| 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 Navy Environmental Leadership Program (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: |
Switching from traditional paint stenciling to
an Improved Stenciling and Marking System will result in reduced hazardous waste
generation and disposal costs, which contribute to compliance under RCRA (40 CFR 262)
and Executive Order 13148. It will also help facilities to meet the Federal
acquisition and waste prevention requirements of EO 13101. Furthermore, non-paint-based
stenciling and marking may help a facility to reduce its reporting requirements
under SARA Title III (40 CFR 355, 370, 372).
In addition, by reducing HAP and VOC emissions related to
solvent use, a facility will be more likely to meet the emissions limits of an air
permit issued in accordance with 40 CFR 70 and 71 or related state
requirements. The switch may also decrease the need for a facility to obtain
an air permit in the first place.
The compliance benefits listed here are only
meant to be used as general guidelines 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:
|
No material
compatibility issues were 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 SE pieces being stenciled per year.
- NELP method would require stenciling 143
pieces per year..
- This is based on the test site stenciling
429 SE pieces 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)]
|
| NSN/MSDS:
|
None identified.
|
| Approving Authority: |
Appropriate authority for making process changes should
always be sought and obtained prior to procuring or implementing any of the technology
identified herein.
|
| Points of
Contact: |
For more information
|
| Vendors: |
This is not meant to be a
complete list, as there may be other suppliers of this type of
equipment.
Tonas Graphics
2121 Noblestown Road
Pittsburgh, PA 15205
Phone: (800) 535-7553
FAX: (412) 937-1607
E-mail: info@tonasgraphics.com
URL: http://www.tonasgraphics.com/index.html
|
| Related Links: |
Do You Mark Equipment And
Paint Signs?, Navy Environmental Quality Initiative (EQI)
Improved Stenciling and Marking System
|
| Sources: |
Mr. Tom Rua, NAWC
Lakehurst.
Pollution Prevention Equipment Program, 1998 Preproduction
Initiative Final Report, Improved Stenciling and marking System, NAS
NORTH ISLAND, CA, 13 December 2000, Naval Air Warfare Center,
Lakehurst, NJ.
Preproduction Initiative - NELP, Improved Stenciling and
Marking system, Cost Analysis Report.
JG-PP Information Sheet for:
Low-Voc Identification Marking, March 2000.
Paper, "Technology Survey
for Alternatives to Solvent-Based Ink Stenciling for Identification
Marking, NDCEE, October 29, 1997 and July 16,
1998.
|
| Supplemental: |
Picture of Improved Stenciling and Marking System
|
