CASE STUDIES

Company

Manufactures chairs and other furniture for hotels and restaurants

Waste Stream Targeted

Paint-related Waste

Original System

Solvent-based Topcoat Lacquers are used in finishing wood furniture. Typical solvent-based lacquers contain 60% to 80% volatile organic compounds (VOCs), many of which are also listed as hazardous air pollutants (HAPs).

Initial Equipment Costs

Four IR ovens were purchased and installed for ~$200,000. A new conveyor system was added fir ~$100,000. Stainless steel equipment modifications (new pumps, lines, guns, to prevent rust problems cost $30,000. Total Cost: $330,000.

Operating Cost Savings

The new system will allow them to nearly double their production and sales.

Material Cost Savings

Solvent-based topcoat lacquers cost $10.50/gallon. Waterborne topcoat lacquers cost $16.00/gallon. For each coating, 12 chairs can be coated/gallon using solvent-based lacquer. 16-18 chairs can be coated/gallon using waterborne lacquer. Therefore, the cost per chair is nearly the same: $.87/chair for solvent-based and $.94/chair for waterborne. However, water-based topcoat lacquers eliminate the use of solvent-based lacquer thinners as a thinning agent/cleaner which, will also be a substantial cost savings (not yet quantified).

Payback Period

Because of the increased production rates allowed by the new system, the overall payback period will be about 3 years.

Major Benefits

Reduced VOC emissions from 80 tons/year to 1 ton/year(HAPs reduction was not quantified).
Reduced fire hazard.
Improved worker health and safety, liability reduction.
Positive business image.

Main Reason Introduced

Reduce VOC and HAPs emissions and regulatory burdens and liability.

 Key to Success in Making this P2 Change

Management support/commitment to Pollution Prevention. Employee involvement, training in P2 modifications.