LACAY FABRICATION & MANUFACTURING, INC.

South Bend, Indiana
April 1997

POLLUTION PREVENTION FINAL PROJECT REPORT

INTRODUCTION

Lacay Fabrication & Manufacturing, Inc. contacted the Indiana Pollution Prevention and Safe Materials Institute (IPPI) in August 1995 requesting assistance in determining whether or not the company would be required to have a Title V air permit. At that time, IPPI strongly urged the company to reduce their xylene usage by using less hazardous cleaning and thinning materials and to convert to high solids paints so that they would be exempt from Title V air permit regulations.

COMPANY BACKGROUND

Lacay Fabrication & Manufacturing is an automotive rack producing company located in South Bend, Indiana. The company stamps, fabricates, and paints material handling racks for the automotive industry. The company employs approximately thirty-three people.

MANUFACTURING PROCESS

Lacay used xylene to clean all of the fabricated parts prior to painting and to clean paint spray guns. The parts dried almost immediately and were hung on the conveyor line and painted with a low solid, high volatile organic compound (VOC) paint.

ENVIRONMENTAL ISSUES

Xylene is a hazardous air pollutant (HAP). VOCs are criteria pollutants. The potential-to-emit 10 tons of any one HAP (25 tons of any combination) or 100 tons of any criteria pollutant generally requires the company to obtain a Title V air permit, which requires a variety of reporting and operating restrictions. Lacay had the potential-to-emit 74 tons of VOCs and actually emitted 10 tons of xylene, subjecting them to a Title V Air Permit.

P2 PROJECT

Lacay reduced their xylene usage through the installation of a closed-loop cleaning system using an aqueous cleaner for cleaning its metal parts. They also switched from xylene to Solvent 100© (a less hazardous material) for cleaning paint spray guns. These changes resulted in a reduction of emissions to the environment of 4 tons of xylene per year.

In order to reduce VOCs and further reduce xylene emitted to the environment, Lacay switched to high-solids paints and more efficient paint spray guns. By switching to high-solids paints, Lacay reduced paint usage, due to their ability to achieve a greater coverage rate (sq. ft. per gallon). It is estimated that using more efficient spray guns increased paint efficiency by approximately 20%. Overall, total paint usage was reduced by approximately 53%, due to the innovative actions Lacay undertook. The company incorporated all of the improvements in May 1996.

POTENTIAL ENVIRONMENTAL AND COST BENEFITS

When all of the changes were accomplished, it is estimated that the following was achieved: