United States
Environmental Protection
Agency
Air and Radiation
(ANR-445)
EPA/430/R-92/110
October 1992
&EPA
Vacuum Panel and Thick Wall Foam
Insulation for Refrigerators:
Cost Estimates for
Manufacturing and Installation
Printed on Recycled Paper
-------
-------
5-EPA
United States
Environmental Protection
Agency
Air and Radiation
(ANR-445)
EPA/430/R-92/110
October 1992
Vacuum Panel and Thick Wall Foam
Insulation for Refrigerators:
Cost Estimates for
Manufacturing and Installation
-------
-------
VACUUM PANEL AND THICK WALL FOAM
INSULATION FOR REFRIGERATORS:
Cost Estimates for Manufacturing and Installation
prepared for
US Environmental Protection Agenqr
Global Change Division
Office of Atmospheric and Indoor Air Projgrams
Office of Air and Radiation
U. S. EPA Project No. X818749-01-0
James M. Waldron
Center for Robotics and Manufacturing Systems
University of Kentucky College of Engineering
Lexington, Kentucky 40506-0108
October 1992
-------
-------
VACUUM PANEL AND THICK WALL FOAM
INSULATION FOR REFRIGERATORS:
Cost Estimates for Manufacturing and Installation
ABSTRACT
Improved insulation between the outer case and the inner liner is among the technologies
available to refrigerator manufacturers to achieve significant reductions in energy con-
sumption and the pollution associated with its generation. One approach is to add more
insulation to the refrigerator cabinet. A second, "super insulation", is a developing technol-
ogy which would allow refrigerator manufacturers to significantly improve energy effi-
ciency without compromising the internal to external volume ratio of the refrigerator. One
approach to super insulation is the use of vacuum insulation panels (VIPs).
i ' '
The fixed and variable costs for these two cabinet insulation technologies are evaluated in
this study. The manufacturing costs for VIPs are examined by developing the material,
process and equipment requirements for producing and transporting VIPs on a mass pro-
duction basis. VIP installation costs are established by developing a generic refrigerator as-
sembly line and then the material, epuipment and process modifications required for re-
ceiving, storing, delivering, and installing VIPs into refrigerators.
modifications are also developed for the added foam approach.
PLant and component
Raw material bulk densities suggest that the VIP plant be located adjacent to the silica plant
to minimize transportation cost. Silica processing must be optimised between the silica
plant and the VIP plant to minimize the required investment in plant: and equipment.
Trade-offs between VIP plant efficiency and refrigerator energy efficiency must be made
during development to determine the best mix of panel dimensions. .
Existing refrigerator assembly plants can be retrofit to receive and install VIPs, but some
-n-
-------
-------
may require significant rearrangement. The technology to install VIPs into refrigerator
cases and doors exists now in some plants.
• I
Thickening the foam insulation may be more cost effective on snualler refrigerators (<20/)
where kitchen dimensions are less limiting and where internal /external volume ratios are
less important.
-Hi-
-------
-------
CONTENTS
Abstract.
Figures .
Tables
Abbreviations .
Acknowledgements
Introduction
Findings
Recommendations ...
Generic refrigerator assembly line
Vacuum insulation panel requirements
Vacuum insulation panel manufacturing ..
Panel installation into refrigerators
Total program and product cost for VIP production and installatiDn.
Thick wall alternative
Energy analysis
References
Appendices
.11
.v
...VI
• •
..Vll
.viii
.....1
4
.....5
6
.....9
...14
...43
...54
...62
...73
...75
...77
-IV-
-------
-------
FIGURES i
!
'!•
'I
Number ' Pa9e
1 Equivalent Insulations • • 3
2 Case and Liner Pre-foam Areas • 7
3 Door Pre-foam Area * • • 8
i
4 Refrigerator Panel Locations • :-10
5 Panel Plant Layout - 17
6 Panel Plant Organization • r 19
7 Silica Processing Flow Chart r22
8 Jet-O-Drier Flash Drier '. • 26
9 Vacupress Densifier » • -30
10 Vacupress Installation « 31
11 Process Specifications -Form, Fill, and Seal Line 33
i
12 Form, Fill, and Seal Line • 35
13 VIP Receiving Area - Refrigerator Plant 44
14 Case and Liner Pre-foam Areas with VTPs • • —48
15 Door Pre-foam Area with VIPs ,-••• 50
16 VIP Project Schedule • | 59
17 Start-up Curve - VIP Plant • : 61
-v-
-------
-------
TABLES
Number
Page
1 Vacuum Panels for 21' & 24' Refrigerators .1 .... 12
'i
,|
2 Vacuum Panels for 21' & 24' Refrigerators—Material Size....; 13
3 Panel Plant Equipment . ,; 18
4 Annual Panel Plant Operating Cost ;!....., 20
5 Average Silica Use Per 8 Hour Shift ;... 24
' i
6 - Silica Silo Inventory ! 27
7 Form, Fill, and Seal Line Changeovers and Scheduling.. j 28
8 Average Daily Panel Requirements for Refrigerator Assembly One 40
9 48 Foot Trailer Loading :....... ....42
10 Flow Thru Rack Requirements .
11 Refrigerator Plant Equipment
12 Additional Operating Cost—Refrigerator Plant
13 Vacuum Insulated Panel Manufacturing Program Cost
14 Product Cost for VE? Manufacturing and Installation
15 VIP Product Cost Sensitivity Analysis
16 Thick Insulation Alternatives External Dimensions
17 Carton Sizes for 18' Refrigerators with Thicker Insulation.
18 Thick Foam Alternatives Retooling Requirements
19 Cost to Increase Insulation Thickness on 18' Refrigerators
20 Thick Wall Product Cost Sensitivity Analysis
21 Cost to Increase Insulation Thickness on 18' Refrigerator Doors Only 71
22 Baseline 1991 Refrigerator
23 Energy Consumption Analysis Results.
-vi-
.45
.52
.'53
.55
.57
.58
.64
.66
.68
.69
.70
.74
.74
-------
-------
ABBREVIATIONS
AGV—Automatic Guided Vehicle
Board Foot—A volume element 1' x 1' x 1"
CFC—Chlorofluorocarbons
DOE—Department of Energy ;
K—A specific property of a conducting material defined as the quantity of heat conducted
across a unit area normal to the flow path in unit time and for unit temperature gradient
along the flow. Expressed as Btu-IN/HR-SQFT-DEG F j
,i
NAECA—National Appliance Energy Conservation Act
ORNL—Oak Ridge National Laboratory j
Torr—pressure equal to a column of mercury one millimeter high.
VIP—Vacuum insulation panel
-VII-
-------
-------
ACKNOWLEDGEMENTS
'i •
This study was .completed with the assistance of a technical consul teint, Louis W. Dawson,
who has more than 30 years of experience in major appliances — primarily in refrigerator
manufacturing.
'!
General Electric Appliances (GEA) provided samples of 18 cubic foot refrigerator cabinets
and liners and samples of prototype VIPs. Refrigerator specifications and cost information
were made available, through a non-disclosure agreement, to support the study. Ken
Downs, GEA, assisted in the development of VIP sizes and served as a sounding board as
the VIP manufacturing and installation processes were developed. GEA also assisted in de-
veloping tooling costs for thick wall alternatives. ;
engineers, W. Robert Keelen and Richard Muse, from the University of Kentucky (UK)
Center for Robotics and Manufacturing Systems, and with combiined manufacturing expe-
rience exceeding 60 years, provided valuable assistance and input.
Stephen Poulter, a senior in the mechanical engineering department at UK, provided ca-
pable CAD assistance in preparing figures and tables.
.i
Also, considerable technical and cost information on raw materials and manufacturing
equipment was provided by many companies which are listed as references on page 75.
Two companies in particular; Fres-Co System USA, Inc. (Larry Restivo) and Degussa Cor-
poration (Roger Caffier & Nick Ludovic) were especially helpful in providing key inputs.
— viii -
-------
-------
INTRODUCTION
The construction of a typical U. S. refrigerator consists of a thermoformed plastic inner liner
and a steel outer case with CFC blown polyurethane foam insulation in between. The doors
usually are of similar construction. Two technologies, vacuum insulation panels (VIPs) and
thicker foam insulation, have been proposed to reduce the thermal load through the refrig-
erator cabinet wall and the resulting power requirement. j
The current design evolved from the use of fiberglass insulation during the sixties and
brought significant energy efficiency improvements. The use of foam insulation allowed
refrigerator manufacturers to increase the food storage capacity of a given refrigerator
while maintaining the same external dimensions. This "thin wall" concept has been a key
in refrigerator design. Increasing the thickness of the walls could require consumer com-
promises in food storage capacity for available kitchen space for consumers of larger (> 18')
i
refrigerators. j
CFCs used in the foam insulation have been banned by the Montreal Protocol and the
Clean Air Act Amendments of 1990. Furthermore, President Bush has mandated that their
use be completely eliminated after 1995. •
The Department of Energy (DOE), authorized by the National Appliance Energy Conserva-
tion Act (NAECA) of 1987, has issued stringent refrigerator energy standards to be met for
1993 production. These standards require, on the average, a 30 percent additional effi-
ciency increase over 1990 requirements; and possible further efficiency increases for 1998..
'i
Many technologies can be used to reduce the energy consumption of refrigerators. Im- .
provements can be made to the hermetic system, control systems, such as the defrost sys-
tem, and components, such as fans, or to the cabinet enclosure. Improvements to the cabi-
net are limited to increases in thermal resistance through better gaskets, increased insula-
tion, or lower thermal conductivity insulation. Insulation like VIPs would enhance thermal
resistance without adversely affecting the internal volume to external dimension ratio.
-1-
-------
While buyers of smaller capacity units (<2D may be willing to accept some compromises
to avoid additional cost, buyers of larger units are more likely to pay a premium to pre-
serve food storage capacity. The need to maintain this "thin wall" concept while meeting
new, regulatory, refrigerator energy efficiency standards and. other future requirements for
energy efficiency improvements without CFCs may necessitate the use of new thermal
insulation technologies.
One approach to improved thermal insulation is the use of vacuum insulation panels in
conjunction with a non-CFC blown foam. These panels may be manufactured by filling a
porous bag with a micro-grained powder, placing the bag into an envelope impervious to
water and gases, and evacuating and sealing the envelope. The evacuated space provides a
barrier to the transfer of heat which is more effective than any modern day insulation.
These panels have about 67% lower thermal conductivity than CFC blown foam (Figure 1).
Research and development on vacuum panels has gone on for several years but the feasi-
bility and cost for actual production and application continues to be debated. Oder impor-
tant issues such as the long term degradation of the vacuum and the impact of CFC substi-
tutes, are being addressed elsewhere.
This study evaluates the manufacturing feasibility and estimates cost to produce and install
vacuum insulation panels into refrigerators. It also estimates the manufacturing and prod-
uct costs of adding more foam to thicken the urethane foam insulation.
— 2 —
-------
Figure 1
Equivalent Insulations
K=BTU-IN/HR-FT2-°F
6" Fiberglass
3" Urethane Foon
I" Vacuun Insulated Panel
-3-
K = 0,240
0,120
K z 0,040
-------
FINDINGS
It is feasible, with existing technology, to manufacture vacuum insulation panels
(VIPs) in sufficient volume and with sufficient quality for installation into household
refrigerators.
Existing refrigerator plants can be retrofit to install VIPs but may require significant
rearrangement and cost.
This technology will allow significant reduction in refrigerator energy usage without
increasing the external dimensions of the refrigerator.
Replacing urethane foam with VIPs will significantly increase the variable manufac-
turing cost and thus the retail price of refrigerators. The increase in variable manufac-
turing cost of the refrigerator is estimated to be $1.39 per board foot of VIPs or about
$40 for a 21 cubic foot refrigerator. This would translate to about $120 higher retail
cost. This cost can probably be reduced through optimization of silica processing
steps between silica manufacturing and VIP manufacturing. Also, other filler materi-
als, such as aluminum silicate, in place of or in combination with precipitated silica
may prove more cost effective. A goal of $1.00 per board foot is probably attainable
within three to five years of initial production.
Investment and expense required to implement the production and application of
VIPs for three hundred thousand 21 or 24 cubic foot refrigerators per year is estimated
to be about $24 million. This cost can probably be reduced by optimization of the flash
drying and densification processes between the VIP plant and the silica plant. In-
creased costs to the consumer will be minimized if the total systems cost, from the
manufacture of silica to the final panel installation, is optimized.
As the cost of urethane foam increases, the cost difference between foam and VIPs
will decrease by about $0.02/board foot for every 10% increase in foam cost. This
— 4 —
-------
assumes that VIP cost will remain the same although a decrease is likely as the mariu-
ii
f acturing process is optimized. j
i
Thicker foam insulation is a viable alternative on smaller models (<18') where kitchen
installation dimensions are less limiting. Maintaining the same approximate height
width: depth ratios will be necessary to avoid significant kitchen fit problems (re-
duced market) when adding more insulation.
Adding VIPs will not increase refrigerator shipping cost because even with the added
weight of VIPs, the weight of a 48 foot trailer remains less than one half the gross
weight limit. Shipping cost will increase for thicker insulation, even with a one half
inch increase in insulation thickness, because the number of refrigerators per trailer
will be reduced. i
i
The product and transportation cost increase to add one inch of foam to an 18* cabinet
will be about 50% of the cost of adding vacuum insulation panels to a 21' cabinet and
will give comparable energy improvement.
RECOMMENDATIONS
i
i * •
1. A prototype facility should be built by an appliance manufacturer or an independent
company to develop and optimize VIP manufacturing. A joint venture with either a
silica manufacturer or a form, fill, and seal equipment manufacturer is an alternative.
2. Long term vacuum and insulation degradation should be
tests and field trials, so that refrigerator life cycle benefits and!
and out of warranty costs) are better understood.
evaluated via accelerated life
liabilities (in warranty
-5-
-------
GENERIC REFRIGERATOR ASSEMBLY LINE
As a basis for this study a generic refrigerator line and factory has been defined. Product
assumptions for this line are:
1. Three cabinet sizes may be produced: 18 cubic foot, 21 cubic foot and 24 cubic foot.
2. Steel case and plastic liner construction. Steel doors also have plastic inner liners.
3. Urethane foam insulation in both the cabinet and door.
• 4. Foam blowing agent will be R-ll or a suitable substitute. Foam, in conjunction with
vacuum insulation panels, will provide a mechanical structure equivalent to the
current design.
5. Product redesign changes to accommodate VIPs will be minimal.
- Process assumptions are:
1. The fabrication and assembly line will operate two 7.6 hour shifts, five days/week,
220 days/year.
2. The line will produce one unit every 20 seconds.
3. At 85% efficiency the line will have a capacity of about 500,000 units per year. (180
units/hour x 7.6 hours/shift x 2 shifts/day x 220 days/year x .85)
4. Output will average 1,163 units per 7.6 hour shift.
The areas of the plant which are examined in this study are case and liner pre-foam and
door pre-foam. The case and liner pre-foam area is shown in Figure 2. The door pre-foam
area is shown in Figure 3.
The layouts of the affected areas will be different in each refrigerator plant and the actual
rearrangement and costs required to install VIPs will vary from this study and from one
manufacturer to another.
.-6-
-------
(0
.(0
E
(0
0
»- Q_
u- .E
CO
o
V)
CO
o
-7-
-------
Figure 3
Door Pre-Foam Area
Door
Delivery
fron Point
To Inner Door
Assenbly
Door Foon
Systen
II
I I
I I
I I
I I
I I
I I
Jl
1. Freezer Door
2. Fresh Food DOOP
3. Lood Foon Conveyor
4. Unload Foan Conveyor
(X) Hanuol Operators
-8-
-------
VACUUM INSULATION PANEL REQUIREMENTS
This study assumes that all 21 and 24 cubic foot refrigerators made on this generic line will
receive vacuum insulation panels and the total annual volume of these models is 300,000
per year. Eighteen cubic foot models are not included since this siize is more price sensitive
and would be less likely to use VIPs. A thicker insulation alternative for smaller, more price
sensitive models is discussed in 'Thick Wall Alternatives".
All of the 21 and 24 cubic foot models will be produced on the line with an annual capacity
of 500,000, thus using 60% of that line's capacity. The other 40% would be used for 18'
models. When running models with vacuum insulation panels, the 20 second cycle time
. will still be maintained.
;i
It is assumed that the refrigerator line will schedule the models which will receive VIPs an
equivalent of three days or six shifts each week, or a maximum of 6,978 refrigerators with
VIPs per week. These models normally wi" be 60% of each day's production or 1,396 per
day on two shifts, but sufficient in-process storage is provided to support a continual two
shift run.
Both cabinet sizes use the same set of panels, giving slightly less coverage for the 24 foot as
a trade off for increased manufacturing efficiency in the panel plaint. The 18 foot model also
could use these same panels. As the volume of models with VIPs increases, justifying a
second panel line, panel sizes could be further tailored to specific models to attain greater
energy improvement.
Through analysis of an actual 18 cubic foot cabinet, optimum panel locations and sizes
were developed. All of these panels would, of course, fit into a 21 cubic foot and a 24 cubic
foot cabinet since all of the dimensions are the same or slightly larger. A 21 cubic foot
refrigerator with VIP locations is shown in Figure 4.
-9-
-------
Figure 4
Refrigerator'Panel Locations
21ft3 Refrigerator with 10 Panels
-10-
-------
There are ten panels in each refrigerator. The panels will be produced in five sizes with two
thicknesses (1/2" & 1") and two lengths (21" & 28"). Table 1 shows the panel dimensions for
each location and the installation area where they would be attached!. Table 2 shows the
sizes for the barrier and porous pouch material required to produce the five panel sizes in
the panel plant.
A panel was not planned in the freezer back because interference with the suction line, ice
maker fill tube, and air flow duct necessitated a small panel which was deemed ineffective.
A product redesign to relocate some of these could allow a freezer back panel to be large
enough to be justified.
-11-
-------
•
CO
i
2
CD
•£
*5
cc
Is
oc5
»
"o
1
E
3
CO
^^
|
1
I
z
<
3
.
u
CO
H
PL,
1
£
0>
a
a,
?
P
t-;
a
X
X
r-i
-
T— 1
I
£
u
IS
1-1
s
£
o\
T-l
X
t-l
CM
X
r-i
CO
CM
I
fi
Q>
^
U
(A
•8
83
1
"fj
fii
o
CO
X
X
t— 1
VO
2
I
I
•t5
Jlfl
** s
•"j ^j
O^ &H
|^^ fs|
•
c^ " '
|| a
S **j 01
PU, o a;
III
"3 3 !§
o o o
H H H
-12-
-------
CO
o
*-»
• G>
5ffi
CM £
«S m
• N
O <
*: oc
o <
C 2
Q_
E
3
5
O
en
w
O
^
i
N
w
H
1
g
r?
CO
ffi
£
a
§
s
8
•S
W
£"*• O rH CM
Q CO CM CO
f\j -XXX
+ CO CO CO
>— ' CM CM CM
m m in
•f^ . OS O rH
l^ CM CM CO
,-4 X X X
+ in in "^
' ' CM CM CM
CM CM CM
00 OS O
CM »-i CO
XX X
r-i rH r-l
CM CM CM
X X X
rH rH i— i
in co vo
«y efej «y
rH CM ''t*
iq in
C^> '! T-^ O
in i rH f^i
^ i X X
+ ; no in
v~' ! cK os
CM CM
,]
i
— • ! CvJ CM
,i
JO. OS
,; r-i rH
X X
; oo oo
, r>i .CM
' X X
1 "*> ^
i °'
.1 T-H
OS
! • oo"
1
in
IX
OS
in
in
I
1
£
rt
&,
tn
5
OS
CM
oo
in
R:
t
CM
X
I
-13-
-------
VACUUM INSULATION PANEL MANUFACTURING
This section describes the facility, organization, materials, and equipment required to
produce three million VEPs per year for three hundred thousand 21 or 24 cubic foot refrig-
erators.
When selecting the location for the facility with regard to the appliance assembly plant,
several elements must be considered. Raw material sources and transportation, the possible
requirement to make VIPs for multiple assembly plants, and the trend away from vertical
integration and toward "assembly only" plants are all items which must be factored into
this decision.
Materials for VIPs were selected from those currently being used for R & D, and costs were
obtained from the materials manufacturers or their representatives.
The VIP manufacturing process was defined and the equipment selected after numerous
discussions with several parties vvho have produced VIPs for R & D; manufacturers of
form, fill, and seal equipment who incorporate vacuum packaging in their equipment;
users of form, fill, and seal equipment for vacuum packed products such as coffee; manu-
facturers of silica and bag materials; and many equipment manufacturers who supply
equipment which has the capability to perform portions of the VIP manufacturing process.
Some equipment manufacturers whose equipment was considered but not included in the
final design are included in the references.
VIP manufacturing is discussed in the following sections.
A. Facility and equipment
B. Panel plant organization and operation
C. Silica material
D. Bag materials
E. Silica material handling
-14-
-------
F. Flash drying
G. - Silo storage
H. Densifying
I. Bagfilling
J. Panel manufacturing line
K. Quality control
L. Packaging
M. Bar coding
N. Shipping and transportation
0. -Safety and environmental considerations
A. Facility and Equipment
It was assumed that the panel plant would be built 100 miles from the refrigerator plant
and next to the silica plant, and that the silica plant would be next to the silicate plant
Sodium silicate and sulfuric acid are the raw materials for the production of precipitated
silica. A major consideration for the location of the complex would be transportation means
and routes for sand and soda ash, which are the raw materials for sodium silicate.
About three pounds of sodium silicate are required to produce one pound of silica: Silica is
transferred to the VIP plant at about four pounds per cubic foot and completed VIPs are
about 12 pounds per cubic foot. These ratios suggest that shipping VJPs may be less expen-
sive than shipping silica or its raw materials.
ij -.„.,."
The building would be sized to accommodate three panel .lines for future expansion to ten
million panels (one million refrigerators) per year. Cost for only one panel line and sup-
porting equipment is included in this study. Building cost was estimated based on actual
cost of a recent plant and includes normal power distribution, lighting, offices, heating and
air conditioning, and other utility equipment plus truck docks, parking lot, landscaping,
roads, etc.
-15-
-------
The building would be air conditioned to provide the required humidity control as well as
employee comfort. There would be one sheltered, two trailer receiving dock and one shel-
tered, two trailer shipping dock. A layout of the panel plant is shown in Figure 5.
The panel plant equipment, which will be discussed in detail later, is summarized in Table
3, along with the estimated costs. A 25% contingency, commonly used by manufacturers
for feasibility study estimates, has been included.
B. Plant organization and operation
The plant will have nine salaried and 22 hourly personnel, as shown on the organization
chart in Figure 6. Hourly personnel will be paid on a day work plan. Position descriptions
for all personnel will allow them to do any job which they are capable of performing. Cross
training and job flexibility will be rewarded with higher hourly rates.
Quality control personnel will be responsible for inspection work as well as quality engi-
neering and process cor irol. Foremen will be responsible for process control and have
dotted line responsibility to the quality control manager. The quality control manager will
also be responsible for safety and OSHA compliance.
Machine control personnel will be responsible for set-up, machine control, process control,
loading material on and off equipment, minor maintenance and unjamming, preventive
maintenance, and housekeeping in their area.
Shipping material handlers will be responsible for loading trailers and keeping the line
stocked with material, which will be done primarily during changeovers. Three operators
are planned on each shift so that adequate relief to trailer loaders can be provided by as-
signment rotation. Panel plant operating personnel and costs are summarized in Table 4.
-16-
-------
I
CO
—I
o>=r
CO
Q_
-17-
-------
O
.B-
"5
0 LLJ
Q.
"55
c
CO
a,
T-« CO CM ^! OO O O
r-i m a\ CM r-" in in
3 Sf S 8" £ 8.8
CT)
CM OO
T-« CM 'S CM
Ift
CO
SLr>
r-i
" tr>
-frS
«o S
ni O
fc «
•c
5
o-.o-.CQ
QJ (U "
sr W^ ,.,
< < jg
1
•s-s
.s -c >.
•p *
in S
C.TT O"JJ-i-l'i-l>^>i»oc>i!C*
|ll|l||l|llisi|
CD
1C
R
o
CM
-18-
-------
C
O-
>B_
en
TO
N
C
«»
O >-
il ro
Q.
V*
c
a.
rn
S
<
1-
1
a.
2
I
I
E 2 «o>E z §«c»i
f 1 '1 1 < 1 '|1 $ 1 1 '|i
i s w o ^ i w o ^ 1 2 w c
I O O 1
1 LL LL 1
-19-
-------
1
12
Q.
"o
I
I
O
en
c
<
o o o
o o ~
O O O
C5 ^j^ *^r
co in" 06* CM"
CM O CM CM
. -
CO
CJ\ CJ'T CTs CO
. Fs in ID CM
CM CO CO O
:*. vo" CM" CM" oo" o" «?
000
C3 O O
O O O
O
O
o
o o o
CO CO CM
O
CM
O
O
o
VO
CM^ vq^ vo^ ON
rH \O v£> '^
CO rH rH CM
r
&
o o o o
0000
iri 06 od CM
ITi
rH rH rH rH CO
CO CM
CM
£
&
$
SLl
O
CD
« 60
P ^ « "3
5 §0 % O ..
g I fi e -a
I I
<. *j
s
£
8
2
O
1
O
PN
CD
2
1
8
O
z
§i -
•43 2 W
1
II
-20-
-------
C. Silica material
The silica used for filling the panel is FK500LS, supplied by Degussa [4]. A product infor-
mation sheet is shown in Appendix A. Material cost is assumed to be $0.75/pound, as
stated in a letter from Degussa (formerly North America Silica) to Mr. Alan Fine, EPA, on
June 11,1991 (Appendix B).
Flash drying and densifying equipment provided in this plant would most likely facilitate
the use of a less expensive silica with a larger particle size and higher moisture content.
Thus, it may prove feasible to start with a less expensive silica by doing further processing
in the panel plant. Whether or not this is feasible would have to be determined through R
& D and pilot operations where trade-offs between panel unit cost and insulation efficiency
could be evaluated. ;
D. Bag materials
The rnicroporous bag, which will contain the silica during compaction and evacuation, is
TYVEK supplied by Snow Filtration, Cincinnati, Ohio [23]. This material is quoted at
$0.036/ square foot in the volumes assumed for this study.
i '
'! • ''•'.
The barrier bag, which retains the vacuum, is VECAT. A multi-lajrered material supplied
by Fres-Co System USA, Inc., Telford, Pa.[l]. It is quoted at $0.111/square foot at the vol-
umes assumed for this study.
E. Silica material handling
Silica is transferred by a Vac-U-Max pneumatic system (Roessler) [9] from the silica plant,
assumed to be adjacent to the panel plant, into a flash drier located in. the panel plant and
then into a silo, as shown in the flow chart in Figure 7. Silica coming into the panel plant
has an average particle size of 3.5 microns, a density of four pounds per cubic foot, and a
moisture content of 3-4%. - I
-21-
-------
Figure 7
Silica Processing Flow Chart
Transfer from silica
plant to flash dryer
Hash Dry
Transfer to silo
Store in silo
Transfer to densifier
Densify
Transfer to VIP line
Product VIPs
MOISTURE
3-4%
< 1
< 1%
DENSITY
41b/ft3
Ib/ft3
settle back
to41b/ft3
8-101b/ft3
final density
12 Ib/ft3
Silica will flow from the silica plant to the VIP plant at a rate of 2000 to 2200
pounds per hour.
VIPs will be produced at a rate of 900 per hour less losses for downtime,
rejects, etc., and changeovers of one to three hours between panel runs.
-22-
-------
Silica usage will average 16,000 to 18,000 pounds per eight hour shift (see Table 5). Maxi-
mum usage with the line operating at 100% efficiency, no changeovers and producing the
largest panel (#4 & #6) will be 31,536 pounds per eight hour shift
F. Flash Drying
Silica coming into the panel plant from the silica plant would first be processed through a
flash drier before entering a silo.
Experimental panel manufacturing processes have dried the silica in an oven after it has
been put into the porous bag. This process is acceptable for R & E> but was judged too
expensive for high volume production.
The flash drier is designed to reduce the moisture content of the silica from 3 to 4% to less
f,
than 1%. The equipment selected for this application is a Jet-O-Drier® produced by Fluid
Energy Aljet [6]. The Jet-O-Drier is a flash/spray drier with a material retention time of less
than one second. This equipment can accommodate very high inlet temperatures without
causing product degradation while still maintaining a low outlet temperature.
'i
Aljefs description of the Jet-O-Drier operating principle is: '
"Drying gas, usually air, is pressurized, heated, and introduced into the Jet-O-Drier
by specially designed nozzles. The energy of the pressurized hot fluid (or wet pow-
der) is converted into velocity. The directional flow from the nozzles develops a
controlled high velocity drier circuit. The system velocity is balanced by mass flow
and evaporative rate which maintains a system pressure inside the drier slightly
above atmospheric. Wet solids are introduced pneumatically or by means of a rotary
vane. The violent action in the drying chamber deagglomerates the individual par-
ticles, thereby exposing enormously large drying surfaces. At the drier outlet title
finely dispersed dry particles are removed by the frictional drag of the exhausting
gases and the heavier moist particles are returned to the drying chamber due to their
higher momentum." i
i . .
-23- ;
-------
21 0)
CD
,o
CO
O
J- (0
oo QL
I
0)
3=
111
CO 00
I®
PL,
tx IT5 IT) r-t IX
ON CT\ ON OO ON
•<* vo VO vO "*
tN| rH r-l IS CM
CNICNCMCJCNCNCNCMCNlN
r-i i—I t—IT—I r-i r-< i—i r-i p-i «—I
\O \o \o VO VO VO \O \O VO VO
NO
00
o
OO 00
en o
IT) ID ID
00 00 00
0
CN
t-i CM (f)
IT) vO
00 ON
C3
s^
CO
T-I CN
-24-
-------
Immediately after being processed through the flash drier the silica would have a density
of about one pound per cubic foot. It would redensify to about four jpounds per cubic foot
as it settled in the silo. Air would be removed from the top of the silo to speed up densifica-
tion.
Figure 8 shows a typical Jet-O-Drier system.
G. Silo storage
Two silos will be used; one will receive incoming silica from the flash drier while the other
• ; '
dispenses silica to the panel manufacturing process. Each silo will be 71 feet high and 14
feet in diameter with a 60 degree hopper. Silos are aluminum with welded construction,
manufactured by Peabody TecTank [17] (Appendix C).
With a ten foot head clearance, each silo has a capacity of 7000 cubic feet (28,000 pounds @
four pounds per cubic foot). One full silo will support about eight hours of production on
the form, fill, and seal line when producing the largest panel size (Tx28"x30") at 85% effi-
ciency. Changeover from silo to silo will be simple and quick through the use of electroni-
cally controlled, rotary actuated valves. Silos will be piped so they cam be filled from any of
•!
the flash driers and can feed any of the densifiers. ' • .
Table 6 shows that starting with one full silo and using the schediiling plan shown in Table
7, two silos are adequate to accommodate a continuous flow of silica from the silica plant
The maximum silica inventory reaches 39,040 pounds at the end of the panel 8,9 and 10 •
run and drops to a low of 14,816 pounds at the end of the panel 1 and 5 run. Two silos will
. hold 56,000 pounds of silica at the planned density of four pounds per cubic foot.
H. Densifying !
i
I
Silica will flow from the silo into a densifier by means of a pneumatic: transfer system. The
densifier will increase the silica density to 8-10 pounds per cubic foot
-25-
-------
6
GO
"
£
3 ^
O
-3
5 ^
-26-
-------
&
lf> SO t>* GO CN sp GO O CM ^J sD OO O CN NO
O CO CO CO CO CO CO CO CN CN CN CN CN
CN
ON
^SSSS 3
CM CM CM ri »-c 1-1 ri
CM CM CM CM CM CM CO
a
I
co
E
§
fp CO
oo oo
CM
S.88S
CM CM CM CM
|Jp
Ji
w o E
»
fe
O
H CO CM
8-d
= §
to 5
o
fj
g
CM
in
oo •"*
CM CM CM
O
\B
CM
t-i o\ oo
CM t"^ r-«
00
ri CM
CM CM
CM
i-^CMvOOO\OO^ VOID^"
CMrxONCMtxfOONtni—itx
ON O O r-< ^ OO rH lf> ON CM
VO OO O CM CM CM CO CO fO -g1
CM CM CO CO CO CO CO CO CO CO
I
CM vO O T-< CM CO ^J
CO CO CO CO CO CO CO
§
£
i"O
K -S
IQ «O «O K i «O
\O NO MO r ^3 ON
0^ VO NO 60 u ^*
IS CM CM
£ •£
v •&
"
W
n
I
CMCMCMCMCMCMCMCNl
CM CM CM
ON
od"
CM CM CM CN CM C4
ro
n
-27-
-------
Oi
c
O JS
C -3
CO
E
o
>
o c
IL. (0
6
Ift
•8
D w «M
SI-
2
t?
W
_
O
oo"
SS
Si
2 Q
O
CM CS i-i
CN
tn
en CD
es
O OS OS
CN
00"
-28-
-------
Fluid Energy Aljet builds a VACUPRESS densifier designed to increase the densities of
very fine powders (finer than 40 microns) where their high air content hinders further
processing [6].
Aljet's description of the VACUPRESS operating principle is:
"The densifying effect is achieved by a combination of vacuum and mechani-
cal pressure. The VACUPRESS process is achieved by means of two drums
turning in opposite directions, designated filter drum and pressure drum.
[Figure 9]
"The product to be densified encloses the filter drum and thereby allows the
filter or de-aeration action to take place. As the drum revolves, the particles
rearrange to form by vacuum effect a continuous layer on ithe surface of the
filter drum and pre-densify by the exhausting air passed through. The layer
of de-aerated powder passes through the gap between the filter and pressure
drums where it is subjected to a preselected rolling pressure. The rolling
pressure action brings the de-aerated powder particles clos>er together as
dense powder or soft agglomerates. Afterwards, the densii:ied product is
continuously stripped off the filter drum up to the filter layer and leaves the
machine."
A typical VACUPRESS installation is shown in Figure 10.
I. Bag filling
Dry and dense silica at eight to ten pounds per cubic foot and less; than one percent mois-
ture is transferred from the densifier into an auger feeder via a pneumatic conveying sys-
tem, i
i
The microprocessor-controlled auger feeder measures and feeds a volumetric fill for each
panel size. Different weights for different panel sizes are held in the feeder memory and
-29-
-------
.0)
(
o
-------
3 CO
OC/>
il£
Q.
D
O
CO
-31-
-------
changed with the push of a button. Fills for each panel are controlled to plus or minus a
few grams. Five different fills are required for the panels used in this study. Change over
would be instantaneous.
A Mateer-Burt Neotron System Series 1900 (Appendix D) was selected for this application
[3]. The 1900 is designed for application on automatic form, fill, and seal machines and has
an accuracy of plus or minus two to three grams.
J. Panel Manufacturing Line
The auger filler feeds a vertical form, fill, and seal machine which bags the silica in a po-
rous bag [I]. The machine then places the porous bag into a multi-layer plastic bag which is
inserted into a vacuum chamber where it is evacuated and sealed. Process specifications for
the form, fill, and seal line are shown in Figure 11.
Horizontal equipment could be used and should be reviewed further before discounting it
[2]. Also, some other types of equipment can vacuum form the barrier bag into a tray. This
could be an advantage, but was not considered because it was felt that the multi-layer
barrier bag could not be vacuum formed without destroying its integrity. This capability
should be investigated further before ruling it out. Vertical equipment was assumed to be
best suited for manufacturing VIPs.
-32-
-------
Figure 11
Process Specifications- Form, Fill, and Seal Line
Equipment operation sequence: j
j
• form porous pouch |
• fill with silica
• lay pouch down
• vibrate flat ;
• compress i
• • form barrier bag around porous pouch :j
• seal on three sides and tack on forth i
• cut apart I
• insert bag into vacuum chamber
• compress at controlled vacuum I
• seal forth side '
• remove panel from chamber
,i
1. Fully aut- made
i
2. Cycle time—4 seconds ,|
'i
3. Evacuation time—5 minutes
t
4. Vacuum—1 millimeter of mercury (1 Torr) .
5. Maximum panel size—Tx 21 "x 30" j
6. Semiautomatic changeover for thickness and length i
7. Capability for two thicknesses (0.5" & 1.0"), and two lengths (21" & 28")
8. Five pounds maximum fill
9. 85% efficient
10; Reject rate < 1 % at steady state
11. Materials: porous bag—Snow Filtration TYVEK
barrier bag—Fres-Co VECAT
silica—Degussa-FK 500LS
-33-
-------
Form, fill, and seal machines have long been used in the food industry for vacuum packed
products such as coffee, and are a proven technology (Appendix E). Although VIPs are
somewhat larger than the typical food package, it is felt that these machines can be de-
signed to produce them. Form, fill, and seal machines typically run from 80 to 100 pieces
per minute. The VIP process will run only 15 panels per minute. Figure 12 shows the layout
of a form, fill, and seal machine for food packaging.
The process sequence in the form, fill, and seal machine for VIPs would be:
Station 1 - Form porous bag, seal bottom, fill with silica, seal top (which is bottom
of next bag), cut off and drop on belt conveyor. The bag is formed as a
continuous tube which is filled by the volumetric auger filler. The tube
is sealed at selected dimensions by a resistance heated hot bar and cut
off by a shear.
Station 2 - Locate bag, vibrate to level silica and press to compact.
Station 3 - Form barrier bag around porous bag, seal on three sidec and tack os
fourth side.
Station 4 - Load and unload evacuation chambers. Four panels per chamber.
Station 5 - Evacuation. Inside each chamber the control sequence will be: a. com-
press at a controlled vacuum; b. secondary vacuum; c. final compres-
sion; d. final vacuum; e. seal fourth side; and f. exit chamber.
There are 26 vacuum chambers and 20 vacuum lids on the line. With
four panels per chamber, five and one-third minutes of evacuation will
occur for each panel at the four second line cycle.
Station 6 - Secondary seal all four sides of barrier bag—three hot bar hits per side.
• Station 7 - Transfer to belt conveyor.
Changeovers from one size panel to another will necessitate changing porous bag and
barrier bag material sizes, changing mandrel for porous bag forming, adjusting both bag
stations, adjusting compression stations outside and inside vacuum chambers when a
-34-
-------
CM
-------
thickness change is made, and adjusting hot bar sealers. It is estimated that changeovers
will take from one hour for a one dimension change to three hours for a three dimension
change.
The line can be scheduled so that there are no three dimension changeovers. The best run
sequence which requires two one dimension changes and only three two dimension
changes is shown in Table 7. Planning run and changeover sequence will reduce overall
setup time which is the major component of efficiency loss. The line normally will run each
panel for eight hours and then change to another. This plan will produce a maximum of
7200 panels on each run, i.e., one week's requirement for one panel for the refrigerator
plant (6980 units/week).
With a five day, 24 hour work week, this schedule allows 80 hours per week for production
(10 panels x 8 hours per panel), 20 hours for changeovers (10 changeovers x 2 hours aver-
age time per changeover), and 20 hours for maintenance, downtime, and other losses.
-36-
-------
O)
O =
C 3
1 T3
I °
CO -
O C
LL (0
O
in
2
z
£
IANGEDM
NUMBER
| 4&6
$£
tf> Z
>^P ^"3 _j^
O c* «S
53 O «N
Z H
S u
D |
pu z 2
o
-------
K. Quality Control
Panels coming off the panel line would be 100% tested to determine whether or not the
pressure was below an established limit. This test would be done in the four second cycle
and panels without the proper vacuum would be diverted into a reject bin and an alarm
would be sounded. Controls would be integrated so that the line could be shut down and a
control person summoned if a panel failed the test limit.
This test would be done using a single head transducer which generates an electromagnetic
impulse which then creates an audible tone. The frequency or pitch of the tone indicates the
relative vacuum or pressure in the panel. A high pitch denotes high vacuum and a low
pitch represents low vacuum [14].
This technology is proven, and equipment which is now being used to test vacuum bagged
products is commercially available (Appendix F). Further development would be required
for this specific application and for determining the actual "icuum range which could be
measured.
Control operators would salvage the silica from rejected panels and take scrap bag material
from the plant to an outside dumpster daily. •
A quality control laboratory would perform more accurate vacuum measurements on an
audit basis. Laboratory equipment would be a different type, which would -allow an entire
panel to be placed into a vacuum chamber which would be pulled down until an equilib-
rium with the internal vacuum in the panel was reached. Optic sensors would detect a
slight movement of the outer panel membrane at this point.
This equipment, which would be accurate within one or two Torr, has been produced for
laboratory use [16] (Appendix G). Equipment which would use only a small vacuum head
placed against the panel but using the same principle is being developed at ORNL [15].
-38-
-------
This approach could reduce the cost of laboratory equipment. Its capability to meet a four
second manufacturing cycle and be feasible on a manufacturing line is yet to be estab-
lished. If it should prove feasible, accuracy would probably be significantly improved over
the magnetic pulse approach. j
L. Packaging
Panels coming off the form, fill, and seal line every four seconds will be automatically
stacked into bundles and strapped. Bundles are sized so they can be handled manually to
avoid the need for skids and fork lift handling. Weights for each size bundle are shown in
Table 8. A cardboard top and bottom cap will be placed on each bundle as it is stacked by
an automatic stacking machine. !
. ' • ' | .-.."••
Each stack will be transferred automatically into a Cyklop ASM-1A (Appendix H) auto-
matic strapping station where each bundle will be secured with two plastic straps [13]. This
equipment, supplied by Zelierbach, heat seals the strap and makes high strength seal joints
which are easily removable without tools. The ASM 1A is fully automatic and incorporates
a powered belt conveyor and photo-electric controls. j
j " .•.
Alternative packaging considered included shrink bundling and shrink wrap. These alter-
nates were discarded because more dunnage would be generated, at the refrigerator plant
and the extra protection was not warranted since the bundles will be handled automati-
cally or manually without fork lifts.
Bundles of panels will be transported automatically by belt conveyor
(Appendix I) which will carry them into a van trailer where they
stacked manually. The Adjustoveyor will be mounted on tracks to
tween shipping docks [10].
rs to an Adjustoveyor
will be unloaded and
allow it to travel be-
-39-
-------
LES
DAY
g
CM
CM
S
CM
l&I
O 'C w
fl> "
§
«
S
EL
Y
DA
o in o o o
CM
p\
f\
CM
CM
Csl
O\
P"*
CM
L*
1/i
CO
^}
CM
\O
oo
-40-
-------
M. Bar coding :i
$ • .!
Each bundle of panels will receive a label bar code to identify the panel size and date of
manufacture. Label bar coding was selected because of its superior clarity over ink jet bar
coding when applied to cardboard. Labels will be printed at the line and placed on the
cardboard cap of each bundle of panels automatically. Equipment selected for this applica-
tion is the LPA/80T thermal label printer/applicator manufactured by Lord Label Systems,
Inc. [13] (Appendix J). I
N. Shipping and Transportation
I
Panels will be shipped to the refrigerator plant on a just-in-time basis by a captive trailer
fleet. Trailers will be Dorsey vans (48'L X 8.5'W X 13.5'H) which ivill be retrofitted to give
maximum protection to the panels. Tractors will be Kenworth T600A, fuel efficient day
cabs with a five year, 750,000 mile warranty [19].
All production from the panel plant will be loaded directly into trailers. A sufficient num-
ber of trailers is provided to store the equivalent of two shifts of production for the refrig-
erator plant in addition to having one being loaded and an empty standing by.
The average daily requirement for production at the refrigerator plant will be about 14,000
panels or 1000 bundles (Table 8). An average of one trailer per d&y will be needed to de-
liver this requirement (Table 9). j .
0. Safety and Environmental Considerations !
FSK5OOLS silica is an odorless, dry, white powder. The material is completely safe to the
panel plant employees. It is neither toxic nor flammable and there is no explosion hazard.
Adequate ventilation is required and, where dust occurs, a NIOSH-approved dust respira-
tor is recommended.
A Material Safety Data Sheet is shown in Appendix K.
-41-
-------
73
CO
O
~
«
£
00
»•!
H
vo f* o\ en o\ »o
ts «-< cs o «-« (j\
Q pi gll ® d o c> 6 d
|S
S *5
D g
<;
5. W
«O CH
~5 ^3
s o*
1
g
^ 1
•* «"< i-« CS «^
X X . X X X
X X X X X
en en
-------
PANEL INSTALLATION INTO REFRIGERATORS
This section describes the facility modifications and equipment needled at the refrigerator
plant to receive, handle, and install 3,000,000 VIPs per year into three hundred thousand 21
or 24 cubic foot refrigerators. Modifications are based on generic plant assumptions and
would be different for an actual plant and vary from one plant to another. Panel installa-
tion is discussed in the following sections.
A. In-plant receiving, material handling and storage
B. Delivery to assembly areas
G. Adhesive application and panel insertion
D. Quality control
E. Foaming around VIPs
F. Refrigerator plant equipment and incremental operating costs
A. In plant receiving, material handling, and storage
Panels would be received at two new docks in a new 9,774 square foot building addition.
(Figure 13) Panels would be unloaded using an extendable adjustoveyor in reverse of the
loading method at the panel plant. The adjustoveyor would feed a sortation conveyor \
which would feed eleven, five tier, flow-through racks which hold each of the ten panels
for a refrigerator [11]. A bar code reader integrated with the conveyor controller would
select a tier that was not full and divert the bundle to that tier. A second reader would
divert the bundle into the proper flow-through rack. Each five tier rack would hold from "
195 bundles (panel # 1,4,5 & 6) to 350 bundles (panel # 7)
The eleven lanes would hold enough panels to allow the refrigerator assembly line to run
two continuous shifts of models with VIPs. (Table 10) The delivery conveyor will hold
almost enough panels for another shift's run. Since the assumption is that the assembly
lines would average running VIP models only six shifts per week, this is a very conserva-
tive inventory plan.
-43-
-------
Figure 13
VIP Receiving Area - Refrigerator Plant
Refrigerator
Plant
0 Monorail Conveyor
to Prefoan Areas
©Flow Thru Racks
(36" x75')
0 Sortation
Conveyor
® Adjustoveyor
© 48' Trailers
® ' Material Handlers
-\
™
DDDDDDDDC
t.o
181.0
— 44 —
-------
CO
O .2*
£ 8
.— c
3 «?
in
x
S oK
.CO (0 x
CM
o
(0
oo
es
•8
4 B
00
Z
en
es
oo
w>
0\
r
en
es
O
es
CS
x
o
en
es
en
es
en
es
oo
o\
fS
o
i-«
X
en
es
en
o
en
O
K
O
C1
cs
o
es
CS
^
o
en
-45-
-------
Both the sortation conveyor and the flow-through racks would be center drive belt convey-
ors controlled by a common controller and integrated with laser bar code readers [11].
Three hourly paid material handlers, on each of two shifts, would unload the panels from
the van trailers onto the adjustoveyor and from the flow-through racks onto a continuous
conveyor for delivery to the pre-foam areas.
B. Delivery to assembly areas
Four options were considered to move the panels from the receiving area to the case, liner,
and door pre-foam areas—fork trucks, automatic guided vehicles (AGVs), belt conveyor,
and overhead monorail. Both fork trucks and AGVs would require an overpack and a skid.
These methods would reduce truck loads and create dunnage removal problems. They
would also add to product cost.
Belt conveyor would offer the possibility of feeding individual panels to specific stations on
each line by the use of bar coding. Pant-Is could be automatically fed into magazines for
robotic pick up, eliminating the need for manual material transfer. However, it would be
difficult and costly to retrofit most existing plants with such a system.
The overhead monorail conveyor method was assumed for costing in this study [12]. This
system could probably be installed in most plants even though considerable rearrangement
of existing facilities may be required.
Fifteen hundred feet of enclosed track conveyor with 250 four tray hangers on six foot
centers would be installed. The conveyor would run about 18 feet per minute, which would
provide as many as 120 panels per minute to any one station. The case line would require
only 18 panels per minute.
This system, with required drives and other auxiliary equipment, was estimated by
Unibuilt, a division of Jervis B. Webb Company (Appendix L) to cost approximately $110
per foo.t, installed [12].
-46-
-------
It was assumed that 2000 square feet of floor space would have to be added, either as a
mezzanine or a building appendage, to offset the space consumed by rearrangement to
install this system. Actual rearrangement requirements and costs would have to be ad-
justed for a given plant and would depend on that plant's construction, layout, and avail-
able floor space. j
i
This conveyor would deliver panels to case pre-foam, door pre-foam, and liner pre-foam,
and have storage capacity for about eight hours of production.
' • ' '<
Panels will be unloaded manually from the monorail conveyor, the strap will be removed,
and individual panels will be placed on the appropriate queuing conveyor at each case line,
liner line, or door line station. Two material handlers per shift will! service the case and
liner lines, and one material handler per shift will service door pre-foam. Queuing convey-
ors will have appropriate indexing devices to locate each panel for accurate robot pick up.
<
C. Adhesive application and panel insertion '
On the case pre-foam line, the case will be positioned via shot pins or some other position-
ing and holding mechanism and a GMF S-500, six-axis, articulated, electric robot (Appen-
dix M) will apply an adhesive dispensed from a bulk unit to the case interior [8]. Two.
robots will be required to spray patterns heeded to hold the six VIPs to be placed at the
succeeding stations. Both robots will be supplied from a common Nordson hot melt unit
(Appendix N) [5]. The hot melt material cost is included @ $0.08 / square foot. Three more
GMF S-500 robots will be used to place six panels into the case as shown in Figure 14. Each
robot will place two panels.
Hot melt and panel placement stations would be added between
the existing case seal
stations and the foam release stations, requiring some line rearrangement. The existing
foam release stations would be converted to panel adhesive application and two new foam
'! '
release stations would be added after panel insertion. j
-47-
-------
o
>
CO
CO
o
r
-48-
-------
On the liner pre-foam line, one GMF S-500 will apply adhesive to the fresh food back panel
and place the panel on the liner back (Figure 14). A third Nordson hot melt unit would be
used for this robot. !
Two GMF S-500 robots will be required on the door pre-foam line. Each of these robots will
apply adhesive inside the doors and place one or two panels into the doors. The robots will
place one or two panels on alternate cycles to meet the station cycle time. Figure 15 shows
the modified layout of the door pre-foam area. Some rearrangement also will be required
on this line. A common Nordson hot melt unit would feed bom 6'f these robots.
It was assumed that 4000 square feet of mezzanine or building apipendage would have to
i
be added to accommodate rearrangement required to make room for the adhesive and
panel insertion stations. Actual rearrangement requirements and costs would have to be
adjusted for any given plant and would depend on that plant's layout and available floor
space. ,
I
A budget estimate of the cost for these stations, including eight robots, end effectors, panel
and case/liner/door positioning stations and hot melt units was developed by Remtec, Inc.
and is shown in Appendix O [7]. Remtec's cost estimates for the hot melt and pre-foam
stations were deemed to be considerably low. Based on an estimate from Nordson, the hot
melt stations were re-estimated at about 160% higher than Remteic's estimate. Also, UK
engineers replaced the Remtec estimate for pre-foam stations with one about 250% higher.
D. Quality Control
Each panel will be checked for vacuum before it is placed into the case, door, or onto the
liner. This will be done using a TapTone magnetic impulse unit as part of the robot end
effector or as an independent unit at the end of the panel queues [14].
-49-
-------
Figure 15
Door Pre-Foam Area with ViPs
Doer
Delivery To Inner Door
Assenbly
fron Paint
II
Door Foon
Systen
ji
I. Freezer Door
2. Fresh Food Door
3. lood Foon. Conveyor
4. Unload Foon Conveyor
5. Panel Delivery Conveyor
6. Adhesive Application &
Panel Placenent Robots
©Manual Operators
3D Added Material Handler
-50-
-------
E. Foaming around VIPs
After VIPs are positioned in the cases and doors and on the liner back, units will enter the
respective foam systems where the VEPs will be foamed in place. Both the dimensions and
location of the VIPs will affect the foam flow path and, therefore the quality of the fill.
Panel sizes used in this study were developed with this consideration. Considerable devel-
opment of VIP sizes and foam chemical compositions and distrib ution will be required
prior to implementation of a production system. Compatibility between foam chemicals
and barrier envelopes could also be an issue which may require further development.
F. Refrigerator plant equipment and incremental operating cost
Equipment required for the refrigerator plant is summarized in Table
associated costs. A 25% contingency is included. Additional personnel
operating costs are summarized in Table 12.
-Si-
ll, along with the
and incremental
-------
ooooooooooooooo
OvomOOOOOOOOOOOsO
OO\OOO\«OCOOOOOOOCSOOO\CO
o o o o
o o o o
O CM VO O
co
o\ co •,-!
oo
en
co in
CN o
CM O
CO
1
1
o o o o
o o o o
O)
o
cc
o
o
«J O O O O
'*•' o o o o
OOO
OOO
o o
o o
o o
O O O «J
O O O «*i
o o o
es
o o o
CM CM CM
2
es
g1 -I
- *- «8
CO
00
CO
CM »-i
0\
V
52
60
O
8
g e-g
S e 2
60 > g
.5 o £
I
8
11 =
g
B
- "
.lrll'1
«> j3 ^ co ^2 ^ W) o e e o § •
y* _~ S 4^ 7\iB^N2C3C3^2r ^("*
O ^^^ A C w " C3 *5 *u ,P jjj ^3 ^» y ff
O*OOo«8>"O*OOOOO«jS
aii « ^ « a > <
o o o
o o o
TT \0 C3
VO VO CO
Tt CO 00
O\ t~. vo
CM
CO
g §
60 O
Is
o >
80
"3 wo "3
>n
CM
-52-
-------
a.
o
S
o
CM
cc
I
o 52
J£ O
•8 O
E
S
Q.
O
15
05
pa
o
o
o
•**
oo
o o o o
\O VO O CS
»-< o
o -i «n
OO «S C--
o o o
^- 04 O
C*^ ON OO
ol tn oT
o
o
o
V*
o
o
o
000
CS VO O
•-i ON "fr
i-T \o ^o
C4 CO C4
V5-
-------
TOTAL PROGRAM AND PRODUCT COST FOR
VACUUM INSULATION PANEL PRODUCTION AND INSTALLATION
Program Cost
Program costs are non-recurring costs to plan and implement the project. These costs
indude investment to purchase and install facilities and equipment, expense for tooling,
and any rearrangement expense required in the existing refrigerator plant. Historic ratios
of investment and expense for similar projects were used.
Program costs also include manpower to plan and implement the project, and start-up cost
incurred in both the panel plant and the refrigerator plant. Seventy-five thousand dollars
per man year was used for manpower cost.
Start-up costs for the panel plant includes manpower, as described in the section on
"Project Schedule and Start-up/7 associated overhead and material for 50,000 development
panels, and lost labor and material from the start-up curve. An assumption was made that
60% o/the silica can be reclaimed from panels produced during development. An estimate
of start-up cost at the refrigerator plant also is included.
A summary of the program cost is shown in Table 13. . '
Product Costs
Product cost includes all direct material and direct labor included in or added to the prod-
uct or its packaging and shipping and associated overhead cost. Overhead includes items
such as overtime premium, night shift bonus, rework, scrap, and hourly employee benefits
(medical insurance, vacation and holiday pay, etc.). . "
Other operating costs include utilities, trash removal, taxes, insurance, office expenses,
security, safety, etc. No added warranty costs are included although there is likely to be
additional warranty cost as a result of the incorporation of VIPs. Some amount of warranty
reserves should be planned for service calls which may result from VIPs.
-54-
-------
D)
O
-
NO
i
i
06
il
CO
« "55
°- O
-O O
S E
- I
II
I
T-; O
"^
CO
OO
o\
CO
O
(0
-------
Table 14 summarizes the added product cost to add 29 board feet of VIPs to 21 or 24 cubic
•foot refrigerators being produced at a volume of 300,000 per year.
Some appliance manufacturers may have designs with condenser loops to heat the mullion
or cross braces in the doors. These parts may need to be retooled to remove interference
with VIPs. Cost to retool these parts and the added product cost, if they require additional
material, is not included in these summaries.
Sensitivity Analysis
To test the sensitivity of costs per board foot of VIPs, a sensitivity analysis was made by
varying certain elements of product cost and program cost and recalculating the resultant
cost per board foot. In order to include program cost in this analysis, these cost were amor-
tized over a five year period or 43.5 million board feet of VIPs (300,000 refrigerators/year x
29 board feet of VDPs/refrigerator x five years). This analysis is shown in Table 15.
Project Schedule and Start-Up
After feasibility is established and funds are appropriated, it would take about two and one
half years to be in production as depicted in Figure 16. Since product redesign is limited to
the addition of VIPs to existing refrigerators, the longest tasks are equipment procurement,
installation, and development. Some minor modifications to existing refrigerator parts
tooling may be necessary and considerable product evaluation would be required.
The panel plant would be staffed with partial crews six months prior to start-up. These
would include the plant manager, quality control manager, material control manager,
financial manager, one foreman, one skilled maintenance person, one control person, and
one material handler. The full plant crew would be added two months prior to production.
It is estimated that after a four to five month development period about seven weeks
would be required to bring the plant up to rate as depicted in Figure 17. Current users of
-SB-
-------
C/>
a,
>^
3- CO
*- o
IS
e ^W
Is 5
+•* CO _l
•r^ o
CO CD
•S
.S
"£I
CO
s
p
o b
w
<
D
5
I
IS
i
i
5
in
§8 a
JS 53 .
NO
'S »
^ fi
—
-57-
-------
Table 15
VIP Cost
Sensitivity Analysis
VARIABLE MFG. COST/ 'PROGRAM COST/ TOTAL COST/
BOARD FOOT BOARD FOOT BOARD FOOT
vtmms-
MATERIALS:
Silica
+10%
-10%
-20% •
' Foam
+10%
+20%
+30%
PANEL PLANT OPERATING COSTS:
+25%
-25%
PROGRAM COSTS:
Buy existing building
at$25/squrefoot
Building at 0$ cost from
industrial development
organization
Manpower
+25%
-25%
" Panel plant
Start-up costs
.+25%
-25%
$1.39
$1.47
$1.32
$1.24
$1.37
$1.35
$1.33
$1.44
$1.34
$0.54
$0.48
$0.45
$0.55
$0.53
$0.56
$0.52
$1.93
$2.01
$1.86
$1.78
$1.91
$1.89
$1.87
$1.98
$1.88
•$1.87
$1.84
$1.94
- $1.92
$1.95
$1.91
* $23.6/MM amortized over 5 years or 43.5MM board feet
-58-
-------
3
u_o
CL
CL
CM
CC
tr
o
oo
UJ
o
CD
_j
I-
UJ
2
UJ
CC
CO
UJ
CO
Q UJ
O CO
^ -I CO EL
t§g££
0 - UJ UJ
o m
^Is
cK8i
Q CO CL [jj
O !z t°
LLI < CC
CL Q.
82 8
CL
CL CL '^ CC
CL Hi UJ —
Q
^ QJ =iS
I- CL CL
-59-
-------
form, fill, and seal equipment felt this was a conservative estimate, considering the devel-
opment period planned [18].
-60-
-------
0-
Q.
£
II
iZO
Q.
3
CO
CO
OD
ur>
s
lil
(M
s
*
-61-
-------
THICK WALL ALTERNATIVE
Another approach to increasing the thermal resistance of the refrigerator cabinet is to
increase thickness by adding additional non-CFC foam insulation. This section estimates
the manufacturing cost impact of increasing insulation. Since this scenario is more likely on
smaller refrigerators (<21') an 18' refrigerator, which represents a major share of the mar-
ket, was used for this analysis.
Facility Assumptions
A facility producing five hundred thousand 18 cubic foot refrigerators per year was as-
sumed. Multiple models hi multiple sizes would further complicate this analysis and
would definitely affect the cost estimates.
Scenarios
Four increases in insulation thickness from the current representative product were stud-
ied. These were +0.5", +1.0", +1.5", or +2.0". Thickness was increased on top, bottom, back,
doors, and both sides.
Four methods were used for increasing the external dimensions to accommodate the . .
thicker insulation.
• Case "All" allowed all external dimensions of the unit to increase. This case main-
tained the exact internal'dimensions as well as the width of the front flange.
• .. Case "H" allowed only the height of the unit to change to accommodate the change in
thickness, and reconfigured the inside to maintain 18 cubic feet of storage space. For
example, when 1" of insulation is added to the top, bottom, back, doors, and both
sides, the new height must become 74.5" since the width is held at 29.5" and the depth
at 31.5" (Table 16). The liner would be long and narrow.
-62-
-------
• Case "W" allowed only the width of the unit to change and maintained the internal
volume. ;
• Case "D" allowed only the depth of the unit to change and maintained the internal
volume.
All cases except Case "All" change the internal dimensions of the refrigerator. Typically, a
given size box is used for numerous models which then have different internal parts or
features to upgrade the model. For this reason, retooling cost for these scenarios could be
$5 - $10 million more than case "All".
This analysis was made with the understanding that there are restrictions to dimensional
. changes: i
• Any increase in depth beyond the current 27.75" (w/o door) prohibits entry through
28" doors and, reduces the market served; shallowness is an important consumer
feature and any increase in depth makes the box less marketable. From a
manufacturer's viewpoint, a common depth across several ntodels enhances factory
productivity.
| . \ • -
• Height is limited in FHA homes, and most others, to 84". This is caused by having an
eight foot ceiling with a 12" soffit. Typically, a 12" cabinet under the soffit further
reduces the limit to 72". The ability to reach into the back of a top mount freezer is an
important consumer consideration, which puts practical limitations on height.
• Width also is limited in FHA specifications to 36". Npn-FHA homes also have width
limitations. Increases in width will reduce the potential market.
. , i -'
Thicker foam walls may present process control problems such as bowed liners, which
can make shelves difficult to install at final assembly, and bowed cases, which may
cause appearance problems as well as kitchen fit problems. These problems will have
to be assessed and resolved during development.
-63-
-------
Table 16
Thick Insulation Alternatives
External Dimensions (inches)
for 18' Refrigerators
Current
Dimensions
Added ,
Insulation
+0.5
+1.0
+1.5
+2.0
VAIT
ALL
H-65.0
W-30.5
D-32.5*
H-66.0
W-31.5
D-33.5*
H-67.0
W-325
D-34.5*
H-68.0
W-335
D-35.5*
KING DIMENSK
HEIGHT
64.0
69.0
29.5
31.5
74.5***
29.5
31.5
80.0***
29.5
31.5
85.5»*
29.5
31.5
DN (Inches)
WIDTH
29.5
64.0
32.0
31.5
64.0
34.6
31.5
64.0
37.1**
31.5
64.0
39.7**
31.5
DEPTH
31.5
64.0
29.5
33.9*
64.0
29.5
36.3*
64.0
29.5
38.7*
64.0
29.5
41.1*
CAB. DEPTH
27.8
29.7*
32.1*
34.5*'
36.9*
NOTES: * Will not fit through 28" door with refrigerator doors removed.
** Exceeds FHA specification dimensions.
*** Exceeds FHA dimensions with 12" cabinet under soffit.
-64-
-------
Table 16 is a matrix of dimensions for each scenario. Some combination of the above cases
may be the best solution when all factors are considered.
Cost Analysis.
A cost impact analysis was completed for all four levels of thickness increase, using Case
"All". A retooling matrix was done for the other three cases but cost analyses were not
completed. All foam insulation costs were based on CFC 11. Alternative blowing agents
would very likely make these changes more expensive, at least initially.
• Variable manufacturing cost increase—An analysis of the required changes was com-
pleted for each case and the percent increase in part size was calculated. Using de-
tailed part and material cost information obtained from an appliance manufacturer,
via a nondisclosure agreement, a variable manufacturing cost increase for each part
was calculated. The major contributor, by far, to the increased cost was the cost of the
additional foam insulation, which accounted for well over half of the increase.
• Transportation cost increase—Carton sizes were calculated for each new dimension
for all four cases (Table 17). Using standard 48' trailer dimensions and 60' high cube
rail car dimensions, the number of refrigerators per load was; calculated for each
thickness increase in case "All" and compared to the existing load size. Using an
estimated average mileage to a distribution center, an average cost per truck and rail
car and an estimated percentage of truck versus rail, a transportation cost increase per
refrigerator was calculated. ,
Cost of additional warehouse space at the factory, distribution centers and dealers
was not estimated. As product/carton sizes increase more floor space will be needed.
Cost of adding this space would be $100 to $125 per square foot. If inventory levels
were reduced in lieu of adding warehouse space, service to dealers would be ad-
versely affected, resulting in lost sales.
-65-
-------
Table 17
Carton Sizes for 18' Refrigerators
with Thicker Insulation
Current
Dimensions
Added
Insulation
+0.5
+1.0
+1.5
+2.0
ALL
H-68.0"
W-33.0"
D-35.8"
H-69.0"
W-34.0"
D-36.8"
H-70.0"
W-35.0"
D-37.8"
H-71.0"
W-36.0"
D-38.8"
VARYING DIM
HEIGHT
67.0"
72.0"
32.0"
34.8"
77.5"
32.0"
34.8"
82.0"
32.0"
. 34.8"
89.5"
32.0"
34.8"
ENSIGN (Inches)
WIDTH
32.0"
>*7.0"
34.5"
34.8"
67.0"
37.1"
34.8"
67.0"
39.6"
34.8"
67.0"
42.2"
34.8"
DEPTH
, 34.8"
67.0"
32.0"
36.8"
67.0" .
32.0"
39.2"
67.0'r
32.0"
42.0"
67.0"
32.0"
44.4"
-66-
-------
• Tooling and Investment cost—Required tooling and facility Changes were developed
'•."••, ' •-&"-.; , • i -
for each scenario using the representative 18' refrigerator and a representative manu-
facturing facility. Costs were then estimated for each retool or facility change for each
of the four levels of thickness change in case "All". Increases in foam demold time,
caused by thicker walls, were off-set by adding foam fixtures in +1.0", +1.5", and +2.0"
scenarios. j
A 20% contingency was added to these numbers. This is a typical contingency factor
for an estimate of this quality. A matrix of required changes is shown in Table 18.
Investment costs are for capital expenditures and can be depreciated over several
years. Tooling and other expenses must be written off as they are incurred. The same
is true for manpower and start up cost.
" ;' '
• Manpower cost—Design engineering, manufacturing engineering, quality assurance,
and other man years were estimated to implement each level of change in case "All".
Seventy-five thousand dollars per man year was used to calculate manpower cost.
,j
• Startup costs—Costs to build development models and run trial runs in the plant, plus
the cost of lost units while each change is implemented, were estimated.
Product cost, including transportation, for thicker foam insulation ranges from $12.28 for
one-half inch to $37.65 for two inches. Program costs range from $16.6 million to $22.5
million. Thicker foam only on the doors would cost $3.23 and $12.28, respectively and the.
program cost would be about 25% of the numbers above.
' !• . — .. •
A summary of all cost impact elements is shown in Table 19. A sensitivity analysis for
product cost increase/unit when the cost of foam material is increased is shown in Table
20. The cost impact of increasing insulation thickness on doors only is shown in Table 21.
-67-
-------
X
e~
w
D
_ Q
2 5
0 £
So
—
W f^
S X
5"
0"
2 =
£
•^ -j
X X X X
X X X X
XX X X
«s-§
O. co '2
co •-* cs t->
.itf i; o
t) M ^ w
2 §.S
- o' -
O C j^ O
"w 2 c ^
C3 f\ f» CQ
W> £: .= tQ
XXX XX X
xxxx xxxx
X
„,
CD
3 a
e. . -o
u u C
•o en > 6CbO ^5Cre--
J. r- j: o o o ?">o>c
tr>cntn>>> cnoocvS
X X
X X
X
X
MISCELLANEOUS
fresh food top
frz. bottom
door handles
\
X X;X
XXX
X
XXX
«
PACKAGING
carton
top & bottom caps
skid -
XXX
XXX
X X
XXX
1- (O
cy to
•O "c "re
iS 5 .S
cx ^ y:
|
D
ac
t-
z 5
o >
sl
o g
< J
> J
XXX
X X
X X
XXX
— 55
g -
o .
•* Ji o
t- c o e
E — •£_ w
CQ o c
X
X X
X
.-
X X
o
u
£
3
0 ^
? 1
X
X X X X X X X
XXX
XX X X X X X
CO
o.
S, w
J^ o
o *? 00.
« g .* o _
£ IS S -2 IS E
i M i- a ca
— 0. J3 i_ _g J2
"~ £•* «• Cj MM Vi f~ ^IM
2 | J o | g | g
g 1 "i 1 1 § | «
"EeEEu-D>
X
*
X
X
X
xturcs
C3
£
X X
X X
u
u
c
u
CO
CO
0
u
C3
1- —
a •—
CJ ""-
U. MJ
Di
FOODL
X
X
X
X
CO
2
"5
E
E
c
Ihcrmof
X
X
X
X
CO
"3
c
E'
•c
u
2
u
'El
XXX X
XXX X
XXX X
••
CO
2
"3
E
j ^ S' £ ^ "3
E- «- •" t O C
M C O O O U
s o c o X j=
S-o-o-o O t:
- X
X X
X X
X X
1 1
U C
o <^
•'&£
X
X
-
X
1
£3
t«
3
U
E
ra
£
-68-
-------
S2
o
.5>-=
•a>
E 8
O
00 '5
= I
°5
IE
•2 ^- G> n
•g»- .Er-
CO (T- co cn
H o c ?
•S « c-
13 2
"3 w
§1
~ co
d> o
CO E
85
.ii
•= a
O £
CO
o
O
Si
W «
tO C
2 .2
U4 —
w
2 .0
to :=
>A?
5£J
S 5
|1
18
H .fc
RODUCT
CASE
in
in
•&
t^i
cr
W UN
en
I
-69-
-------
Table 20
Thick Wall Product Cost Sensitivity Analysis
Thickness
Increase
0.5"
1.0"
1.5"
2.0"
Product Cost
Increase/Unit
$6.81
13.46
21.16
29.20
+10% Foam
Cost
$7.25
14.35
22.53
31.19
+20% Foam
Cost
$7.69
15.24
23.90
33.18
+30% Foam
Cost
$8.13
16.13
25.27
35.17
70-
-------
C
O
g
o
o
a
i- "O
0-g
•*J {Q
CO >
m co
«fc W
•«i
coS
^f™ co
= £^
O £J 'w'
CB
o D
'co o>
Pi
C co
.Si
O
Jis c
=3 g
W .1
£ D
O g
(0 ?t
5 '
§ EH
3 5
^ ^
i <
a 1
s §
g HH
PRODUCT COST
INCREASE^JNIT
^^
w a
K ^
0 ?
1— 1 v_
M
: 'i
•CO CO ^}* ^*
o e> e> o
to t- o> >-i
i-J i-< i-i c«
ia to ao ao
co' oi
-------
Implementation Timetable
Changes of this magnitude woud take at least one and one-half to two years to design and
implement, depending on the manufacturer's model mix and production equipment flex-
ibility. The major time elements would be product redesign, tool and equipment redesign
and procurement, and prototype evaluation.
-72-
-------
ENERGY ANALYSIS
The total energy consumption of 18 cubic foot refrigerators with thicker foam insulation or
vacuum insulation was modeled using the EPA Refrigerator Analysis program [21]. A
"typical" 1991 refrigerator was used as the baseline for the analyses. Some of the dimen-
sions and characteristics of the baseline unit, i.e. the unit without thicker walls or vacuum
insulation, are shown in Table 22. Additional details can be found in the description of
Model D given-in reference 22. Thicker foam calculations were made on the 18 cubic foot
unit with 0.5,1,1.5 or 2 inches of foam added on all of the exterior surfaces, including
doors.
Refrigerators which had 18,21 or 24 cubic feet total volumes and contained vacuum panels
having a resistivity of 25 h ft2 °F / (Btu inch) and the dimensions shown in Table 2 were
also modeled. The 21 and 24 cubic foot units were identical to the 18 with the exception of
one inch added to the exterior dimensions of the 18 to make a 21 cubic foot unit and 2
inches added to the 18 to make it into a 24.
i
Calculated energy consumption per day decreased by as much as 24 percent for adding
two inches of foam to the exterior of the 18 cubic foot unit, see Table 23. Similar energy,
reductions would occur for adding insulation to the exterior of the 21 and 24 cubic foot
units.
Incorporating the vacuum panels into the refrigerator produced an average 16 percent
energy reduction, with the 18 cubic foot unit having a slightly better improvement and the
24 slightly worse. Since panels sized for the 18 were modeled in all three units, the panels
cover less of the area in the larger units and the energy reduction, decreases accordingly.
Finally, comparison of the calculations for the 18 cubic foot unit indicates that addition of
one inch of foam produces the same energy reduction as the inclusion of the vacuum pan-
els. Similar results would be expected for the larger units.
-73-
-------
Table 22
Baseline 1991 Refrigerator
Internal Volume
Recip. Compressor
Refrigerant
r-value
Freezer walls
Freezer top
Freezer door
Fresh food walls
Fresh food bottom
Fresh food door
Evaporator
Condenser
INSULATION
FANS
i8.o fa
5.3 HER
CFC12
7,9 h ft2 °F/(Btu in)
2.375 inches
2375 inches
1.75 inches
1.875 inches
2.0 inches
1.75 inches
8W
10W
Table 23
Energy Consumption Analysis Results
MODEL
18 ft3 baseline
18 ft3 +0.5" foam
18 ft3 +1.0" foam
18 ft3 +1.5" foam
18 ft3 +2.0" foam
18 ft3 +vac. ins.
21 ft3 baseline
21 ft3 +vac. ins.
24 ft3 baseline
24 ft3 +vac. ins.
ENERGY CONSUMPTION
kWh/day
1.75
1.58
1.46
1.38
1.33
1.46
1.83
1.54
1.91
1.62
% reduction
•
9.7
16.6
21.1
24
16.6
15.8
15.2
-74-
-------
REFERENCES
Equipment and Material Suppliers ;
1. Fres-Co System USA, Inc., Telford, Pa., Larry Restivo (form, fill, and seal equipment
and vacuum packaging)
2. T. W. Kutter Inc., Avon, Ma., Fran Ventura & Vinnie Faherty, (form, fill, and seal
equipment and vacuum packaging)
3. Mateer-Burt Co. Inc., Wayne, Pa., DiehlMateer (auger fillers)
4. North America Silica, Ridgefield Park, N. J. (as of 3/1 /92, the Silica Division of
Degussa Corp.) Roger Caffier & Nick Ludovic. (silica material)
5. Nordson Corp., Florence, Ky., John McKenna (hot melt equipment)
6. Fluid Energy Aljet, Plumsteadville, Pa., William Rodzewich (flash driers and
densifiers)
7. Remtec, Inc., Cincinnati, Oh., Charlie Gaynor (robots and assembly stations)
8. Technical Automation, Cincinnati, Oh.,Tom Zito (GMF robots)
9. Roessler Company, Cincinnati, Oh., Ron Roessler (vacuum transfer equipment) ;.
10. Advanced Material Handling/Stewart Glapat, Louisville, Ky., Ijes Kepley (adjust-
oveyors, belt conveyor)
11. Mathews Conveyor, Danville, Ky., Debbie Hoskins (belt and roller conveyor)
12, Unibuilt/Jervis B. Webb, Farmington Hills, Mi., Robert Fredricks (overhead, enclosed
track conveyor) i
13. Zellerbach, Louisville, Ky., Chuck Andres, Gary Weil (strapping and bar coding
equipment and strap and cardboard cap material)
14. TapTone, North Falmouth, N. J., Leslie Martin (vacuum test equipment)
15. Oak Ridge National Labs, Oak Ridge, Tn., Tom Kollie (vacuum test equipment)
-75-
-------
16. Babcock/Wllcox, Lynchburg, Va., Kenneth Camplin (vacuum test equipment)
17. Peabody Tec Tank, Parsons Kansas, Sharon Long (silos)
18. JFG Coffee Co., Knoxville, Tn., Brian Morse (user of form, fill, and seal equipment and
vacuum packaging)
19. World Wide Equip./Kenworth, Lexington, Ky., Greg Mills (Kenworth trucks and
Dorsey trailers)
20. Portman Material Handling/Clark, Lexington, Ky., Thomas DeLuca (Clark fork
trucks)
21. Merriam, R. L. 1992. ERA, The EPA Refrigerator Analysis Model and Computer Pro-
gram, in press, U.S. Environmental Protection Agency, Washington, D.C.
22. Environmental Protection Agency. 1992. Multiple Pathways to Super Efficient Refrig-
erators, in press, U.S. Environmental Protection Agency, Washington, D.C.
23. Snow Filtration, Cincinnati, Ohio, Dan Wenke (pourous bag material)
-76-
-------
APPENDICES
A Product information sheet-FK500LS
B Letter quote - FK500LS
C Silica silos
D Volumetric auger filler
E Form, fill, and seal machine
F Tap tone unit
G VIP test chamber
H Strapping machine
I Adjustoveyor
J Bar coding unit
K Material safety data sheet -FK500LS
L Unibuilt enclosed track conveyor
M GMF S-500 robot
N Nordson hot melt equipment
O.. Remtec estimate of adhesive and panel insertion stations
-77-
-------
-------
APPENDIX A
Degussa <§>
Degusss
Corporation
Product Information
425 Metro Place North
Dublin, Ohio 43017
PRODUCT: FK500LS
(614)761-0658
METHOD
PCM-37U
PCM-23U
PCM-20U
PCM-25U
PCM-32U-1
PCM-41U
PCM-03U
PCM-lOU
PCM-S1U
PCM-50U
PROPERTIES
SURFACE AREA (MICROMERITICS)
MOISTURE (1) (DIN 53 198)
pH-VALUE (5%, DIN 53 200)
TAPPED DENSITY (DIN S3 194)
AVERAGE AGGLOMERATE SIZE (COULTER)
DBP ABSORPTION (1)
SILICON DIOXIDE (2)
504(2)
At203(2)
Fe2O3(2)
TYPICAL
UNIT VALUE
iq-m/g 475
% 2.5
6.7
&n . so
am 3
g/lOOg 325
\* 99
•>s 1.0
\
% 0.2
% 0.03
(1) based on material dried lor 2 hours @ 105 deg-C <
(2) based on material ignited for 2 hours @ 1000 deg-C
(• • •) currently not a standard method
CAUTION: inhalation of synth«tie amorphous precipitated silica «ay irritate tho respiratory trtct.
Adequate ventilation and, «A«re dust occurs, a HIOSH-approved dust respjratw »« reconnended. Material
Safety Data Sheets are available on request. .
This product is •anufactured to conply with FDA requirements for Direct Food Additives Subpart E
—Anticaking Agents (21 C.F.R. § 172,480). and Subpart D--Specific Usage Additives: Defeating agents {21
This product'is manufactured to comply with FOA requirenents for Indirect Food Additives for Use Only as
Components of Adhesives (21 C.F.R. $ 175,105). for Indirect Food Additives for Use Only as Componentsof
PapeTand Paperboard (21 C.F.R. S 176,200, 21 C.F.R. i 176.210). for Indirect Food Additives for Use Only as
Cosponents of Coatings (21 C.F.R. f 175.300). for use as Basic Components of Single and Repeated Use Food ,
Contact Surfaces: Cellophane (21 C.F.R. § 177.1200). Rubber articles intended IFor repeated use (21 C.F..R. $
177,2600), and for Indirect Food Additives: Adjuvants and Production Aids tn Annmal Clue (21 C.F.R. »
178,3120).
Information herein is accurate to the best of our knowledge. Suggestions
are made without warranty or guarantee of results. Before using, user
should determine the suitability of the product for his inicended use and
user assumes the risk and liabilityon connection theremth. tfe mc: Synthetic Amorphous Prccipitilted Silica
-------
-------
APPENDIX B
1 Of 2
North America Silica Company
"c/o DEGUSSA CORPORATION
65 Challenger Road
Ridgefield Park, NJ 07660
Phone: (201) 641-6100
Fax:: (201) 807-3182
a joint vanture of
Oegussa Corporation and PQ Corporation
June 11, 1991
Mr. Alan Fine
U.S. ENVIRONMENTAL PROTECTION AGENCY
Technology and Substitutes Branch
Global Change Division
Office of Air and Radiation
401 M Street SW
Washington, DC 20460
Dear Alan:
Reference your work with the Center for Robotics and Manufacturing
Systems at the University of Kentucky, I've enclosed two Degussa
Corporation technical bulletins. These brochures "Forms Supplied
and Handling of Synthetic Silicas and Silicates" and "Experience
Gained in the Dust-Free Handling of Solid Materials in Powder Form
with Extremely Low Bulk Densities" may 'help you with your University
of Kentucky discussions. " -
Regarding the price of our two precipitated silicas that are being
used for the production of vacuum insulation panels, here is some -
general information:
Product
Bag Bags/ Pallet Pallet 48 ' Trailer Truckload
Weight Pallet Stacking Weight Quantity Price/Lb.
Sipernat® 22LS 25 30
FK 500LS 20 15
3X10
3X5
750
300
18,750
15,000
$.85
$1.12
Until your organization or one of the appliance manufacturers that
you may be working with, get to a point where they require direct
truckload or bulk delivery of our material, we would like to offer
the following: ..
We agree to sell Sipernat 22LS and FK 500LS as follows:
Sipernat 22LS
FK 500LS
$.65 per pound, any quantity, FOB our Louisville
Distributor William B. Tabler & Company.
$.75 per pound, any quantity, FOB our Louisville
Distributor William B. Tabler & Company.
Once someone moves past the scale-up -stages for this application,
we can work out the details of a contract price, stocking point, lead
time, bulk deliveries, etc.., etc.
-------
APPENDIX B
2 Of 2
North America Silica Company
a joint vtiyum of
Dtguisa Corporation and PQ Corporation
c/o DEGUSS.A CORPORATION
65 Challenger- Road
Ridgefield Park, HJ 07660
Phones (201) 641-6100
Fax.- (201) 807-3182
for engie« ps«
with your associates.
»
Sincerely,
pr h* '"
prices can also be discussed openly
"uestio»= «- "JT =f the above matters please gi
^..
Kenneth c. Cwick
General Manager
North America Silica Company
A Joint Venture of
T3eguasa Corporation
and PQ Corporation
KCC:hr
Enclosures
/026
CC:
J. Boggess, William B. Tabler Co.
J." SJstoff' SSS1*3?1 t9 De?ussa Corporation
R NK~«7 '* gussa CorP°ration
R. Niccol, Degussa Corporation
Ri Reich, NASILCO - PQ-VF
H. Strack, Degussa AG VTC-A
-------
APPENDIX C
1 Of 3
-------
APPENDIX C
2 of 3
PeabodyTecIank
Putting More Into Storage
With Bolted and Welded Tanks for Liquids
and Dry Products
At Peabody TecTank we're putting more Into :
storage. As a result, more storage Is going to
Peabcdy TecTank. Two modem plants produce
factory coated bolted and factory welded tanks for
both liquid and dry storage application*. The in-
dustries we servo often require tanks that meet
certain recognized standards and codes. Some of
these, routinely a part of our design and
fabrication, include FDA, BISSC. UBC, AISC.
AWS. API, NFPA, FM, EPA. and AWWA.
To.Meet Industry's Needs
Experienced sales professionals can assist you In
specifying the tank for your needs. Our engineering
staff, utilizing computer aided design, provides
tanks which are engineered to meet your special
retirements. Peabody TecTanlfs customer
service department can provide help during the
construction phase, including supervision or
complete erection service. This complete service
is at your disposal, whether your tank requirements
call for a large multiple tank installation or only one
tarh."
in Demanding Applications
A range of sizes and factory coatings are available
to tackle most industrial applications. When storing
bulk solids, interior coatings are selected to protect
against corrosion and abrasion. Exterior coatings
are selected to provide protection against tr»»
effects of weather and the tough environment found
in industrial settings. Tanks may be designed to
accommodate most untoding systems; they may bo
hoppered or flat bottom, skirted or on structure.
They may be designed for funnel (tow or mass ftow
and may store a variety of Industrial materials such
as minerals, chemicals, plastics, grains, and
processed foods.
Experience, service. quality...the reasons our list
of repeat customers continues to grow. Our
reputation is your guarantee. When you nead
storage, let Peabody TecTank put more into
storage for you.
-------
C
3 of 3
Foods
Our Storage tanks for food products are used
extensively in the milling, baking and food
processing industries. Peabody TecTank's FDA
approved coatings are often specified by major
food companies. Large capacity tanks are
available to store up to 750,000 bushels of
unprocessed grains.
Minerals
Whether it is iron powder a! 250 Ib/ft3, barite at
160, lime at 80 or silica gel at 6, Peabody TecTank
can provide the storage. Bolted tanks are available
in sizes up to 130 feet in diameter and in heights
up to 129 feet. Welded tanks are available in sizes
to 14 feet in diameter and 85 feet high.
Peabody TecTank's bolted structures allow
access for truck or railcar toadout. Spread leg
welded tanks offer an economical drive trhough
loadout design. Our experience and engineering
give us the ability to provide special applications for
storage.
Chemicals and Plastics
Our factory applied coatings make our bolted
and welded tanks extremely popular in the
chemical and plastics industries. The high cost of
many of these products and the problems resulting
from contamination make a superior coating
system a must. Extensive use by major producers
and the many processors make this one of our
largest markets. Tanks are often supplied through
systems companies who specialize in a complete
material handling package.
Our capability to design and fabricate a variety
of hoppers and outlets allows our tanks to fit any
material handling system.
-------
-------
APPENDIX D
NEOTRON SYSTEM
SERIES 1900
Convenient All-Electric Model
The Neptron Series 1900 filler offers the convenience of an
electromechanical clutch brake without compromising the
high operating standards of Neotron System fillers. The all
electric Series 1900 is ideal as a replacement filling head
on form/fill and seal machines, as. standard equipment on
automatic filling machines, or as semiautomatic filling
machines. A high-cycle-life clutch is also availavle as an
option. i
NEOTRON SYSTEM
SERIES 1990
Heavy Duty Model For Difficult Fills
The Neotron Series 1990 filler is designed for use in heavy duty
applications where the type of product and/or the fill size offer
unusual difficulties. The rugged Series 1990 is built with a clutch
brake rated at 95 foot pounds of torque and a five-horsepower
drive motor.
-------
APPENDIX E
Automatic Vacuum Packaging System
GL-26
Features
•Output
Up to 40 bags per minute
•Weight of Bags
2 oz. to 5 Ibs.
•Programmable Logic
Controller
•Finished Bag Types
Square bottom qussetted
bags with square or
cathedral top
•Packaging Material
Multi-ply Laminates
•One Machine Operator
•Net Weigh Scales
fres-co®
SYSTEM USA. INC,
Options
•Degassing Valve .
•Easy Open
•Reclosure Tape
•Tin Tie
•Top and/or Bottom Flap Hot
Melt
•Double Folding of Bag Top
Flap
•Hot Stamp Imprinter
•Gas Flush
•Vacuum Compensated With
Inert Gas
Dimensions
•23'(L)il3'(W)rH'(H)
•Wieght
17,000 Ibs.
-------
APPENDIX F
1 Of 2
-------
APPENDIX F
2 of 2
MODEL DESCRIPTION
APPLICATION
SPEED
PER/MIN
OPTIONS
PV2000-CM
PV2000-SA
SO-1
40U-PF
4024-1
, 4044-1
t
4044-CB
4054-2-CB
»
4054-4
4104-4
4049-4A
4049-A
TRACKER/Conveyor Mount
TRACKER/Stand Alone
PLASTIC BOTTLE
INSPECTOR
PUFFER
LOW SPEED TAPTONE
HIGH SPEED TAPTONE
AUTOMATIC LINE
TAPTONE FOR VACUUM
TESTING FOIL
PACKAGES
AUTOMATIC CASE
TAPTONE FOR VACUUM
TESTING FOIL
PACKAGES
AUTOMATIC CASE
TAPTONE
AUTOMATIC SWELLED
CAN DETECTOR
CASE SCANNER
PORTABLE TAPTONE
Check vacuum and pressure in cans and jars
without head space.
Checks leaks in plastic bottles with or without foil
inner seal.
Plastic cups and trays with foil membrane lids.
Can or jar lines where headspace is available
and speeds do not exceed 350 cpm.
Can or jar lines where headspace is available
and speeds exceed 350 cpm.
Vacuum bagged products from such systems
as SIG VAC.8 where a "brick" results.
Same as 4044-CB. for testing products in trie
sealed case. Inspection grade conveyor
included.
Warehouse or distribution center testing of
product with headspace in the sealed case.
Inspection grade conveyor included.
Warehouse or distribution center testing of
product with or without headspace in the sealed
case. Inspection grade conveyor included.
Subjective/manual testing of cans/jars with clear
headspace in the case or individually.
Subjective/manual testing of cans/jars with
clear_headspace.
500
120
300
Max speed
at least
350 cpm
1800 cpm
Contact
Factory '
50 cases
50 cases
50 cases
N/A
N/A
PV2000-DOData Output
PV2000-PS Pedestal Stand
PV2000-RK Retrofit Kit
Oscilloscope Housing
903-Spare Parts Kit
404-CR Crank
. 4024-CK Changeover
903-2 Spare Parts
404-CR Crank
4044-CK Changeover
405-DL Datalogger
903-4 Spare Parts
404-CR Crank
405-DL Datalogger
903-7 Spare Parts
405-SM Spray Marker
405-DL Datalogger
405-R Rejector
903-8 Spare Parts
903-5 Spare Parts
40S-SM Spray Marker
405-DL Datalogger
405-R Rejector
405-SCD Swell Can Del
4054-CK Changeover
405-SM Spray Marker
405-R Rejector
903-6 Spare Parts
4049-4H Case Head
4049-S Single Head
N/A
-------
APPENDIX 6
1 Of 3
VACUUM PACK INSPECTION SYSTEM:
The vacuum pack inspection system(s) ware designed and buill- by
Babcock & Wilcox, CIM Systems, to inspect vacuum packed insulation
, n
panels used in the appliance industry. The system reporrs e
actual vacuum in the pack on a monitor for operator disposition.
The system utilizes a custom designed vacuum chamber, a high
precision pressure /vacuum transducer, and a optical laser
triangulation sensor in order to measure the vacuum in the packs.
The chamber and sensor mounting design enables many different
sizes of packs to be inspected by the system. The control siystem
utilizes an IBM compatible computer and B&W software to lead the
operator through the inspection process. The operator initiates '
tne inspection process from the main menu and places a pack in the
chamber. Once the lid is closed, a vacuum is pulled on the
op*ical lasar sensor, which is contained inside the
vacuum chamber, is focused onto the surface of the insuljitiem
pacx. When the vacuum inside the chamber reaches the sazie vacuum
level of that inside the insulation pack, the insulation pacsk
wrapper expands. The laser sensor detects the deflection
(expansion) of the insulation pack and triggers the computer to
read the vacuum transducer at the time of deflection. This
reading is an indication of the actual vacuum level insicle the
»**•*•• ia&ion poGjC •
ADDED FOR AUTOMATED HANDLING:
na,^Js a manual system with respect to thai handling
it Si I, and unloading) of the insulation panels, and initiation
of the functions via the terminal. The vacuum chamber design
^o*h2e5 gM springs to assist the operator in opening and closing
the heavy cover similar to the liftback of an automobile. This
design can easily be modified to accommodate robotic handling
where the robot would load the panels into the chaaSJ^SiSLing
for example, vacuum suction pads for the end effector, and
"™^nicate.with toe vacua* system computer to start and stop the
processes without operator intervention. The vacuum system
software, with some modification, can then perform the inspection
2^?-aU*0matt?a;Lly Where Ule onlv additional hardware required to
fa™^«%HUllY aut°mai:ic operation would be to replace ?he gas
springs with solenoid controlled air cylinders. • ,
tnrou
-------
APPENDIX G
2 of 3
the vacant: porrion of the chamber. Therefore, this time can
be greatly" reduced (approaching the 10 second range) if the
chamner(s) can be sized to be only slightly larger than the
packs to be inspecred. Loading, closing, bleeding, opening,
and unloading* (the remaining steps of the cycle) only require
a cumulative of about 10 additional seconds). In order to
supporr higher througnpur requirements, several vacuum pack
inspection systems can ba utilized per robot.
Babcock 5 Hilcox is experienced with custom automated robotic
handling and inspection systems, and can provide both the
automated version of the vacuum pack inspection systems or the
entire turnkey system, inclusive of the robor, to the end users.
-------
APPENDIX G
3 of 3
-------
-------
APPENDIX H
CYTOOP
Automatic, All-Electric
Plastic Strapping Machines for a
Variety of Bundling, Carton Glosing
and Unitizing Applications
ITS PORTABLE!
The ASM Series feature swivel
casters for machine portability
and a jacking leg for operational
stability. Combined with its "plug
in and operate" electrical require-
ments, the machines can be eas-
ily moved about your production
area as needs change.
SIMPLE JAM CLEARING
Unlike most competitive models,
the ASM's feature a simple, very
accessible jam clearing system.
A pushbuttom opens the strap
track allowing the operator to
remove trapped strap. Another
pushbutton cycles the sealer, cuts
off the old strap and re-feeds.
DUAL PRESS BAR OPTION
A pneumatically powered dual
press bar option for some track
sizes is available with up to 120
Ibs. of compression to help pre-
settle package contents, close
telescoping cartons and stabilize
packages during the strapping
operation.
POWERED CONVEYOR
AVAILABLE
The ASM-1A features powered
belt conveyor with hinged top
plates and photo-eye controls for
PC controlled application of one
or two straps. The ASM-1 AA with
adjustable table top and external
dispenser is available with either
roller top or belt conveyor.
-------
-------
APPENDIX I
1 Of 2
Adjustoveyor
extendable conveyors offer
many MONEY-SAVING benefits
When you use the job-proven Adjustoveyor you cam expect these
benefits to your dock and whorehouse operations::
• Labor product!viy improvement of 500% in most applications
• Reduced turnaround time for trucks, improving their on-the-road
productivity
• Reduced product damage, resulting in fewer claims, and improved
product quality
• Improved dock space utilization through the avoidance of staging areas
• Smooth uninterupted flow to or from the truck
,[
These operating benefits translate directly to cost reductions which easily
allow the Adjustoveyor to leap over those 40% after-tax corporate hurdle
rates used for capital bugeting decisions. In fact, many applications result in
a payback of less than one year! If the productivity improvement of your
overall system is one of your objectives, the Adjustoveyor is your best
investment.
-------
APPENDIX I
2 of 2
i
-------
1 of 2
LPA/80T LPA/86T
THERMAL LABEL PRINTER/APPLICATOR
The LPA/8QT and LPA/86T are heavy duty industrial direct thermal
printer/applicators which create high quality barcodes and variable
text on demand. The LPA/80T can process up to a 4" wide label and the
LPA/86T up to 6" in width. Labels are smudge proof and oil and water
resistant. Print rate is up to 4" per second. The thermal printing pro-
cess uses no ink or ribbon. Images are produced on temperature sen-
sitive label material as it moves past a stationary print head. Dual
microprocessors control printing and labling functions. Advanced
programming includes graphic data base systems, free format
systems and custom software packages. Each printer/applicator in-
cludes stand, control box and product detection devices. Already pro-
ven by years of service, the LPA/80T printer/applicators provide a stan-
dard in high speed in line thermal label applications.
LORD LABEL SYSTEMS, INC.
(214) 647-2504
-------
APPENDIX J
2 of 2
LPfl/SOT & LPfl/86T SP€CIFICflTIONS
Head Dlminsion
Length 15 5/16' (40)
Width 13V4 (35)
Height 22% (57)
(3974) (ADJUSTABLE) -f\f
_n
(107)
Applicator
• Drive Motor Vu HP gear motor, 115 VAC
• Label Control: Photoelectric sensing, electric
and clutch
• Application Method: Air cylinder actuated tamp pad or
high pressure air blast
• Construction: Anodized aluminum and stainless steel
Label Sizes:
LPA/80T 4 '/•" wide x 4" repeat (111mm x 102mm) max-
mum standard size. Larger sizes available at extra cost.
UPA/86T 6%" wide x 4" repeat (165mm x 102mm) max-
imum standard size. Larger sizes available at extra cost.
Printer
• Method: Ceramic thick film thermal print modules.
• Print Pattern: LPA/80T single row of 300 print points
approximately 76 dots per inch. Dot dimension 0.013"
(0.33mm). Print field width 3.9" (99mm).
LPA/86T single row of 450 print points, approximately
76 dots per inch. Dot dimension" 0.013" (0.33mm). Print
field width 5.9" (150mm).
• Rate: 3" (76mm) per second standard. Rate may vary
depending on application. •
Electronics: .
• Enclosure: NEMA 12, water resistant; may be remote
mounted.
• Control: Z80 Microprocessor CPU with solid state
memory .and control chips. Label format, character
generator, fixed label data and print routine are stored
• in plug-in EPROM's.
• Display: 16 Character LED display indicates the status
of the printer/applicator. Test functions are
commanded from a 16 button keypad and read out on
the display. In addition, error messages are displayed
to pinpoint mechanical malfunctions or input data
faults to minimize troubleshooting time.
Data Input:
The unit may operate as a stand-alone printer/applicator'.
by means of the integral keypad or an optional, terminal
using on-board programming. Data input can-come from
any computer output device with an RS232 serial inter-
face, such as an electronic scale, barcode reader or host
computer.
Label Material:
Thermal sensitive paper: smudge proof, oil and water
resistant. Paper is available for infrared scannable bar-
codes (900 nanometers).
Label Formatting:
Available barcodes are interleaved 2 of 5, Code 39, UPC
and EAN. Other barcode structures can be provided. For-
mats are designed to suit the application. Several variable
fields can be provided within a format. Character sizes
can be up to 1.0".
Power Required:
115 VAC, 10 amp circuit
Air Required:
60 to 80 psi filtered (15 micron), dry air at V» CFM
LORD meet SVSTCMS, INC.
1200 Ave. H East
Arlington. TX. 76011
(214) 647-2504
1-800-433-5310
MEMSERCOMWNY
Authorized Distributor
RecommwxiM «nd dotribuMd by:
® Zellerbach
1101 tnduttntl Blvd
Louisvilt* Kentucky 4Q219
Ttfwnorw, 5Q2-964-64S1
-------
APPENDIX K
1 Of 3
Degussa
Degussa
Corporation
Material Safety Data Sheet
I. PRODUCT INFORMATION
Trade Name: FK« 500LS Precipitated Silica
Chemical Name: --. Synthetic amorphous silicon dioxide hydrate
CAS Registry No. : 112926-00-8
II. SUMMARY OF HAZARDS j
May cause eye and skin irritation. Causes irritation to lungs and
respiratory tract. If inhaled, immediately remove to fresh air. In <=afe
of eye contact, immediately flush eyes with plenty of water for at least 15
miautes, call a physician. Flush skin with water. See Section V for
additional information on health .hazards.
III. HAZARDOUS INGREDIENTS . !
A new CAS registry number has been assigned to Amorphous Precipitated
Silica which will differentiate it from crystalline forms of silica. . .The
-new CAS number is as shown, 112926-00-8, changed from 7631-86-9.
Name CAS No. _$_ \
Amorphous silica 112926-00-8 91% 10mg/m3
Not listed by OSHA, NTP, or IARC as a carcinogen.
IV. CHEMICAL AND PHYSICAL PROPERTIES .
APPEARANCE: Dry, white powder SPECIFIC GRAVITY: N/A
SOL. IN WATER: Negligable VAPOR PRESSURE: N/A
i
EVAPORATION RATE: N/A BOILING POINT: N/A
VAPOR DENSITY: N/A pH: ; N/A
150 Spnngside Dnve Suite 11C Akron OH 44333 216-668-2235 FAX 216-668-3846
-------
APPENDIX K
2 of 3
Degussa
Degussa
Corporation
V HEALTH HAZARD DATA & FIRST AID PROCEDURES
Amorphous silica, unlike crystalline silica, is considered biologically
benign.
EYE CONTACT:
SKIN CONTACT:
INHALATION:
CHRONIC HAZARDS:
SIGN AND SYMPTOMS
OF EXPOSURE:
May cause eye irritation.
May cause skin irritation.
Causes irritation to lungs and respiratory tract.
No known chronic hazards.
Sneezing and dryness mucous membranes'(inhalation)
May cause dry, chapped skin (skin exposure). May
cause redness and tearing (eye exposure).
MEDICAL CONDITIONS
AGGRAVATED BY EXPOSURE: Skin diseases (dermatitis), asthma and lung
diseases.
VI. EXPOSURE CONTROL MEASURES
GLOVES:
EYE PROTECTION:
Tightly woven cotton, plastic, or rubber.
Chemical goggles are recommended.
RESPIRATORY PROTECTION: Use NIOSH approved dust respirator where dust
occurs. •
ENGINEERING CONTROL:
Use with adequate ventilation.
OTHER PROTECTIVE
EQUIPMENT: Safety shower and eyewash fountain should be within
direct access.
PERSONAL HYGIENE:
Avoid breathing dust. Wash thoroughly after
handling.
VII. REACTIVITY DATA
STABILITY:
CONDITIONS TO AVOID:
INCOMPATIBILITY:
HAZARDOUS
DECOMPOSITION PRODUCTS:
Stable
N/A
N/A
None
150 Spnngside Dnve" Suite 110 Akron OH 44333 2I6-668~-2235 FAX 216-668-3846"
-------
APPENDIX K
3 Of 3
Degussa
Degussa
Corporation
Vjll. FIRE AND EXPLOSION HAZARD DATA
FLASH POINT: Noncombustible
FLAMMABLE LIMITS: , N/A
EXTINGUISHING METHOD: -' N/A
"FIRE FIGHTING
INSTRUCTIONS: N/A
UNUSUAL FIRE AND
EXPLOSION HAZARDS: None
IX. ENVIRONMENTAL & DISPOSAL INFORMATION
ENVIRONMENTAL HAZARDS: No known adverse effects. Not a listed
toxic chemical undetr SARA Title III, §302,
§304, or §313.
SPILLAGE: Sweep, scoop, or vatcuum discharged
material.
WASTE DIS1OSAL METHOD: Landfill according to local, state, and
-federal regulations!. Not a hazardous
waste under RCRA regulations.
X. SUBSTANCES FOR WHICH STANDARDS HAVE BEEN SET | :
COMPONENT: Amorphous Silica/Percent: 91% as SiO2
OSHA Exposure Limit: 20mppcf (5mg/m3) SiO2 Respirable dust. 8 hour
time weighted average.
TLV*: 10mg/m3 Total dust; 5mg/m3 respirable.
EXPOSURE ANALYSIS METHODS: NIOSH Manual of Analytical Methods. 3rd ed. ,
Method 7501, (1984).
XI. SOURCE OF INFORMATION !
John G. Blumberg, Product Safety Coordinator, 10/19/89"
150 Spnngside Drive Suite 110 Akron OH 44333 21-6-668-2235 FAX 216-668-38415
-------
-------
APPENDIX L
UNIBILT«ENCLOSED TRACK CONVEYORS
The Unibilt Division of the Jervis B. Webb Com-
pany was created in the early 1960s to provide
manufacturers of all types with a multi-purpose
enclosed track conveyor. Designed and built
upon the principles of increasing productivity,
Unibitt*Enctosed Track Conveyors incorporate
reliability, economy, flexibility and simple instal-
lation either by weldng or bolting.
Unibilt Enclosed Track Conveyors contain many
features normally associated with conventional
l-Beam conveyors, plus features that are unique
to this type of system, such as:
1
Completely enclosed chain helps prevent ac-
cidental contact with moving parts.
2
An enclosed track helps prevent contminatfon
from reaching the chain or track bearing sur-
faces.
3
The universal link chain is designed to provide
maximum flexibility in all directions, featuring
easy assembly or disassembly with simple
hand tools.
4
The enclosed track design helps provide pro-
tection from the elements for the chain and
other moving parts.
5
Shorter radius curves and closer spacing of
curve tangents are possible due to the univer-
sal link chain.
I 6
Easier installation...no bulky roller turns or trac-
tion wheels to erect.
7
Caterpillar-type drive units provide flexility for
all enclosed track power requirements in a
single compact package.
Qualified local distributors and regional Unibilt
representatives are available to assist you in alt
phases of a conveying system: design/
engineering, plan layout, installation and
application.
Unibitt Enclosed Track conveyors offer a sys-
tem that has applications in both simple and .
complex handling problems. . . '
-------
-------
APPENDIX M
1 of 2
GMranuc Robotics
Basic Descrition
The GMFanuc Model S-500 is a six-axis,
simultaneously controlled, articulated coordi-
nate, electro-mechanicaily operated robot. It is
controlled by the KAREL® Robot Controller
which features user-friendly programming
language and built-in card slots for MAP and
integrated Vision Boards. The S-500 has an
exceptionally large work envelope allowing it to
handle many applications.
Features
• 6 axes of motion.
• 15 kg (33 Ibs.) payload.
• Excellent path repeatability ±0.25mm (±0.010").
• 300° base rotation.
• 2700mm (106.3") horizontal travel.
• 4000mm (157.5") vertical travel,
• 1500mm/sec (597sec) max. sealing speed.
• Slender arm design.
• High speed option on axis 6 of 600°/sec.
• Analog output signal proportional to tool
tip velocity. • •-:*
• Precision gears and sealed-for-life bearings.
• Compact FANUC AC servo motor with
absolute pulse coders.
• High efficiency, compact drive train.
•Maintenance dust covers and external
lube fittings.
S-500
S-500 Applications
• Sealing
• Material Handling
• Deburing
• Machine Load/Unloading
• Parts Transfer
• Welding
Customer Benefits
• Large work envelope for wide
application range.
• Precise path control and
repeatability allow consistent
and predictable sealing beads.
• High speed wrist option to further
minimize cycle times.
• Analog control output signal
allows consistent bead
widths throughout varying
path geometries.
• Reliable and precision
electronic and mechanical
components mean longer
MTBF and lower production
downtime.
Maintenance is quick and
easy with dust covers and
external lubrication on
fittings.
•Safety limit switches pro-
vide overtravel protection
and a safe environment for
workers.
-------
APPENDIX M
2 of 2
S-500 Dimensions
Capacities
Spcodeacons subject to efange without notice
- Robotics
GMFanuc Robotics Corporation
2000 South Adams Roao
Auburn Hills. Ml 48326-2800
Uterature Reauest 1-800-47-ROBOT
Phone (313) 377-7000 Fax (313) 377-7366
GMFanuc RoDotics Canada. Ltd.
6395 Kestrel Road
Mississauga. Ontario
Canada L5T 1Z5
Mam OHice 1416) 670-5755
GMFanuc Robotics Europe GmbH
Heinncn-Heru-Strasse 16
P.O. Box 3345
D-4006 Erkratn 1. West Germany
Main Office 211-20060
:K • :e sis s^c ec: ro cr-anqs.-. TOUI -KM ce
-------
APPENDIX N
1 Of 3
Automatic Density Control
The Nordson 170 Series
Processors feature a simple, re-
peatable one-step setting for
maintaining consistent foamed
material density. A density sensor
is located in the filter/density con-
troller, which automatically moni-
tors and adjusts the gas/adhesive
mix. ft is capable of achieving
density reduction to within ±2.5
percentage points of the pre-
determined value.
Sequential Startup
In sequential startup, the hose heat-
ers are activated only after the pro-
cessor approaches operating temp-
erature, and the gun heaters are
phased in when the hose channels
are nearing their setpoints. This
staged warm up process minimizes
char formatbn. lowers energy con-
sumption, and reduces maintenance
costs by minimizing stress on seals
and other sytem components.
Wid« Selection Of Gun* And
Hoses
Full)' compatible with over 100
Nordson RTO-controlled guns,
Series 170 Processors can meet the
requirements of almost any applica-
tion. In addition to standard single-
module and mufti module guns, 170
units can be equipped with low-pro-
file guns, zero-cavity guns, water-
resistant guns, spray guns, and a
variety of handguns. Both automatic
and manual hoses are available for
the 170 Processors, including stan-
dard hoses, water-resistant noses,
and the new Nordson biaxial hoses.
With! the supply
and return pas-
sagos combined!
in the same
bundle, biaxial
hosos are very
cost effective,
and their
superior ma-
neuverability
makes them
especially useful
in hadgun applications.
Additional features
Many other beneficial features are
standard on FoamMelt 170 Proc-
essors. They include:
• Quiet, variable-speed DC motor
• System Ready Delay to prevent
pump operation before material in
the applicator reaches ope rat ing
temperature
• O-i'ing fittings on manifold, hoses.
ami guns
• Filler/density controller, drain
valve, and pressure control valve
front mounted for easy access
• Contacts for customer-supplied
inputs and outputs
• Quick electrical disconnects on
hoses and guns
• Comprehensive overtemperature
protection with continuous moni-
toring of temperatures on all zones
• Advanced self-diagnostic capability
-------
APPENDIX N
2 of 3
Nordsorr Foam Melt
170 Series Processors
• Specifications Model 170T
Type of System Circulating, gear pump
Holding Capacity 35 Ib
Melt Rate' - 27 Ib/hr
Continuous Delivery Rate2 55 Ib/hr
Independent Temperature Control Tank, manifold, 6 hoses
4 guns
Temperature Control Stability ±1°F
Temperature Control Method PID3
Temperature Range (All Channels) 150°F-450°F
Model 170H
Circulating, gear pump
60 Ib
Exceeds CDR (see next line)
55 Ib/hr
Reservoir, grid, hopper, manifold,
6 hoses, 4 guns
±1°F
PID»
150°F-450°F
Electrical Service • 220-240 VAC, 50/60 Hz, 1/3 0 220-240 VAC. 50/60 Hz 1/3 0
380Y/220 VAC. 50 Hz, 3/1 0 380Y/220 VAC, 50 Hz, 3/1 0
Amperage* 50 A max.
Maximum Power Requirement9 5,000 wans
Viscosity Range 1 ,00i) to 50,000 cps
50 A max.
11, 000 watts
,. -1,000 to 50,000 cps
Gas Supply Industrial grade carbon dioxide Industrial grade carbon dioxide
or nitrogen (30-50 psi) or nitrogen (30-50 psi)
Weight 350 Ib
Hose Ports 4
350 Ib
4
Air Supply • 90-150 psi of dry, filtered air 90-150 psi of dry, filtered air
-- Note 1: Actual rates can vary depending on adhesive
viscosity and other characteristics.
Note 2; Based upon a 50% density reduction.
Note 3: PID stands (or proportional/integral/derivativa.
Note 4: Includes applicator and total allowable hoses.
guns and auxiliary devices.
Note 5; Does not include power requirement of ^
guns and hoses.
•~ir -in
nn~
f£2=&
Sin. I
-|L-
^ fjplYEARl fft RH't**"'"
jj lfc~--C SiSJSf^fSaaSi
SiJCuLujuuS On Selected Components
u ' '•• •
30.0 in.
Nordson
Nordson Corporation
350 Research Court
Technology Park/Atlanta
Norcross. Georgia 30092
Toll Free (800) 241-8777
11990 Horovxt Corporanon 306-18-777 luueo 6/90
-------
APPENDIX N
3 Of 3
Unsurpassed Design,
Unmatched Performance
Advanced
Application
Technology
FoamMelt® 170
Processors
empby the most
advanced hot
melt application technology
available - the patented Nordson®
FoamMelt Process. First Intro-
duced in 1981, the FoamMelt
Process dramtically improves the
performance of most hot melt ad-
hesives by mixing them with an
inert gas. Typical benefits include:
• Increased adhesive mileage
• Longer open times
• Faster set times
• Increased penetration
• Improved gap-filling capabilities
• Increased bond strength
The degree of improvement in
adhesive performance will depend
upon application conditions and the
adhesive used. While all of the
benefits of foamed adhesives will
not be experienced in every
application, the benefits in most
applications will be significant.
The FoamMelt 170 Processors
The 170 Series FoamMelt Proces-
sors are designed to provide ad-
vanced automation and pinpoint
temperature control in a system that
can melt and deliver up to 55 Ifa/hr of
high-viscosity foamed material. The
series includes two types of proces-
sors, a unit with a tank (the 170T),
and a unit with a heated hopper
and grid for high performance ad-
hesives. (the 170H).
The patented gear pump con-
tains two stages. The first stage
(the top gear set) pumps only
melted adhesive. The second
stage, which contains larger
gears,, forces inert gas into solu-
tion with the adhesive.
Highly Automated Control
System
A sophisticated microprocessor-
based controller directs the opera-
tion of FoamMelt 170 Processors.
Among the functions that take place
automatically after initial setup are
sequential startup, temperature
control, density reduction, system
monitoring, self-diagnosis, and sys-
tem shutdown when fault conditions
are not corrected.
State-Of-The-Art
Temperature
Control
RTD temperature
sensors and a PID
(proportion/
integral/
derivative) control system
combine to maintain the
temperature of s-stem components
within ±1 ° F of setpoint. With 16
individual-heating channels,
FoamMelt 170 units can control the
temperature of up to four single-
module or multi-module guns, six
hoses, the manifold, the reservoir,
the grid, and the hopper. On 170T
units the tank is controlled instead
of the reservoir, grid, and hopper.
Mounted on a swivel arm at optimum
viewing height, the 170 Series control
panel is designed to cut training time,
reduce operating errors, and minimize
downtime. All controls and indicators
are dearly tabled and grouped accord-
ing to function. Separate digital display
windows provide quick access to system
pressure, gas pressure, pump RPMs,
and temj^eratures on all zones. The
temperature window also displays error
messages that aid in troubleshooting
the unit.
i ne temperature
control section
of the operator
panel incorpo-
rates a variety of
useful features:
• Digital Readout
• Ability to scan the
temperatures on all zones in
sequence (SCAN) or on one zone
continuously (FREEZE)
• Capability of displaying actual or set-
point temperatures on all zones
• Ability to display temperatures in either
•F'or.'C
• Ability to set all temperatures to the
same setpoint simultaneously (SET
ALL) or .enter different setpoints on
each zone
Integrated Run-Up Control
By automatically adjusting system
pressure as production speed varies,
Run-Up control keeps bead thick-
ness constant. With Run-Up Control,
Nordson FoamMelt 170 units produce
more uniform bonds, minimize
product waste, and further reduce
adhesive consumption.
Large-Bore Manifold
Larg e-diameter flow pathways
permit the use of high-viscosity
materials and allow higher flow rates
with reduced fluctuations in line
pressure during demand cycles.
Larger diameter hoses may be used
with the 170 Series units to improve
material flow and reduce system
pressure drops.
-------
-------
APPENDIX O
1 Of 4
February 20, 1992
University of Kentucky
Center for Robotics and Manufacturing Systems
College of Engineering
Lexington, KY 40506-0108
Attention: Mr James M. Waldron P.E. •
Subject: Advanced Refrigerator Manufacturing System
Dear Jim: • ;
This letter is in response to your request for our review of a
portion of your advanced manufacturing system for the
production of . a new low energy refrigerator.
wt+>-t0 *** portion °f the Project that has to do
with the application of "new age" ir^ulating panels to the
inside of the case and doors, and the back:side of the plastic
liner. Our comments and responses will address those separate
areas.
1- Application of hot melt spray adhesive \ •
We feel that two (2) robots will be adequate to .spray the
required areas at the anticipated line rate of 200 cases-.
per hour - 18 seconds.
The equipment required in this area is as follows:
2-BMFanuc S500 robots
2-2'risers
2-adhesive dispensing systems
incl dual nozzle setups
2-stop,square and meter stations
in the case line conveyor
Total
Installation of liners into~cases
Each Total
* 100,000 * 200,000
2,OOO 4,OOO
15,OOO
3,OOO
30,OOO
6,OOO
.* 240,000
We feel .that three (3) robots will be sufficient to insert
the different panel sizes into the case as it
.4858 Provident Drive
Cincinnati, OH 45246
Phone: (513) 860-4299
Fax: (513)860-4587
-------
APPENDIX O
2 Of 4
University of Kentucky
Page 2
*•?''
progresses down the line. We anticipate handling two
parts at a time with the panel delivery conveyors arranged *
a little bit differently than your concept. Rather than
having a conveyor at the 3 o'clock and the 9 o'clock
position for parts 1 and 7,we would propose that those two
conveyors lie along side of each other at the 3 o'clock
position.The long arm of ,the S500 robot could reach over
both conveyors to access both parts in less time than
swinging over to the 9 o'clock position for each cycle.
We have not done any conceptualising on the material
handling that could be used to carry the panels from the
delivery trucks or warehouse to the part delivery
conveyors. We are assuming that the panels will be
unbanded and placed onto the panel delivery conveyors
manually. We are assuming a stack height of 2-3'.
The equipment required to install all 6 panels (four
different sizes) at three work stations is:
Each Total
3-GMFanuc S500 robots * 1OO,OOO * 300,000
3-2'risers 2,OOO 6,000
3-du,=>l end-efff'tors ,, 6, OOO 18,000
3-stcrp, square and meter stations ' 3,OOO 9,OOO
in the case conveyor
1-central vacuum system 5,000 5,000
6-panel delivery conveyors- 3,000 - 18,000 ;
S'roller
6-stop,square,and meter stations 2,OOO 12,OOO
in the panel conveyors
Total * 368,000
3. Affixing panel to back side of plastic liner
This operation is to be done on another separate but
merging line. Since only one panel is being applied,' it
is envisaged that a single robot fitted with a special
dual purpose end-effector could do the application of the
adhesive as well as present the panel to the liner.
The equipment required here is as follows:
Each ' Total
1-BMFanuc S50O robot $ 10O,OOO * 10O,OOO
1 -2' r i ser 2, OOO 2., 000
1-dual purpose end-effector, 6,OOO 6,000
spray and mat'1 handling
1-adhesive dispensing system 15,OOO 15,000
-------
APPENDIX O
3 of 4
University of Kentucky
Page 3
I—stop,square and meter station 3,000 3,OOO
in the liner conveyor -
1-panel delivery conveyor 3,OOO 3,000
8* roller ~
1-stop,square and meter station ' 2,000 2,000
in the panel conveyor ________ •
Total * 131,000
4. Assembly of panels to freezer door and main door
We are assuming that the door set is moving down the
assembly line in matched sets and is properly fixtured
when it is stopped at the robot assembly station.. Since
the door panels are expected to be the same si?e (two for
the main door and one for the freezer docir) only one panel
delivery conveyor will be needed. Two robots ought to be
sufficient to do both the spray adhesive and material
handling if special dual purpose end-effectors are used.
The two robots would share the same panel delivery
conveyor but each would have the ability to spray adhesive
as well as handle the panels; i.e. the panel (s) will
already have been picked up by the end- effector and be
. moving with the end-effector while the adhesive is being •
applied.Once applied the end-effector is turned over and
the panel(s) are applied. -
The equipment required her is expected to be as follows:
'Each Total .. .
2-GMF S-500 robots * 1OO,OOO * 200,OOO
2-Dual purpose end-effectors 6,OOO 12,OOO
spray and mat'1 handling
2-Adhesive systems 15,OOO 3O,OOO
1-Panel delivery conveyor-8 ft 3,OOO 3,OOO
1-Stop,square and meter station 2.OOO 2.OOO
Total ; * 247,000
Summary:
The total estimated cost is:
1. Application of hot melt spray adhesive * 243,OOO
2. Installation of 6 panels into case ; 36B,OOO
3. Affixing panel to back side of liner 131,OOO
4. Affixing 3 panels to freezer and main 247,000
door sets _ ',
5. Project management and installation ! 50,OOO
supervision . _
Brand Total , * 1,O39,OOO
-------
APPENDIX 0
4 of 4
University of Kentucky
Page 4
4
We have reviewed these numbers with Tom Zito of Technical
Equipment in Cincinnati, OH, and Bob Borgmann of Nordson in
Florence, KY, who feel that they are adequate enough to be
in,ciyded.«in you»*.report. Needless to say Jim, we are all
looking forward to working with you and others on this project
in the future.
I should point out Jim, that although we have followed a
robotic scenario in this proposal, it is possible to come up
with other automation alternatives in areas where the prices
might be a little high for justification. This could be the
case at the liner area and the door area.
Thanks again for giving us the opportunity to participate
in your project.
Sincerely,
REMTEC, INC.
Ci arlie Gaynor
Vice Preside--t
Sales 8c Marketing
CG/kjh
-------
-------
------- |