/unit/mo |
$ 37,775/mo |
$ 32,201/mo |
$ 5,574/mo |
| Labor |
22 units/mo |
$ 57,464/mo |
$ 50,006/mo |
$ 7,458/mo |
| Maintenance |
equipment |
$ 1,100/mo |
$ 569/mo |
$ 531/mo |
| Paperwork |
VOC tracking and manifests |
$440.00/mo |
$616.00/mo |
+ $ 176 |
| Waste Handling |
solvent, paint, waste |
$ 1,212/mo |
$ 386/mo |
$ 826/mo |
| Utilities |
gas, water, sewer |
$ 4,508/mo |
$ 2,519/mo |
$ 1989/mo |
| |
Total Operating
Costs/Savings |
$ 16,202/mo |
Operating Costs Explanation
- Material and labor based on 22 units/month
- Cost of hazardous waste handling increased from $69.00 to $100.00/ barrel
Payback Period
24 Months |
| Benefits |
VOC air emissions were reduced by changing
from 5.3#VOC/gallon to 3.5 #VOC/gallon paint. The HVLP spray guns provide much better
transfer efficiency and less overspray while emitting fewer VOCs to the air. The
computerized paint matching system reduces the amount of incorrect paint being mixed,
reduces the need to repaint certain parts of the units, and provides precise paint
formulas. The new building configuration added additional employee safety benefits and
product quality benefits. Accidents are reduced because the vehicles are no longer being
backed out of the finishing operation. The new building allows faster production rates and
improved product quality. |
| Technology Transfer |
Designing a more efficient finishing
operation building can be adapted to many different industries. More efficient painting
techniques can also be used by any industry that has similar painting operations. |
| Other Environmental Programs |
The pollution prevention activities
described above are only the first steps toward a full environmental management system. 3D
also expects to install a Precision Mix system to allow more consistent paint usage which
will further reduce the amount of solid and hazardous waste generated. The P-Mix System
should drastically reduce the amount of paint waste and spent thinner generation. 3D
anticipates a two year payback period on the P-Mix System as well. 3D is working toward
ISO 9000 certification to provide QA/QC on all of their operations. In addition, 3D uses a biodegradable cleaner to clean units after body work is
performed. Wipe-down rags are laundered and reused. Empty paint cans are recycled for
metal recovery. Solvents are reused until no longer effective.
3D uses board made of recycled HDPE for parts on fire trucks that once
were made of wood. This eliminates the need for high VOC content varnish. A Eurovac unit
withdraw dusts form the body filler work areas both at the tools and suction hoods. Excess
wire is collected and taken to a scrap yard for copper recovery.
All painters at 3D are trained and certified by the paint supplier and
many are also certified by ASE. |
| Company Address |
3D Manufacturing, Inc.
3545 E. Richmond
Shawano, WI 54166 |
| Contact Person |
Patrick Schutt, Plant Manager, Final
Assembly Plant
Phone (715) 524-5653 Ext. 253
FAX (715) 524-9997 |
| Waste Reduction Resources |
Free, On-site Technical Assistance
University of Wisconsin Extension
Solid and Hazardous Waste Education Center
Milwaukee area: 414/475-2845
Remainder of state: 608/262-0385Environmental Assistance
Publications Order Form
Wisconsin Department of Natural Resources
Cooperative Environmental Assistance
608/267-9700 |
 |
Bureau of Cooperative Environmental Assistance
Wisconsin Department of Natural Resources
P.O. Box 7921
Madison, WI 53707
608/267-9700
PUBL-CO-056 |
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