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Technology Transfer

Short abstracts of each P2 Brief are provided on this page. The complete P2 Brief is available by choosing the specific company.

AM GENERAL CORPORATION
Date of Report: September 1996
SIC categories: 34, 35, 37
Primary SIC: 3711

AM General Corporation manufactures the Hummer, a premier off-road vehicle. The company looked to CMTI for assistance in proper application of high-solid/low-VOC paint to their vehicles in order to achieve lower VOC emissions while still maintaining a high quality finish on their product.

Emission reductions:
	Xylene:		0.2 tons 
	MEK:		0.1 tons
	Toluene:	0.1 tons
	Misc. VOC:	1.2 tons
	Total VOC:	1.6 tons
	Cost savings:	$76,500
Keywords: volatile organic compound, VOC, HAP, hazardous air pollutant, coating,paint, automotive, transportation

ALTEC ENGINEERING, INC.
Date of Report: August, 2001
SIC categories: 30, 37
Primary SIC: 3089

Altec Engineering, Inc. is an open-mold fiber-reinforced plastic composites manufacturer. The company worked with the Magnum Venus Products (MVP) and Ferro Corporation in pioneering processes within its plant to implement non-atomized gel-coat application to open molds on a full production basis. The non-atomizing application equipment uses a convergent-stream technology and significantly reduced the emissions of HAP/VOC (styrene) normally associated with the application of resins and gel-coats in the open-molding process.
Emission reductions:
	Styrene:         13.2 tons 	
	Cost savings:    $13,000 per year
Keywords: volatile organic compound, VOC, HAP, hazardous air pollutant, gel-coat, FRP, automotive, marine

AMERICAN LIFTS
Date of Report: March 1996
SIC categories: 34,35
Primary SIC: 3537

The American Lifts Company worked with CMTI to select a water-based paint that could replace the solvent-based paints the company was currently using. The switch resulted in a reduction of VOC emissions.
Emission reductions:
	Total VOC:	7,600 lbs.
Keywords: volatile organic compound, VOC, HAP, hazardous air pollutant, paint, electrostatic, water-based, solvent, coating, metal fabrication.

ATLAS FOUNDRY COMPANY, INC.
Date of Report: July 1996
SIC Category: 33
Primary SIC: 3321

Atlas Foundry Company converted from a cupola melting furnace to an electric induction furnace. The company contacted CMTI to review this change of process with regard to hazardous chemical emissions, solid waste reduction, and economics. This Pollution Prevention Technology Implementation Report documents CMTI's findings.

Emission reductions:
	Total pollutants:	1,168 tons
	Cost savings:		$126,084
Keywords: air contaminant, particulates, cupola, landfill waste, foundry.

AUTOMOTIVE PARTS COMPANY (MV003)
Date of Report: March 1996
SIC Category: 34
Primary SIC: 3429

MV003 is an automotive parts company that cuts, welds, and paints metal parts for the automotive industry. This Pollution Prevention Opportunity Assessment Report outlines how CMTI could help the company switch to a closed-loop water-based part cleaning system and a water-based paint system. In the future, this switch will allow the company to reduce its VOC emissions;
Emission reductions:
	Total VOC:	23.5 tons
	Cost savings:	$3,500
Keywords: paint, cleaner, volatile organic compound, VOC, HAP, hazardous air pollutant, water-based coating, automotive, metal fabrication.

CHILDCRAFT INDUSTRIES -Report #1
Date of Report: March 1996
SIC Categories: 24, 25
Primary SIC: 2511

Child Craft Industries manufactures high quality children's furniture. This Pollution Prevention Opportunity Assessment reports on the trial of an "on-demand" sponge reservoir staining process. Though Child Craft chose not to adopt the process, other companies may find this process allows them a significant reduction in VOC emissions.
Emission reductions:
	Total VOC:		2.5 tons
	Cost savings:		$10,000
Keywords: paint, stain, sponge, finish, volatile organic compounds, VOC, MACT, maximum achievable control technology, coatings, wood, furniture, transfer efficiency.

CHILD CRAFT INDUSTRIES, INC. - Report #2
Date of Report: September 1996
SIC Categories: 24, 25
Primary SIC: 2511

Child Craft Industries manufactures high quality children’s furniture. This Pollution Prevention Project reports on an electrostatic spray painting project that has allowed the company to reduce VOC emissions by increasing paint transfer efficiency.

Emission reductions:
	Total VOC:	6.2-7.2 tons
	Cost savings:	$40,500
Keywords: paint, finish, volatile organic compounds, VOC, MACT, maximum achievable control technology, coatings, wood, electrostatic paint, furniture, transfer efficiency.

CHILD CRAFT INDUSTRIES and CARL - Report #3
Date of Report: April 1997
SIC Categories: 24, 25
Primary SIC: 2511

Child Craft Industries manufactures high quality children's furniture. This Pollution Prevention Project reports on the optimizations of an electrostatic spray painting project that has allowed the company to reduce VOC emissions by increasing paint transfer efficiency.
Emission reductions:
	Total VOC:		8 tons 
	Cost savings:		$33,000
Keywords: paint, finish, volatile organic compounds, VOC, MACT, maximum achievable control technology, coatings, wood, electrostatic paint, furniture, transfer efficiency.

CMTI/SMALL BUSINESS ASSISTANCE PROGRAM
Date of Report: October, 2003
SIC Category: 25, 30, 33, 34, 36, 37, 39

Indiana's Small Business Assistance Program (SBAP) was a nonregulatory program that provided technical assistance to Indiana small businesses that must comply with the 1990 Clean Air Act Amendments (CAAA) and Indiana air regulations. It focused on compliance assistance, with an emphasis on pollution prevention strategies for reducing the use of toxic raw materials and the generation of environmental wastes.

Keywords: HAP, hazardous air pollutant, volatile organic compound, VOC, metal cleaning, surface coating, metal casting, Title V, permit by rule, BACT, MACT

CMTI/SMALL MANUFACTURER ASSISTANCE PROGRAM
Date of Report: December, 2005
SIC Category: 243x, 285x, 289x, 306x, 308x, 344x, 346x, 347x, 371x, 379x, 399x

Indiana's Small Maufacturer Assistance Program (SMAP) was a nonregulatory program that provided free, confidential technical assistance focusing on clean manufacturing and pollution prevention strategies for reducing the use of toxic raw materials and the generation of environmental wastes, including air emissions. These services were provided through an agreement with the Indiana Department of Environmental Management.

Keywords: HAP, hazardous air pollutant, volatile organic compound, VOC, metal cleaning, surface coating, metal casting, Title V, permit by rule, BACT, MACT

CMTI/WOOD CABINET SMALL BUSINESS INITIATIVE
Date of Report: June 1996
SIC Category: 24
Primary SIC: 2434

This Pollution Prevention Opportunity Assessment Report outlines how CMTI has worked with Indiana's Wood Cabinet Industry to 1) assist and advise the companies with regard to the use and reduction of HAP-compliant and/or HAP-free wood cabinet finishings, and 2) assist the companies in the development of VOC inventory tracking systems so that companies can comply with the new 1990 Title V Clean Air Act permit record keeping requirements.
Emission reductions:
	Xylene:		15,000 lbs
	Toluene:	9,500 lbs
	MIBK:		4,800 lbs
	Ethyl benzene:	1,850 lbs
	MEK:		2,300 lbs
	Total VOC:	33,450 lbs
	Cost savings:	$36,000
Keywords: HAP, hazardous air pollutant, volatile organic compound, VOC, coatings, finishes, wood, Title V Permit, cabinets, furniture.

COMPANY 16 (Water-based Coatings on Metal)
Date of Report: May 2000
SIC Categories: 34
Primary SIC: 3499

This project was initiated with a central Indiana company to evaluate new types of waterborne coatings as potential replacements for solvent-based coatings. The goal: to assist the company to reduce its emissions and its regulatory liability as well as increase its cost savings. As a result of testing at Purdue University's Coating Applications Research Laboratory it was verified that the coatings blended with reduced VOCs can prove to be a viable alternative to traditional VOC coating systems. The tests also verified that efficient IR heat curing systems can accelerate the cure of reduced VOC coating systems to meet this plant's production speeds. The company was able to reduce their VOC emissions by 93% percent, to over 7500 pounds annually.

Keywords: VOCs, solvent-based coatings, IR heat curing systems

ELECTROCHEMICAL COATINGS INCORPORATED
Date of Report: September 1998
SIC Categories: 36
Primary SIC: 3643

Electrochemical Coatings Incorporated (ECC) initiated a project with the Indiana Clean Manufacturing Technology and Safe Materials Institute (CMTI) to identify possible causes of rework in ECC's automatic lead plating process. Eliminating the cause of the rework will save time and money as well as reduce the use of chemicals used in processing. Based upon results from testing conducted at ECC, the ECC/CMTI team recommended that the company continuously monitor and maintain the rinse tanks following the lead plating bath in an optimally clean condition. The team also recommended counterflowing the rinse water in order to save water and reduce wastewater volume. The first rinse immediately following the lead plating bath should receive the fresh water, and the overflow from it should go to the subsequent rinse tanks. This countercurrent discharge should lead to the last unheated rinse, which should discharge directly to waste water treatment. It is also strongly urged that the rinse water from the final heated rinse tank be emptied, cleaned, and recharged on a weekly basis.

Estimated environmental benefits:
	Estimated F006 hazardous waste reduction (yearly)	2,000 pounds
	Estimated savings (yearly):
		Labor cost reduction		$18,900
		Waste cost reduction		2,000
		Chemical cost reduction		   16,875
		Total		$37,775
	Estimated costs (one time):
		Counterflow rinses		$1,500
	Estimated payback period	less than 1 month
Keywords: Lead plating, counterflow, F006, rinse tanks, deionized water

ENVIRONMENTAL MANAGEMENT SYSTEMS GUIDE - A Quick Start Method for Selecting EMS Priorities
Date of Report: August 1998
SIC categories: N/A
Primary SIC: N/A

This guide is not offered as an explanation of the ISO 14000 system, nor is it offered as the only blueprint to begin an EMS within a company. This guide suggests a method to "quick-start" the identification of priorities necessary for developing an EMS program.

FERRO CORPORATION
Date of Report: June 1997
SIC Category: 28
Primary SIC: 2816

Ferro Corporation's Liquid Coatings and Dispersion Division is located in Plymouth, Indiana. The company manufactures gel-coats, pigment dispersions, plastic colorants and repair epoxy formulations, serving the composite fiberglass industry. In 1993 the Indiana Clean Manufacturing Technology and Safe Materials Institute (CMTI) worked with Ferro in a project aimed at reducing VOC/HAP emissions (primarily styrene). Improvements in the covering of containers and in the manner of capturing, containing and exhausting the styrene emitted from the gel-coat blending vats resulted in a significant percentage-wise reduction of these emissions.
Emission reductions:
	Styrene:	     >10.0 tons
         % Reduction   >43%
         Cost:	     <$1,000
Keywords: VOC, HAP, gel-coat, FRP

FLEETWOOD MOTOR HOMES OF INDIANA
Date of Report: April, 1997
SIC Categories: 37
Primary SIC: 3716

Fleetwood Motor Homes of Indiana is located in Crawfordsville, Indiana. The company is recognized internationally as a manufacturer of quality travel trailers. Its assembly processes required many HAP-based adhesives to apply the outer fiberglass skin to the vehicle’s superstructure and to install carpets, tabletop laminates, curtain valances, wood fixtures, etc. Technology transfer information was provided by CMTI that would allow the company to switch to a low-HAP sealant/adhesive and thereby significantly reduce its emissions of VOCs/HAPs.

Emission reductions:
	Toluene:	     10.8 tons
         Cost Savings: $19,000
Keywords: VOC, HAP, adhesive, fiberglass, motor home

FLEXIBLE FOAM PRODUCTS
Date of Report: August, 2001
SIC Categories: 30, 28
Primary SIC: 3086

Flexible Foam Products is a leading manufacturer of urethane polyol foam material used extensively by the automotive, recreational vehicle, bedding, furniture and foam packaging industries. Increasing recognition of the toxic nature of, and environmental degradation resulting from, methylene chloride (a key compound used in large quantity in the foam expanding process), led the company to take major steps to incorporate and develop the techniques and equipment changes necessary to allow the use of carbon dioxide as a replacement blowing-agent for methylene chloride. The company’s timely pro-active move in this direction provided it with the ability to comply with applicable MACT standards that became effective in 1998 for Flexible Polyurethane Foam Production.

Emission reductions:
	Methylene chloride:  350.0 tons
         Cost Savings:        nearly $300,000 per year
	Investment:          $1,275,000
         Payback:             approx.  4.2 years
Keywords: carcinogen, HAP, methylene chloride, foam-blowing

FURNITURE MANUFACTURER (Powder Coating on Wood)
Date of Report: April, 2000
SIC Categories: 25
Primary SIC: 2511

Through the use of an Indiana Department of Environmental Management Pollution Prevention Mini-grant award, the Coating Applications Research Laboratory/Indiana Clean Manufacturing Technology and Safe Materials Institute (CMTI) personnel investigated the reproducibility and quality potential of applying typical powder coating material to MDF and solid wood materials. This project was begun as an early investigation of the potential of using powder coatings in the wood furniture industry for specialty flat top pieces and for certain specialty areas where electrostatic application has already been proven and accepted (such as crib rails). A furniture manufacturer agreed to take part in the test expressly for the purpose of investigating and evaluating this new and early application technology in the wood furniture industry. The MDF/Crib Rail Project provided valuable insight as to the key process parameter required to successfully coat and cure MDF and/or hardwood with powder coating material. The tests demonstrated the heat tolerance advantage of dry wood and its ability to easily withstand powder curing temperatures, as compared to the less heat tolerant wood moisture contents of 6% and above. Overall, the tests provided evidence that typical MDF (as well as hardwood materials) can be successfully and consistently coated with typical, moderate melt temperature powder systems if important process parameters such as wood moisture content and wood conductivity are monitored and strictly controlled. This specialty coating system is in its infancy with regard to market potential and acceptance. However, if this specialty coating was accepted in small niche market applications, the emissions reduction of powder, over the typical liquid/VOC based material, would approach 80-90%. Under such an application, an individual location could easily reduce emissions by 5 to 10 tons of VOC.

Keywords: MDF, VOC, powder coating, heat tolerance

HOLIDAY RAMBLER
Date of Report: August 1996
SIC Category: 37
Primary SIC: 3716

Holiday Rambler manufactures quality motor homes with a seamless fiberglass laminate as the exterior skin. This Pollution Prevention Project Report documents Holiday Rambler's move from high-HAP "red glue" adhesives to non-HAP/VOC emitting adhesives (one water-based and the other a "hot melt" urethane adhesive) with CMTI's assistance.
Emission reductions:
	TCA:		130.7 tons
	Cost savings:	$265,450
Keywords: volatile organic compound, VOC, HAP, hazardous air pollutant, adhesive, red glue, glue, bonding compound, TCA, trichloroethane, hot melt, urethane.

INNOVATIVE TECHNOLOGY REPORT - Controlling Viscosity in High Solids Paint
Date of Report: January 1997
SIC Categories: 37, 34, 35, 25, 34, 36
Primary SIC: 3469

Great strides in cost savings and VOC emissions can be achieved by using high-solids paint products as alternatives to traditional low-solids paint products. Controlling the viscosity of the paint by providing a controlled heat input is the key to using high-solids paint. Heat lowers the high-solid paint's viscosity, makes it easier to spray, and improves its "flow" qualities.
Emission reductions:
	Total VOC:	potentially as much as 62% or more
	Cost savings:	potentially a 33% (or more) savings in applied costs
Keywords: volatile organic compound, VOC, hazardous air pollutant, HAP, viscosity, heat, paint, metal coating, surface finishing, high-solids

ITW MICRO-POISE
Date of Report: April 1998
SIC categories: 35
Primary SIC: 3549

The Indiana Clean Manufacturing Technology and Safe Materials Institute (CMTI), the Coating Applications Research Laboratory (CARL), both located at Purdue University, and an environmentally-minded, central Indiana, manufacturing company, ITW Micro-Poise, participated jointly in a project to evaluate water-based coating alternatives for application to the company's products. The plant's 1998 projected VOC emissions were estimated to be 1,750 pounds, using traditional VOC-based coatings (company sales growth projections are included in the calculations). The new 1998 projection of VOC emissions, resulting from 100% waterborne coating usage is 311 pounds. This 82% reduction in VOC emissions is a result of the company's successful switch to waterborne coatings.
Emission reductions:	
	VOC:			82%, 311 pounds
	Annual cost savings:	$1,000
Keywords: VOC, HAP, solvent-based enamel, MEK replacement, water-based finish coating, painting, paint

JUPITER COIL COATING DIVISION-JUPITER ALUMINUM CORP.
Date of Report: September 1999
SIC Categories: 34
Primary SIC: 3479

The Jupiter Coil Coating Division (Jupiter) initiated a project with the Indiana Clean Manufacturing Technology and Safe Materials Institute (CMTI) to identify methods to reduce or eliminate the need to continuously replenish their aluminum coil cleaning solution. Jupiter also wanted to assure that their water effluent met their National Pollution Discharge Elimination System (NPDES) permit limits with the ultimate goal of zero water discharge. As a result of this project, Jupiter determined that the installation of an ultra filtration (UF) system would extend the life of the cleaning solution as well as that of a subsequent chromate conversion solution. Jupiter has reduced their chemical usage and hazardous waste production by using the UF to remove etched aluminum from their cleaning solution -- thereby accomplishing cost and waste reduction through pollution prevention.

Estimated emission reductions:
	Hazardous waste reduction (yearly):	11 tons
	Special waste reduction (yearly):	55 tons
        Estimated savings (yearly):	        $47,000
Keywords: NPDES, ultra filtration, aluminum cleaning process, etched aluminum, chromate conversion, reverse osmosis

LACAY FABRICATION & MANUFACTURING, INC.
Date of Report: April 1997
SIC Categories: 34, 35, 37
Primary SIC: 3469

Lacay Fabrication and Manufacturing is an automotive rack producing company. This Pollution Prevention Final Project Report outlines how Lacay reduced their HAP and VOC emissions by replacing their xylene cleaning operations with a closed loop aqueous cleaning system, using a less hazardous cleaner, and through the use of high-solids paints.
Emission reductions:
	Xylene:		8.5 tons
	Other VOC:	4.5 tons
	Total VOC:	13.0 tons
	Cost savings:	$17,500 
Keywords: xylene, high-solids paint, volatile organic compound, VOC, HAP, hazardous air pollutant, paint, automotive, metal fabrication.

MIDDLEBURY HARDWOOD PRODUCTS INC.
Date of Report: March 1996
SIC Categories: 24, 25
Primary SIC: 2434

Middlebury Hardwood Products manufactures hardwood doors and drawer fronts for cabinets. Middlebury Hardwood Products joined with CMTI to invite wood coating manufacturers to develop coatings that would help Middlebury reduce VOC and HAP emissions. The coatings manufacturers developed high-solids topcoat, sealer, and stain. Middlebury selected two companies to return for further test trials and ultimately adopted one company's product.
Emission reductions:
	Total VOC:	55%
	Cost savings:	$100,000   
Keywords: volatile organic compound, VOC, wood, HAP, hazardous air pollutant, finish, coating, high-solids, paint, stain, furniture, cabinets

MOTOR VEHICLE EQUIPMENT COMPANY - P005
Date of Report: June 1996
SIC Categories: 37
Primary SIC: 3715

The company manufactures tractor trailer freight hauling equipment. This Pollution Prevention Opportunity Assessment Report documents the collaboration between the company and CMTI to locate low-HAP sealants, which could be used as an alternative to their traditional sealant. Several compounds were located that met quality standards as well as economic standards.
Emission reductions:
	Xylene:		100%
	Toluene:	100%
	Ethyl benzene:	100%
	Other VOC:	25%
	Total VOC: 	90% (36 tons)
	Cost savings:	$125,000  
Keywords: caulk, sealant, volatile organic compound, VOC, HAP, hazardous air pollutant, transportation.

NICKELL MOULDING COMPANY, INC.
SIC Categories: 24, 25
Primary SIC: 2431

This Technology Implementation Project Report describes how Nickell Moulding Company converted from VOC-based wood finish products to water-based systems in 1993. The report describes the positive impacts this conversion has had on the company in regards to the economics of the conversion and its affect on the company's environmental emissions position;
Emission reductions:
	Total VOC:		80% (61 tons)
	Cost savings:		$133,500  
Keywords: wood, sealer, stain, finish, volatile organic compound, VOC, HAP, hazardous air pollutant, coating, water-based finishes, finish, furniture.

NORTHERN INDIANA PLASTICS COMPANY - P021
Date of Report: December 1997
SIC categories: 30
Primary SIC: 3089

The Indiana Clean Manufacturing Technology and Safe Materials Institute (CMTI) initiated a project with a northern Indiana company to investigate the application of water-based coatings to their products as an alternative to their traditionally-used, VOC-based coating.
Emission reductions:
	VOC:		10 tons per year
	Potential raw material cost savings:  $7,000 per year
Keywords: water-based paint, mold release agent, vulcanized, silicone rubber, urethane, VOC, HVLP spray coating system, plastic mold, paint

PAR-KAN COMPANY
Date of Report: February 1998
SIC categories: 26, 34, 35
Primary SIC: 3469

The Indiana Clean Manufacturing Technology and Safe Materials Institute (CMTI) and the Coating Applications Research Laboratory (CARL), both located at Purdue University, initiated a project with the Par-Kan Company to investigate coating requirements and gather production-oriented coating data necessary to successfully operate a new, water-based, paint coating line. Based upon the findings of the CARL tests and because of Par-Kan's cando attitude, the company has successfully converted one hundred percent of its coating operations to water-based coating systems. The project demonstrated that programs offered by the state, universities such as Purdue, and utilities such as NIPSCO, bring value and benefit to companies. In this case, all parties worked together in a common effort to assist in reducing VOC emissions.
Emission reductions:
	VOCs:			12 tons
	Annual cost savings:	$10,000/year
Keywords: VOC, Clean Air Act Amendmentds, continuous coating line, water-based paint coating, painting, metal painting

THE PIERCE COMPANY, INC.
Date of Report: March 1996
SIC Categories: 34, 35, 36, 37, 39
Primary SIC: 3714

This Pollution Prevention Project Report describes how this company which machines, stamps, and assembles automotive parts found an adequate replacement for their solvent (TCE) degreaser tank. CMTI set up a testing program to screen various water-based degreasing solutions for the company. The company conducted aqueous cleaner pilot tests and ultimately adopted a water-based cleaner system;
Emission reductions:
	TCE:		16,000 lbs
	Cost savings:	Undetermined  
Keywords: degreaser, volatile organic compound, VOC, HAP, hazardous air pollutant, TCE, trichloroethylene, cleaner, solvent, aqueous cleaner, metal fabrication

SOLVENT SUBSTITUTION/HALOGENATED SOLVENT REPORT- NESHAP
Date of Report: July 1998
SIC categories: N/A
Primary SIC: N/A

This pollution prevention technology transfer report describes how CMTI assisted Indiana manufacturers in achieving Halogenated Solvent NESHAP compliance. CMTI assisted the manufacturers in either replacing their halogenated solvent cleaners with non-halogenated solvent cleaners or in achieving NESHAP compliance through pollution prevention.
Emission reductions:
 	Halogenated solvents:	136 tons
	Annual cost savings:	$239,026
Keywords: cold cleaning machines, vapor cleaning machine, National Emission Standards for Hazardous Air Pollutants, NESHAP, halogenated solvents, methylene chloride, 1,1,1-trichloroethane, trichloroethylene, perchloroethylene, carbon tetrachloride, chloroform, solvent.

SWISS PLYWOOD COPRORATION/WOODCRAFTERS, INC.
Date of Report: September 1996
SIC Categories: 39,24,25
Primary SIC: 3931

Swiss Plywood is a furniture cabinet manufacturer that finishes its products with a seven- to eleven-step staining and lacquer finish coating process. With CMTI's assistance, Swiss was able to replace some of its coatings with HAP-compliant coatings (far in advance of EPA standards) thereby reducing its VOC emissions;
Emission reductions:
	Total HAP:		20,000 lbs
	Cost savings:		$18,000
Keywords: wood, HAP, hazardous air pollutant, volatile organic compound, VOC, finish, coating, sealant, solvent, furniture

SWISS PLYWOOD CORP.
Date of Report: May, 2000
SIC Categories: 24
Primary SIC: 2499

Through the use of an Indiana Department of Environmental Management Pollution Prevention Minigrant award, the Coating Applications Research Laboratory/Indiana Clean Manufacturing Technology and Safe Materials Institute personnel initiated a project with Swiss Plywood Corporation to test the effectiveness of ultraviolet light curable wood fillers in the company's high-end wood product manufacturing operation. The result of the testing revealed that a UV curing system was unable to achieve full curing of either of the test fillers without damaging the wood's surface. Wood fillers that are not fully cured will bleed into the pores of the wood, resulting in the discoloration of the wood's surface. It was suggested to Swiss Plywood that the company should refrain from using UV fillers until a UV curing system is discovered that is able to achieve a 100% cure, within the parameters defined in the testing.

Keywords: ultraviolet curable wood fillers, UV curing system, discoloration of wood

UNITED TECHNOLOGIES AUTOMOTIVE
Date of Report: April 1998
SIC category: 30
Primary SIC: 3082

United Technologies is an injection molder of thermoplastic products such as side door rearview mirror housings. United Technologies uses a high efficiency electrostatic paint application process, but some of the products it manufactures cannot be painted electrostatically. CMTI investigated the availability of suitable conductive-plastics technology that the company could employ to improve the electrostatic paint application process. This Pollution Prevention Opportunity Assessment covers the use of "fibril" technology in electrostatic paint operatiosns.
Emission reductions:
	Total VOC:		80 tons
	Cost savings:		$500,000
Keywords: paint, electrostatic, automotive, volatile organic compound, VOC, HAP, hazardous air pollutant, fibril, coating, finish, plastics, conductivity, conductive plastics, carbon fibers.

VINCENT BACH
Date of Report: April 1997
SIC Categories: 34, 35, 36, 37, 39
Primary SIC: 3931

Vincent Bach manufactures musical instruments. This Pollution Prevention Opportunity Assessment covers Vincent Bach’s collaboration with CMTI to reduce its use of solvents (TCE) in its production process. CMTI/Bach investigated water-based replacements for lapping compounds, oils, and cleaners.
Emission reductions:
	TCE:			13,000 lbs (est.)
	Cost savings:		$15,700 (est.)
Keywords: degreaser, TCE, trichloroethylene, HAP, hazardous air pollutant, volatile organic compound, VOC, cleaner, solvent, metals.

WOOD FURNITURE AND KITCHEN CABINET NESHAP - Technical Assistance and Training Program
Date of Report: August 1998
SIC categories: 2434, 2511
Primary SIC: N/A

The need for a technical assistance and training program became evident with the promulgation of a new environmental regulation. The regulation titled the "National Emissions Standard for Hazardous Air Pollutants" (NESHAP) forced wood furniture and kitchen cabinet manufacturers to change many of their coatings operations. This regulation not only restricts the chemicals that may be used for coating operations, it also requires the implementation of "work practice standards." The work practice standards outlined in the NESHAP include a written work practice plan, solvent accounting system, leak detection and maintenance plan, and an employee-training program. The employee-training program must include training in chemical storage and handling procedures, coating application equipment setup, and operation and maintenance procedures.
Keyword: NESHAP, kitchen cabinet, wood, training, leak detection, work practice standards, maintenance plan, coating operations

WOODCREST
Date of Report: April 1997
SIC Categories: 24, 25
Primary SIC: 2511

Woodcrest Manufacturing is a major manufacturer of economical juvenile furniture. This Pollution Prevention Opportunity Assessment outlines the development of HAP-compliant coatings for the company's finishing process.
Emission reductions:
	Total HAP:	93 tons
	Total VOC:	42 tons
	Cost savings:	cost impact of $86,000 per year (estimated) 
Keywords: wood, finish, HAP, hazardous air pollutant, volatile organic compound, VOC, coating, stain, paint, furniture.

WOODCREST MANUFACTURING
Date of Report: May, 2000
SIC Categories: 25
Primary SIC: 2511

Through the use of an Indiana Department of Environmental Management Pollution Prevention Minigrant award, the Coating Applications Research Laboratory/Indiana Clean Manufacturing Technology and Safe Materials Institute personnel initiated a project with Woodcrest Manufacturing to test the application and curing performance of a low volatile organic compound (VOC) containing wax stain system under conditions of extreme temperature and humidity. The possibility of using alternative solvents and/or acetone for the reduction of the wax stain coating, was also investigated. Tests were performed to insure that the low VOC coating and solvent blend chosen by Woodcrest would perform in a manner that did not increase the amount of coating repair or rework required, especially under extreme conditions. After evaluating the test results, CMTI recommended that the Company should further investigate systems that activate the flow coater only when a part is passing through the flow coater. This can easily be achieved using an electronic eye at the opening of the flow coat system. A timer would then be used to shut down the system until the next part triggers the electronic eye.

Keywords: VOC coating, wax stain system, humidity, flow coater, solvents

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