Pollution Prevention Case Study

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

  1. New building combined old paint operation and our final assembly operation.
  2. 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

  1. Material and labor based on 22 units/month
  2. 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: 608/262-0385

Environmental Assistance Publications Order Form
Wisconsin Department of Natural Resources
Cooperative Environmental Assistance
608/267-9700

DNR Logo


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

PUBL-CO-056