12-13 IMPROVED STENCILING AND MARKING SYSTEM

Overview:

The Improved Stenciling and Marking System can generate and print labels, markings, signs, instruction plates etc., on a variety of engineered adhesive-backed materials without generating any hazardous wastes or volatile organic compound (VOC) emissions. The traditional method of marking equipment requires the use of a stencil cutout, followed by masking material and paint. This method generates paint and paint wastes (spray cans, tape, rags, and solvent etc.) that must generally be disposed of as hazardous waste.

The system generates durable stencils and signs via a computer-driven graphics output device that prints and cuts vinyl and film material to marking operation specifications. Most desktop computers with the necessary capabilities can run the software. According to the manufacturers, vinyl stencils have an outdoor durability of up to 7 years, and the image has a guaranteed outdoor life of 3 to 5 years. In contrast, spray-painted, stenciled markings must be reapplied every 18 months.

These systems can be used to provide all the marking, stenciling, and sign making for an activity or ship. Examples of applications include aircraft labels, support equipment (part numbers, operational instructions) automotive decals, and facility directional signs.

A NELP Preproduction Initiative Demonstration evaluated the viability of two systems (The Roland Color Camm Pro and the Gerber Edge) for Navy applications. In this project NAS North Island prototyped the equipment and three other sites, NS Mayport, Naval Air Station Joint Reserve Base (NASJRB) New Orleans, and NAS Brunswick, provided input.

The Roland Color Camm Pro (Pc-60) is a one-piece device that prints and cuts stencils. The Gerber Edge and GSx Cutter is a unit composed of two separate components; the edge, which prints the stencil, and the cutter. Consumables used by both the Roland and Gerber units include vinyl (adhesive-backed), transfer tape (used to assist in transferring an adhesive-backed stencil onto the desired surface), and application fluid (applied to the surface being stenciled to enhance proper positioning of the stencil).

The results of the demonstrations indicated that:

The requirements for operating both units were minimal.
Overall, the units performed as expected and satisfactorily replaced spray-painted stencils.
The systems interface easily with operations at locations such as support equipment (SE) maintenance shops, where stenciling is typically performed using traditional methods.
In outdoor conditions, the vinyl stencils last much longer than painted stencils and reduce the amount of hazardous waste produced.
Due to the ease of application and the longer life span of the stencils, the time required to stencil and re-stencil the SE is reduced, which translates into man-hour cost savings.
The Roland unit proved to be easier to use, was less expensive, and had a faster overall stencil generation time than the Gerber.
As a result of the evaluations, printed adhesive labels have been approved as an alternative to painting and stenciling for marking aviation SE*.

For more information regarding these tests, refer to Test Directive NAWCADLKE-PVTD-SE-980001.

*This information is contained in the latest update of NAVAIR 17-1-125, Support Equipment Cleaning, Preservation and Corrosion Control Manual, dated 15 March 2000.

Compliance Benefit:

Benefits include reduced hazardous waste generation and disposal costs, which contribute to compliance under RCRA, Title 40 CFR 262. The reduction in the use and disposal of solvents contributes to compliance under RCRA, Title 40 CFR 262.41 (a) (6).

Reduction of VOC fugitive emissions related to solvent use

results in a decrease in emission reported under EPCRA and potentially under Title V permitting requirements of the Clean Air Act.

The compliance benefits listed here are only meant to be used as a general guideline and are not meant to be strictly interpreted. Actual compliance benefits will vary depending on the factors involved, e.g., the amount of workload involved.

Materials Compatibility:

There were no material compatibility issues identified.

Safety and Health:

The use of the system contributed to a healthier work environment for personnel by removing exposure to solvents and paints and potential cut hazards presented by the traditional method. Consult your local industrial health specialist and your local health and safety personnel prior to implementing this technology.

Benefits:

Reduce the quantity of hazardous waste.
Reduce the cost of hazardous waste disposal.
Reduce the labor hours required for stenciling.
Provide a healthier work environment.
Reduce paint-related volatile organic compound (VOC) emissions.

Disadvantages:

No disadvantages were identified.

Economic Analysis:

The information provided below was generated under the NELP-PreProduction Initiative.

Assumptions:

Previous method is based on an average of 286 pieces of support equipment (SE) being stenciled per year.
NELP method would require stenciling 143 pieces per year..
This is based on the test site stenciling 429 pieces of SE every 1 1/2 years using Previous Method.
NELP method would stencil that same quantity every 3 years (429/1.5=286 and 429/3=143).

Cost Comparison for Spray Paint with Stencil Cutouts vs. NELP Method

Previous Method: Spray Paint with Stencil Cutouts

*Consumables*
Rags used per year: 200 lb. Cost per 50 lb.: $20 Cost of rags per year: $80 Paint spray cans used per year: 214.5 Cost per spray can: $6.81 Cost of spray cans per year: $1,460.75
	Total consumable cost/year:	$1,540.75
*Labor*
Hours per piece of SE for surface preparation, applying cardboard or metal stencils, painting, and cleanup: 1 to 3 Average hours per piece of SE for surface preparation, stenciling, and cleanup: 2 Pieces of SE per year: 286 Hours per year for SE surface preparation, stenciling, and cleanup: 572 Average hourly pay: $16.89 (Based on average basic pay of an E-4 [$15.36/hr.] and E-5 [$18.41/hr.] with 3 years of service)
	Total labor cost/year	$9,661.08
*Waste Disposal*
Disposal cost per pound for paint & solvent-soaked rags: $1.40 Pounds of rags disposed of per year: 200 Disposal cost of rags per year: $280.00 Disposal cost per pound for aerosol cans: $1.70 Pounds of aerosol cans disposed of per year: 75 Disposal cost of aerosol cans per year: $127.50
	Total disposal cost per year:	$407.50
Total Annual Costs		$11,609.33

NELP Method: Improved Stenciling and Marking System (Based on 143 pieces of SE/year and 5 stencils/piece of SE (avg.) = 715 stencils/year)

*Consumables*	Roland	Gerber
Number of average-sized stencils made from one roll of vinyl	25	150
Rolls of vinyl per year	28.6	4.77
Cost per roll of vinyl	$20.00	$150.00
Number of average-sized stencils made from one toner cartridge	12	50
Toner cartridges per year	59.6	14.3
Cost per toner cartridge	$17.00	$100
Number of average-sized stencils made from one roll of transfer tape	100	100
Rolls of transfer tape per year	7.15	7.15
Cost per roll of transfer tape	$10.00	$10.00
Gallons of application fluid per year	1	1
Cost per gallon of application fluid	$28.13	$28.13

Cost Summary	Roland	Gerber
Vinyl Cost	$572.00	$715.50
Toner Cartridge	$1,013.20	$1,430.00
Transfer Tape	$71.50	$71.50
Application Fluid	$28.13	$28.13
Total	$1,684.83	$2,245.13

Labor
Average hours to make and apply one average sized stencil: 0.15
Average hourly pay of the stencil machine operator (E-5): $18.71
Average number of stencils per year: 715
Average hours per year to make and apply stencils: 107.25
Total labor cost per year: $2,006.65

Waste Disposal
The vinyl and transfer tape used in the production of these stencils is considered non-hazardous waste. In addition, toner cartridges from the Gerber and Roland equipment can be recycled by their respective manufacturers. Therefore, cost associated with the creation, use or disposal of vinyl stencils are avoided.

ITEM	Roland	Gerber
Consumables Labor Waste Disposal	$1,684.83 2,006.65 0.00	$2,245.13 2,006.65 0.00
TOTAL	$3,691.48	$4,251.78

Cost Analysis Summary (Per Year)

	Roland	Gerber
Use of Spray Paint with Stencil Cutouts Improved Stenciling System Cost Change Initial Procurement Expected Service Life	$11,609.33 3,691.48 7,917.85 7,470.00 10 years	$11,609.33 4,251.78 7,357.55 22,136.26 10 years
Return on Investment (per 10-year period)*	$71,708.50	$51,439.24
Break-Even Point	0.94 years ($7,470.00/$7,917.85)	3.01 years ($22,136.26/$7,357.55)

*Roland = (10 x $11,609.33) - [$7,470.00 + (10 x $3,691.48)] ; Gerber = (10 x $11,609.33) - [$22,136.26 + (10 x $4,251.78)]

Approving Authority:

Approval is controlled locally and should be implemented only after engineering approval has been granted. Major claimant approval is not required.