Office of Technical Assistance Executive Office of Environmental Affairs Commonwealth of Massachusetts

Summary

Customer pressure, employee concern and the new Federal labeling requirements for Class I ozone depleting chemicals (ODC) combined to motivate Hardigg Industries to eliminate 1,1,1 trichloroethane (TCA) from its manufacturing operations. This was accomplished after six months of testing and experimentation in two procedures using TCA-based agents. In cleaning operations, Hardigg was able to replace TCA with water soluble cleaners. A nonhazardous compound was substituted for a TCA-based mold release. Hardigg's previous annual average emissions of 11,082 pounds of TCA have now been eliminated.

Background

Hardigg, a 210-employee company in South Deerfield, Massachusetts, manufactures plastic containers using rotational, injection and blow molding techniques. TCA was used in several process areas. To facilitate removal of the containers, a TCA-based release was wiped onto the molds prior to addition of the plastic pellets. Elsewhere, a dip tank cleaning operation used TCA to remove cutting oils and metal fines from machined metal hinges and locks. In a third area, following assembly of the metal parts and plastic containers, grease and oils were removed by wiping the products with a TCA-based cleaner. In all operations, TCA was allowed to evaporate from the parts, releasing the chemical to the atmosphere where it has contributed to the destruction of the ozone layer.

Toxic Use Reduction

At Hardigg, each employee is an Associate, and is included in all phases of the manufacturing process, including problem solving. The Hardigg Associates spearheaded the substitution of nonhazardous alternatives for TCA because they had environmental concerns and they found the odor objectionable. Also Hardigg's customers did not want a product delivered with a label stating that it had been manufactured with a Class I ODC as required by the new Clean Air Act Amendments. Hardigg worked with their vendors to select several alternatives to TCA and began approximately four months of trials and destructive testing in order to assure quality. The new cleaner had to be compatible with the plastic substrate and could not contain dyes which might penetrate and color the parts.

Hardigg's cleaning tests found a water-soluble cleaner that was comparable to TCA. In the dip cleaning operations, a new water-based cleaning machine was installed at a cost of $3,500. While the new cleaner is an effective substitute for TCA, cleaning takes longer and additional drying time is needed.

The first TCA substitute used for the final wipe of the containers also required longer cleaning times and caused a problem with residues. Hardigg located another substitute which combined with vigorous wiping, solved the residue problem.

The new mold release agent -- a water-based emulsion -- was a direct substitute for the TCA-based product. This nonhazardous replacement functions as effectively as TCA in preventing the plastic containers from adhering to the mold.

Results

Reductions Achieved: The "alternative" water-soluble cleaner and nonhazardous mold release agent have completely eliminated TCA use at Hardigg, which was 11,082 pounds the previous year. Use of these alternatives has reduced Hardigg's environmental reporting and compliance requirements and their associated costs.

Economics: Hardigg installed new machines for the dip cleaning operation at a cost of $3,500. The new mold release agent has not added to production costs beyond the labor and materials expended during the testing period. Hardigg's labor costs have risen because the new cleaner does not evaporate as quickly as TCA and workers spend more time removing residual cleaner. However, by meeting the demand for non-ozone depleting chemicals, Hardigg satisfied its customers and retained their business.