June 1988
This electronic products and systems leader stands behind its mission statement: COMMITTED TO EXCELLENCE. Tek's policy is to be a clean, non-polluting neighbor, despite the potentially harmful chemicals necessary in the area of design and test computer graphics and communications manufacturing.
"We work to stay ahead of the regulation game with a comprehensive waste management program," says Tom McCue, Environmental Programs Manager. "We look for ways to reduce the amount of hazardous wastes we produce. From product designers to process engineers and manufacturing personnel, our employees are trained to do that. It saves us money in the long run."
The program is designed to minimize waste throughout the production process and prevent transferring waste from one medium to another.
Tek has successfully reduced pollution and the production of hazardous wastes in three key areas: painting, degreasing, and materials handling.
Painting is a vital part of metals production at Tek. The product line requires painting services, and contract painting for other companies is an increasingly important income source for the manufacturer. However, when new state regulations limited volatile organic emissions from paint solvents to 40 tons per year, the question Tek faced was "to paint or not to paint?" Air quality studies showed that the new limit could be exceeded with just one paint line --- and emission-control equipment was prohibitively expensive.
Rather than costly 'end of pipe' emissions treatment, Tek decided to look for ways to prevent pollution in the entire painting process.
New on the market were supplier-developed low-solvent, high-solid paints that could cut emissions almost in half without costly pollution control equipment. But the paints required both new equipment and new production techniques --- that is, before Tek engineers got on the problem. They were able to modify the existing painting process to use the new paint by incorporating high speed, high pressure painting equipment; a paint distribution system; and heaters to thin the paint.
These modifications kept the need for new process equipment to a minimum without compromising quality.
Theresa Perrone, Air Quality and Waste Minimization Program Manager, says other companies still face similar situations today. "The key to a successful adaptation is to work closely with paint and equipment suppliers to solve changeover problems." If local suppliers don't have the answers, she recommends "getting to the technical experts at the main office, the ones with lots of expertise."
Tek's three paint line modifications accounted for a 30 per cent net savings in the applied costs per square foot. Although low-solvent paint is more expensive, the new system uses 40 per cent less product. This means less hazardous waste from the production process and less money spent on expensive disposal.
In addition, operators report case after case of improved efficiency. With fewer moving parts, the revised air-driven discs require less maintenance. Increased pump pressure translates to faster feed rates. Operators have a faster response time to requests for color or thickness changes, and less time is needed for cleanup. And if problems develop during painting, they can be corrected faster.
The low-solvent, high-solids technology also has improved quality control. Instead of being limited to just one variable, paint viscosity, technicians now have a number of possible solutions to problems, including paint feed rate, disk speed, and voltage. There's also less scrap and rework with the new paints.
Some benefits are obvious but still important. The new paints reduce employee health risks from long term exposure to solvent fumes. Electrostatic painting equipment, particularly when modified to handle low-solvent high-solids paint, greatly reduces overspray. In addition, any reduction in the amount of hazardous wastes produced also means reduced liability from the unknowns which are associated with 'cradle to grave' responsibility.
Although the changeover was disruptive in the short run, long term benefits have made Tek's painting operation more efficient and profitable.
Besides minimizing waste throughout the production process, Tektronix prefers to purchase products that can be reused and recycled to minimize waste production. At the end of the process, wastes are segregated to prevent contamination and facilitate reuse and recycling.
When solvents are no longer clean enough for the high-tech quality demanded by Tek, they are used for low-tech applications such as prepainting preparation.
Reuse is even more cost-effective than recycling, and solvent saved is solvent that doesn't have to be purchased.
Tektronix employs what is called a 'zero inventory' or just-in-time control system. The in-process inventory is limited to supplies needed hour by hour. By matching purchasing to current production needs, both the amount of hazardous material stored on-site and the potential of obsolete material becoming hazardous waste have been reduced.
According to Perrone, the system requires planning and the ability to predict output. "It works best with short lead-time commodity-type items", she adds.
Your company need not be a corporate giant to benefit from the waste minimization technology used by Tektronix. All it takes is a commitment to excellence and the willingness to ask for help. DEQ would like to be a part of your company's solution to the hazardous waste problem. Give us a call.
Profile is produced and distributed by the Hazardous Waste Reduction Program of the Oregon Department of Environmental Quality (DEQ).
Oregon Department of Environmental Quality (DEQ)
81 I SW 6th
Portland OR 97204
or
call (503) 229-5913.
Outside the Portland area within Oregon call 1-800-452-4011.
Last Updated: November 22, 1995