WOOD PRODUCTS/FURNITURE MANUFACTURING
|Company||Shafer Commercial Seating
4101 East 48th Avenue
Denver, CO 80216-3298
|Person to Contact||Irwin Suson, Plant Manager
Telephone: (303) 322-7792
|Product or Service||Chairs, tables, and booths for restaurants and hotels|
|Number of Employees||168|
|Waste Stream Targeted||Adhesive-related waste, emissions|
|Original System||Solvent-based liquid adhesives were used in the manufacture of chairs and booths. These adhesives, used in assembly and edge bonding (bonding foam pads and seat backings onto wood or foam), were sprayed on with an adhesive spray gun. Typical synthetic resins and contact or hot melt adhesives contain up to 50% organic solvents such as formaldehyde and 1,1,1- trichloroethane (TCA), which are hazardous air pollutants (HAPs) as well as volatile organic compounds (VOC)s.|
(with P2 Modifications)
|Water-based adhesives and solventless hot melt adhesives (100% solids) replaced solvent-based adhesives in the manufacturing processes. The hot melt pellets are melted in a glue pot and warm glue extruded onto material surfaces or applied with an adhesive spray gun (used to bond foam to foam, foam to wood). Water-based liquid contact adhesives are generally applied with a stainless steel adhesive spray gun (used to attach wood backing onto seating materials). In water-based adhesives, water alone or in conjunction with an organic solvent, acts as the carrying medium, reducing or eliminating VOCs and/or HAPs in the adhesive material.|
|Initial Equipment Costs||A Binks HVLP BBR Spray gun system for use with hot melt adhesives cost ~$3,000.00. A Slautterdack stainless steel adhesive spray system for use with water-based adhesives cost ~$3,200.00.|
|Material Cost Savings||(12) 55-gallon drums of solvent-based liquid adhesives were
used/year at a cost of $1,200/55-gallon or $14,400/year.
Shafer uses ~(4) 55-gallon drums/year of the HP Fuller water- based adhesive at a cost of $1,200/drum or $4,800/year. ~1,500 lb/year of the Slautterdack hot melt adhesive is used at a cost of ~$2.50/lb. or ~$3,800/year. Total material cost savings of ~$5,800/year.
|Waste Disposal Costs||Waste disposal costs are similar since very little adhesive waste is generated from the processes. Payback is about 1 year.|
|Major Benefits|| Reduced VOC and HAP emissions by ~ 50% (~2,600 lb/yr).
Material cost savings of ~$5,800/year.
Positive business image.
Reduced fire hazard.
Improved worker health and safety, liability reduction.
|Obstacles||Employee adjustment to new products.
Equipment for use with water-based adhesives should be corrosion resistant i.e., plastic or stainless steel.
Equipment may need to be cleaned immediately after use.
Water-based adhesives require slightly increased drying times.
|Time Since Implementation||1 year. (1/23/96)|
1663 Catalina St., Sand City, CA
HP Fuller Company
|Main Reason Implemented||Reduce VOC and HAPs emissions and reduce regulatory burden and
Improve employee health and safety and reduce liability.
|Key to Success in Making this P2 Modification||Management support/commitment to pollution prevention.
Working with vendors to find environmentally "friendly" products/materials.
Created by Lighthouse Communications Group, LLC.
Edited for use on this site by Ronald Lee Still and posted with permission of CDPHE.