Zero Waste Logo The Zero Wate Network the University of Texas at Arlington Center for Environmental Excellence Environmental Training Institute Logo  

Join Us on:

Social Network Nav Bar

Lean and P2 Workshops

New Orleans, LA
10/15/14 - 10/17/14

Seattle, WA
10/28/14 - 10/30/14

Arlington, TX
11/04/14 - 11/06/14

Houston, TX
11/18/14 - 11/20/14

 

More...

 

Environmental Management Systems Workshops

Little Rock, AR
10/14/14 - 10/17/14

Arlington, TX
03/03/15 - 03/06/15

Houston, TX
04/07/15 - 04/10/15

Albuquerque, NM
05/12/15 - 05/15/15

 

More...

Case Study Database

           Add Story    |    Search Case Studies    |   

 

Woodfold Mfg., Inc.

Year Submitted: 2009

Process: Painting/Coating

Industry: Furniture Manufacturing

Wastes Reduced: VOC

Location: Forest Grove OR

Contact: Charlie Martin

Phone: 206-352-2050



Description:

Woodfold Mfg., Inc. (Woodfold) in Forest Grove, Oregon, manufactures a custom line of wood products, including specialty doors and shutters. The Pacific Northwest Pollution Prevention Resource Center (PPRC) and Oregon Manufacturing Extension Partnership (OMEP) partnered in a lean and environment pilot project with Woodfold in 2007. Funding for the project was provided by the EPA, with additional in-kind hours contributed by Woodfold, OMEP, and PPRC. The primary objectives of this collaboration were to:

Evaluate the benefits and synergies of integrating environmental considerations into lean practices, and,

Improve product quality, production efficiency, and environmental performance at Woodfold.

Woodfold is well-versed in lean manufacturing. Numerous lean and environmental procedures were already in place prior to this effort. However, Woodfold had not previously combined lean and environmental considerations in one project. They found this to be a very useful tool and added a 9

Collectively, the participants closely scrutinized the current process and identified potential lean and environmental improvements. From June to November 2007, numerous environmental improvements were implemented. The productivity improvements identified for the paint line are pending implementation.



P2 Application:

The group spent one day evaluating the current paint line, and generating the current state and future state VSMs. To include and better identify environmental improvements, any relevant material, water, energy, and waste inputs and outputs were captured on the VSM. The group observed the paint line, and briefly toured the rest of the plant. Opportunity areas were identified:

Reduce production bottlenecks and increase throughput in the shutter paint line;

Improve and standardize spray paint techniques and methods to optimize transfer efficiency and reduce overspray;

  • Reduce energy consumption;
  • Reduce water use for paint line flushing;
  • Reduce solid waste; and,
  • Reduce particulate emissions.


Details of Reductions

  • 968.0 - Pounds/year of   VOC
  • 82.0 - Pounds/year of   HAP
  • 6.0 - Tons/year of   PVC Scrap

Additional Information :

Over the course of several months, Woodfold and PPRC corresponded regarding the environmental opportunities identified above. In addition, PPRC returned and conducted STAR training (www.mass.gov/envir/ota/star/default.htm) to assist Woodfold paint operators in improving their spraying techniques to optimize paint transfer efficiency.

A list of actions and results are reflected in Table 1. Table 2 lists estimated annual cost savings associated with changes. The lean improvements identified during the VSM are complete as well, but are not reflected here.

Table 1. Process Changes and Results

 

Action

Result

Conducted STAR training for improving painting techniques, and evaluated different painter techniques on video.

Increased paint transfer efficiency for lacquer from 15.9% to 19.7% and for primer from 39.6% to 42.4%. Created standard work to sustain this improved paint performance. Reduced overspray and volatile organic compound (VOC) emissions. Increased paint booth filter longevity due to reduced overspray (and therefore decreased solid waste).

Redesigned a paint container from a 12" to a 6" diameter bucket for custom color orders mixed in quantities less than two gallons. (5" paint depth is required so the pump does not intake air).

Reduced overproduction of custom color paints by 48 gallons/year.

Changed to a zipper-mounted filter system for paint booths. These filters are slightly more expensive than previous type.

Expect to eliminate particulate emissions and increase longevity of the filters. Reduced labor for filter changeout and added 156 hours of available paint booth time.

Revised methods and criteria for flush water for line purging.

Reduced water consumption by about 50% for this function – from 12 gallons/day to 6 gallons/day. Reduced energy associated with evaporating this wastewater stream.

Found a local recycler for flexible PVC scrap.

Diverted about 1,000 pounds per month of solid PVC waste from the landfill. Looking into alternative plastics to replace PVC.

Re-evaluated and conducted a cost-benefit analysis for a wood-fired boiler for sawdust waste, to supplement heat during non-summer months.

No further action at this time.

Investigated possibility of eliminating metal pigments in certain stain colorants.

Did not adopt any changes due to the need for UV stability in stain colors. Woodfold and their paint supplier will continue to look for alternatives in the future.


Table 2. Annual Cost, Time, Material, and Environmental Savings for Implemented Changes

Reductions

Source of Savings

Annual Cost Savings

Annual Time, Material, & Environmental Savings

Labor/Increased Capacity

New filter system

$3,800

Over 160 hours

Material

Avoided paint purchase (raw material) due to new paint container design

$1,440

48 gallons/year

Improved transfer efficiency

$34,664

136.3 gallons primer 854.1 gallons of lacquer

Emissions

Improved transfer efficiency

Not quantified

968 pounds VOCs 82 pounds hazardous air pollutants (HAPS)

Disposal

Booth Filters (longer life)

$954

50% reduction in filter material used

PVC scrap to recycler

$670

6 tons scrap PVC

Water

New flush /purge water methods

$4

2,600 gallons/year

Energy

Reduced use of evaporators due to improved water use

$3,300

120,000 kwh electricity

Total Cost Savings (Quantified as of 8/08)

$44,832





Source: PPRC



SHEP Shield
Safety
Health and
Environmental
Professional



ERP Shield
Environmental
Regulatory
Professional



ESP Shield
Environmental
Science
Professional



EMP Shield
Environmental
Management
Professional

Attend a workshop and
earn credits toward a
Professional Certification

 

 



The Zero Waste Network is one of eight Pollution Prevention Resource Exchange P2RxCenters , serving as a national network of regional information centers: NEWMOA (Northeast), WRRC (Southeast), GLRPPR (Great Lakes), ZeroWasteNet (Southwest), P2RIC (Plains), Peaks to Prairies (Mountain), WSPPN (Pacific Southwest), PPRC (Northwest). We are a proud member of the National Pollution Prevention Roundtable.

National P2 Roundtable Logo