United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standard*
Research Triangle Park NC 27711
EPA 4S3(R-94-017
February 1994
Air
Alternative Control
Techniques Document:
Surface Coating of
Automotive/Transportation and
Business Machine Plastic Parts

-------
                                           EPA453/R-94-017
  Alternative Control Techniques Document:
Surface Coating of Automotive/Transportation
       and Business Machine Plastic Parts
                   Emissions Standards Division
                U.S. Environmental Protection Agency
                Region 5, Library i?|-.•?'.')
                77 West Jackson R;v;   <;!, 12th Floor
                Chicago, IL
              U.S. ENVIRONMENTAL PROTECTION AGENCY
                    Office of Air and Radiation
               Office of Air Quality Planning and Standards
              Research Triangle Park, North Carolina 27711
                       February 1994

-------
                       TABLE OF CONTENTS

Section                                                    Page
1.0     INTRODUCTION  	   1-1
   1.1   BACKGROUND	   1-1

2.0  PROCESS DESCRIPTION  	   2-1
   2.1   INDUSTRY OVERVIEW	   2-1
   2.2   CHARACTERISTICS  OF PLASTIC  PARTS  	   2-2
        2.2.1   Characteristics  of Substrates   	   2-8
        2.2.2   Plastic  Fabrication  and Molding   	  2-11
            2.2.2.1 Casting  	  2-11
            2.2.2.2 Compression Molding  	  2-11
            2.2.2.3 Injection Molding  	  2-12
        2.2.3   Molded-In Color   	2-13
        2.2.4   Parts Requiring  Surface Coating   	  2-13
   2.3   CHARACTERISTICS  OF COATINGS 	  2-14
   2.4   COATING PROCESS	  2-17
        2.4.1   Surface  Preparation   	  2-17
        2.4.2   Spray Coating   	2-19
            2.4.2.1 Conventional  Air Spray   	  2-20
            2.4.2.2 Airless Spray 	  2-20
            2.4.2.3 Air-Assisted  Airless Spray   .  .  .   .  2-21
            2.4.2.4 High-Volume Low-Pressure Spray   .   .  2-21
            2.4.2.5 Electrostatic Spray  	  2-22
            2.4.2.6 Zinc-Arc  Spray  	  2-22
        2.4.3   Curing	2-22
   2.5   COATING SELECTION 	  2-23
        2.5.1   Factors  Specific to  the
               Automotive/Transportation Segment  .  .  .   .  2-23
        2.5.2   Factors  Specific to  the Business Machine
               Segment    	2-26
        2.5.3   Factors  Specific to  the Miscellaneous
               Segment	  2-27
   2.6   EXISTING EMISSIONS REGULATIONS  	  2-28

-------
                   TABLE OF CONTENTS (CONTINUED)

  Section                                                    Page
     2.7  MODEL PLANTS   	2-36
          2.7.1  Model Plants for the
                 Automotive/Transportation Sector  	  2-38
               2.7.1.1  Coating Consumption  	  2-80
               2.7.1.2  Process Parameters   	  2-81
               2.7.1.3  Baseline Volatile Organic Compound
                        Emissions	2-82
          2.7.2     Model Plants in the Business
                    Machine/Miscellaneous Segment  	  2-84
               2.7.2.1  Production   	  2-86
               2.7.2.2  Process Parameters   	  2-86
               2.7.2.3  Baseline Volatile Organic Compound
                        Emissions	2-86
     2.8  REFERENCES   	2-92

3.0  EMISSION CONTROL TECHNIQUES   	   3-1
     3.1  INTRODUCTION   	   3-1
     3.2  USE OF COATINGS WITH LOWER VOLATILE ORGANIC COMPOUND
          CONTENT    	   3-1
          3.2.1  Waterborne Coatings   	   3-2
               3.2.1.1  Waterborne Coatings for the
                        Automotive/  Transportation Sector  .   3-3
               3.2.1.2  Waterborne Coatings for the Business
                        Machines  Sector  	   3-4
                    3.2.1.2.1  Primers    	   3-4
                    3.2.1.2.4  Electromagnetic interference
                                and radio  frequency interference
                               shieldings	   3-4
          3.2.2  Higher-Solids Coatings  	   3-4
          3.2.3  Non-Volatile-Organic-Compound-Emitting
                  Coatings	   3-6
                    3.2.3.1  Electromagnetic Interference and
                              Radio Frequency Interference
                             Shieldings	   3-6
                                iii

-------
                 TABLE OF CONTENTS (CONTINUED)

Section                                                    Page
                  3.2.3.1.1   Zinc-arc  spraying   	   3-6
                  3.2.3.1.2   Electroless plating  ....   3-7
                  3.2.3.1.3   Vacuum-metallizing  or
                             sputtering	   3-7
             3.2.3.2   Other  Coatings   	   3-7
                  3.'2.3.2.1   Powder coatings   	   3-8
                  3.2.3.2.2   Ultra-violet  and electron
                             beam coatings	   3-9
                  3.2.3.2.3   Vapor-cure coatings  ....   3-9
   3.3   PROCESS MODIFICATIONS 	  3-10
        3.3.1 Spray  Equipment   	3-10
        3.3.2 Process  Changes   	3-11
             3.3.2.1   Molded-in  Color  and  Texture  .  .  .   .  3-11
             3.3.2.2   Electromagnetic  Interference/Radio
                      Frequency Interference Shieldings  .  3-12
                  3.3.2.2.1   Conductive plastics  .  .  .   .  3-12
                  3.3.2.2.2   Metal inserts  	  3-12
   3.4   ADD-ON CONTROL EQUIPMENT  	3-13
        3.4.1 Carbon Adsorption  	  3-14
        3.4.2 Absorption (Scrubbing)	3-15
        3.4.3 Incineration	3-15
             3.4.3.1   Thermal Incineration  	  3-15
             3.4.3.2   Catalytic  Incineration   	  3-18
        3.4.4 Combination of Carbon Adsorption  and
               Incineration  	  3-18
        3.4.5 Condensation	3-20
   3.6   REFERENCES   	3-22

4.0  ENVIRONMENTAL IMPACT	   4-1
   4.1   CONTROL LEVELS    	   4-1
        4.1.1 Reformulation  	   4-2
        4.1.2 Thermal  Incineration  	   4-2
   4.2   AIR EMISSIONS IMPACTS	   4-5
        4.2.1 Volatile Organic  Compound Emissions  ...   4-6
        4.2.2 Other  Air  Emissions    	   4-7

                              iv

-------
                 TABLE OF CONTENTS (CONTINUED)

Section                                                    Page
   4.3  WATER IMPACTS	4-10
   4.4  SOLID WASTE DISPOSAL IMPACTS   	4-12
   4.5  ENERGY IMPACTS  	4-12
   4.6  HEALTH AND SAFETY  IMPACTS	4-13
   4.7  OTHER ENVIRONMENTAL  CONCERNS   	  4-15
       4.7.1  Irreversible  and Irretrievable Commitment of
               Resources	4-15
   4.8  REFERENCES  	4-16

5.0  CONTROL COSTS ANALYSES    	   5-1
   5.1  AUTOMOTIVE/TRANSPORTATION  SECTOR  	   5-1
       5.1.1  Add-on  Thermal Incineration Systems   ...   5-1
             5.1.1.1   Capital Costs  	   5-3
             5.1.1.2   Annual Costs  	   5-5
             5.1.1.3   Cost-Effectiveness  	   5-5
       5.1.2  Substituting  Lower-Volatile-Organic-Compound
               Coatings	5-10
             5.1.2.1   Capital Costs  	  5-10
             5.1.2.2   Annual Costs  	  5-10
             5.1.2.3   Cost-Effectiveness  	  5-11
   5.2     BUSINESS MACHINE SECTOR  	  5-13
       5.2.1  Add-on  Thermal Incineration System  .  .  .  .  5-13
             5.2.1.1   Capital Costs  	  5-13
             5.2.1.2   Annual Costs  	  5-13
             5.2.1.3   Cost-Effectiveness  	  5-13
       5.2.2  Substituting  Lower-Volatile-Organic-Compound
               Coatings	5-18
             5.2.2.1   Capital Costs  	  5-18
             5.2.2.2   Annual Costs  	  5-18
             5.2.2.3   Cost-Effectiveness  	  5-20
   5.3  REFERENCES  	5-22

-------
                 TABLE OF CONTENTS (CONTINUED)

Section                                                    Page
6.0  ADDITIONAL TECHNICAL INFORMATION	   6-1
   6.1   EXTERIOR AUOTMOTIVE  COATINGS   	   6-1
   6.2   BUSINES  MACHINE COATINGS  	   6-2

APPENDIX A     LIST OF CONTACTS	   A-l
APPENDIX B     EMISISONS CALCULATIONS 	   B-l
APPENDIX C     COST ESTIMATION  . . .	   C-l
APPENDIX D     SAMPLE RULE FOR SURFACE COATING
                OF PLASTIC PARTS  	   D-l
                              vz

-------
                        LIST OF FIGURES


Figure                                                     Page
2-1    Typical  Conveyorized Coating Line  for
       Three-Coat  Systems    	  2-18

3-1    Two-Unit Fixed-bed Carbon Adsorption System  .  .   .  3-16

3-2    Diagram  of  Thermal Incinerator   	3-17

3-3    Catalytic Incinerator 	  3-19

3-4    Shell and Tube Surface Condenser   	3-21
                             VI i

-------
                        LIST OF TABLES
Table                                                      Page
2-1     General  Properties  and  Uses  of Thermoplastic
        Resins   	   2-3
2-2     General  Properties  and  Uses  of Thermoset Resins  .   2-7
2-3     Plastics Abbreviations   	  2-10
2-4     VOC Emission Reductions for  Exterior Automotive
        Coatings From 1980  to 1988   	2-15
2-5     State Regulations   	  2-29
2-6     Summary  of  Model Plants	2-37
2-7     Small Model Plant Parameters for
        Automotive/Transportation Sector  	  2-39
2-8     Medium Model Plant  Parameters  for
        Automotive/Transportation Sector  	  2-48
2-9     Large Model Plant Parameters for
        Automotive/Transportation Sector  	  2-57
2-10    Extra Large Model Plant Parameters for
        Automotive/Transportation Sector  	  2-67
2-11    Automotive/Transportation Model  Plant Coatings    .  2-82
2-12    Baseline VOC Levels for
        Automotive/Transportation Sector  	  2-84
2-13    Model Plant Parameters  for Business  Machines   .  .  2-86
2-14    Baseline Coatings for the Business
        Machine  Sector  	  2-89
4-1     Reformulation Control Level  (Low-VOC Coatings)    .   4-3
4-2     Volatile Organic Compound Emissions  Reductions
        for Control Options	   4-8
4-3     Surface  Coating Process Substances of Health
        and Safety  Concern   	4-14
5-1     Thermal  Incineration System  Parameters for
        the Automotive/Transportation  Sector   	   5-2
                             Vlii

-------
                  LIST OF TABLES  (Continued)

Table                                                      Page

5-2     Capital  Cost  Factors  for Thermal  Incinerators .  .   5-6

5-3     Summary  of Costs  of Control  by Thermal
        Incineration  for  Automotive/Transportation   ...   5-7

5-4     Assumptions for Calculating  Annual  Costs of
        Thermal  Incineration   	   5-8

5-5     Summary  of Cost-Effectiveness  for Applying
        Thermal  Incineration  to  Model  Plants in the
        Automotive/Transportation  Sector    	   5-9

5-6     Estimated Costs and Volatile Organic Compound
        Contents of Coatings  in  the  Automotive/
        Transportation Sector 	  5-12

5-7     Cost-Effectiveness of Applying Reformulation
        Control  Levels to Automotive/Transportation
        Model  Plants  $/Mg ($/ton)	5-14

5-8     Thermal  Incineration  System  Parameters  for the
        Automotive/Transportation  Sector    	  5-15

5-9     Summary  of Cost of Control by  Thermal Incineration
        for Business  Machine  Sector  	  5-16

5-10    Cost-Effectiveness of Applying Thermal
        Incineration  to the Business Machine Model Plants  5-17

5-11    Estimated Costs and Volatile Organic Compound
        Contents of Coatings  in  the  Business
        Machine  Sector   	  5-19

5-12    Cost-Effectiveness of Applying Reformulation
        Control  Levels to Business Machine  Model Plants
        $/Mg  ($/ton)   	5-21

6-1     Automotive/Transportation  New  Coating Option  .  .   6-3

6-2     Exterior Coatings Control  Levels
        Low-Bake - Flexible and  Nonflexible
        (Ib VOC/gal Coating,  Less  Water)    	   6-4

6-3     Exterior Coatings Control  Levels
        High-Bake - Flexible  and Nonflexible
        (Ib VOC/gal Coating,  Less  Water)    	   6-5
                               IX

-------
                  LIST OF TABLES  (Continued)

Table                                                      Page

6-4     National  Impacts  Comparison 	   6-6

B-l     Automotive/Transportation Sector Small Model
        Plant  Emissions	   B-2

B-2     Automotive/Transportation Sector Medium Model
        Plant  Emissions	   B-3

B-3     Automotive/Transportation Sector Large Model
        Plant  Emissions	   B-4

B-4     Automotive/Transportation Sector Extra Large
        Model  Plant  Emissions	   B-5

B-5     Business  Machine  Sector  Model  Plant Emissions  .  .   B-8

B-6     Emissions Reduction	   B-9

C-l     Cost of Control by Reformulation   	   C-4

C-2     Thermal Incinerator  Costing Input  	   C-5

C-3     Emissions Reduction	   C-6

C-4     Control Costs  .   . '.	   C-7

D-l     Coating Categories for
        Automotive/Transportation Coatings   	   D-7

D-2     Coating Categories for
        Business  Machine  Coatings  	   D-8

-------
                       1.0  INTRODUCTION

1.1  BACKGROUND
     The purpose of this document is to provide information on
alternative control techniques  (ACT) for volatile organic
compound (VOC) emissions from the surface coating of plastic
parts for automotive/transportation and business
machine/electronic products.
     This document contains information on emissions,
controls, control options, and costs that States can use in
developing rules based on reasonably available control
technology (RACT).  The document presents options only, and
does not contain a recommendation on RACT.
                              1-1

-------
                   2.0  PROCESS DESCRIPTION

     This chapter presents an overview of the plastic parts
surface coating industry  (Section 2.1) and a description of
plastic parts substrates  {Section 2.2).  Section 2.3 describes
the coating process.  Coating selection is discussed in
Section 2.4.  Section 2.5 contains a summary of current
emissions regulations.
2.1  INDUSTRY OVERVIEW
     Plastic parts are coated to provide color, texture, and
protection; improve appearance and durability; attenuate
electromagnetic interference/radio frequency interference
(EMI/RFI signals); and conceal mold lines and flaws.  The
plastic parts surface coating industry is complex, but it can
be categorized into three general sectors:  (l) automotive/
transportation, (2) business machines, and (3) miscellaneous.
The automotive/transportation sector includes the interior and
exterior plastic components of automobiles, trucks, tractors,
lawnmowers, and other mobile equipment.  The business machines
sector includes plastic housings for electronic office
equipment such as computers, copy machines, and typewriters,
and for medical and musical equipment.  The miscellaneous
sector includes the plastic components of such items as toys,
sporting goods, outdoor signs, and architectural structures
(e.g., doors, floors, and window frames).  The plastic parts
used in all these sectors have similar coating types and are
typically made of the same group of substrates.
     Plastic parts surface coating facilities are typically
one of the following:
                              2-1

-------
     •    An in-house process located at the end-product
          manufacturing site (e.g., business machine
          manufacturing plant,  automobile plant, etc.);
     •    A contractor that specializes in plastic parts
          molding and coating;  or
     •    A job shop that only does coating.
Regardless of who actually performs the coating step, the
characteristics of the finish (i.e., color, gloss, adhesion,
and chemical resistance)  are usually specified by the part's
end-user.
     The types of coatings currently in use include
conventional solvent-based coatings, higher-solids coatings,
and waterborne coatings,  all of which emit VOC's to the
atmosphere during the coating and curing processes.
2.2  CHARACTERISTICS OF PLASTIC PARTS
     The properties of the different plastics determine the
types of coatings that can be used on them.  Some plastics are
damaged by the organic solvents in some solvent-based or
waterborne coatings.  Another important property of plastics
is their tendency to deform at the temperatures often used to
cure coatings on metal parts (see Tables 2-1 and 2-2 for
maximum temperatures for particular substrates).  Plastics
have lower surface tensions than metals and, therefore, it is
more difficult to wet them and obtain adhesion. . Adhesion
characteristics of plastics can differ from plastic to plastic
and even between grades of plastic.1
     Plastic parts are formed from a resin by applying
pressure or heat or both.  The two main categories of resins
used to produce plastic parts are thermoplastic resins and
thermoset resins.  Thermoplastic resins become soft or molten
when heated; however, they do not undergo basic structural
alterations, so they can be reground and reused.  Thermoset
resins "set" or become fixed in shape when first heated and
assume irreversible properties.
                              2-2

-------
u
*«
M

u
CO
z
M
CO
Ed
06
u "S
M '«
e_. u
EH S
co 3
•^
J
°- .
o i
rt£ c
Ed 2
s 3
EH
Eu •„
0 ii
w ^5
Ed 0-2
CO - S
D «•
a ,
s s
co 2l
Ed «-3
S -.2
S a «
Ed jj
0. *'
0 "c
05 .2
* 3
ill
Ed §
z -
Ed ^
C3
•
rH
1
CM
•
w S £~
J JS£
CO 2 « -
«C 3-jj
EH .2

«
U «*
O •«•
£|
M a
2 8
at u
. I , ?
.-i« f i : -us
22U« JJTZ- 1 21^!
»gS3 SifcJ1* -o-Si
« > ~n ui a -• «i ^ xuu*
— 82 -*wo>«: aoo<
28.! fg"--; Js^J
S-S^I ilSci «>!
3xSS -SS!j«52^ri
«M 5-i:il^ll
u • a 9 o •<^bfS~ > S u ? ^^"51
• * 2 ai »
> u. a < i.^

<•
« ~
WC U M -^ Ul U
• a «>, 10 u — to
«I3C — "ff C « • -
tfl UIO — — to !« .
.- r ii 8
•• ** •• * •• a. •• j^ w
si. si s.-sii
at 5 Jf at u a at ± at
Ul AC UIWU IUVUIWO
to 5 « to — • to > to "O 8
arouxxo a o x — a
•>UUUI«O — U Ul Ul X
J3
0
01
(M —
V
2 I
2


o
! 1
3 S
la
8^
2 ?*
Ju= s £*!
sJ2 5 s*«
'w * * ** W^UN
|il s. 11 |1^=
!sl ii ii i|=i
•~* • w • 4 u u S ~ «
I8S5 -=5 fr- 3lt«2
i 5 2 n {? 8 5 2 S 5 at t
S?28- i-5ff f!"?2a

1 it
C •
5 Ul
S

_
I «



f^J
1
a



, 1?
8 ?8 -?8
i ii ill

 **B — U 4» T3 O. "3
— u 3 • ^- > u b. 3
w — o — a o a >. af
• "- _ f ufQ a
u u. c 91 -n 8 t.
o 5 -8 2 — j J • o
9 .« 2 3 a S •" u
v * m ~- « "Q "O uu
a « — awfiSS «- —
8* *S>xS • »
•• k * •• *^ * — " •• 'Q U
S ?i 5-Jli S^«
S*«> ••• OK • ftmrn • fl* *-* aU
ut. SuMuu 3 j: --
S 28 xS3§^ S.?-3
— i» A ui .« ax ui -j at

^»
• * .
8 2 I
s
CM
. "8 .
-5 3
S f X
3 JS s |
— a «_ a x
3 « • x 3
u M w a o.
2-3

-------

(Continued)
Cnnmenr.M
1
z 1 s
"II £
01 i
w
«
0 5
a |
c* C
01 u
3 S
Ou
2 *
i H
W >3
= SI
Eh
O *
-.1
0} « «
3 ||
= J§
0 1
S 1
^*» A
*
w -g
w J
barf «tf
S s
S =5
w a ~
cu < o
0 1
of —
S 3
j
^»
«
u
2
U
U f I1
|fc
V •
• 5 « w
. 5 w
fH x-2
I -8
 u

S • ij S 2 .* a
^ V Ul (B * M OT L
3 r> i-^Si 15
. liiiimii i[j
f •l!l!MlK5|!l
Upiflf llf I
Iff IK ? !J!l|j j
• •••• i ui-~3uau~S. 5. w 7
^ ga
a x
• ^
"* i
"5
U»
I 1
8 8
* M
UJ u|


8 u *•
O O *•!
•a S. S.


«
y <• ,.
ll i
^ u| *^
ll 1
• u.
8 ill 11
« .ti « •'•I
,-gJ!" § .'SS1
iJs.- S l**$ 2
K^I. I i1;1 |
-jlll s*««
II?1! i Jrill i
2 ^ • ~ «-«S5a— 3
SllH S8Sf|-S,8 S
SS5-3J! 2&2llSj 2

%
It • S
» S 2

I
|2 2 *s*
«- 3 S ? "T!
— « S c 5— e
i-5 | Ix-Si
5-S • aaS^si
*? i Slicf
5i 2 ^oial

<•
-highly heat resistant
-good electrical
properties
-used as a coating
component
-resistant to «ost
commonly organic solvent



















S
4*
m

2
k.
5








J
"3L
^
^
2-4

-------

01
|
c^

w
z
H
CO
g
u
H
03
^
04
O
5
S
O

CO
u
CO
9
O
CO
PROPERTIE
J
U
S

f-i
1 •
01
H
J
GO
<
&«



o_
«*
u



•§
«
i
•


5

*•"«
S 3
> M
b
^» O
<• V
<* S
23
ij
u
's
Applicati
Automotive


! i
J ** u-
5
™




0-5
— §,
'•i e
• 8
at u
I . 1
<• M 4*
* i if'
j»« Hi
2. 9 > —"2 «
718 =£8
i-if T2f

^

!• 1^
li
i
a
^
*


J.




||
11
b <•
:1 !ii
- • Jl 3-
-1 si-0
b "3 5— b W
" "• "*a| i
•• < •• •• x 2£
si. 5--
S-z| Ssii
2SJ 221S
in
1 I
R


•o ^
• • •*
s*J §12
illli 1
"3 g a « o «
^^-2 ^ i^ al ^
° •<> 9 9 *• °
a. •«• & i— o.

I
H
|
1

X
8
>
b
"5
1*
|

u
Ul


b
£



|
^
2
1
*
•g «
- 2 b
— X C > O ««
b i| O b «tf 01
W - gMOb««
• 3 •* — u w
— b u — x — 3
U U w • 4* b t*
<• « i» j3 »> •«• >*•
— • C £ * o
X u. _»Sb«3
a • * -• c
C • — Ul O
• * .. .w .. W| «. *M M*
8.2^ §.-§l?3
S^ dC O( — * Of *» *•»
ttWjE UJ « UJ »- « -^

a §





I 1^
1 11!
i •§, « ^
5* 5*^5 ^9
••* ^tf *•• O
S. £25

paintable
S
1

X
8
x
u.








«
b
8.
£
=
a
: Bumpers, End
ock absorber, M
85
3««
sir
Ul U *•

%





s
£
s
^M
£




X
8
x
b
*m
u.
*
•3
b
*




m
b
S.
3
i*.

«
a.
b
o
b
V
c
u
X
ou

•• <^l





li
"?T
^ ^
£5
2-5

-------
1


1

8
CO


H

CO
u

05
CO
&
O
b

O


CO


CO
CO
u


i
u
a.

§
cu
Ed
 I
PI


a


CO
         u



          M
        O —
Appl
        3
                      a    b
                      <•  w a
                      X



                      uu
               b U
               o •

                            o
                      «   O w b
                      _•*«-• .C u
                       *•  w *•

                      .. 2 .. • 5
                      « — «  « a
                                   « C
                                   Sf
                                   « 9
                              I
                              e

                              a
                               •£.5 58
                               JS 3=2
a      S

0      2

3      3
               -Is-  MS
                   •a  £21
                                 2 5-il
<• • O •      b
*• « o —      u
b W ^ b      >
« C "b »-      O
g 5   ^ **   _ "




illig-s  *!

a.5§55  5



«  b b at «  —3
uj ** **  ** >  u u
iZ • M -g b 5  «• •-
xaccao  • x
•— ui •• « CL^  tfc ui




          S
                                ;   i
Po
                                      .
                                    .its
Uft

er
nwp
                                                  §?
                                                  Sir:
                                                  las
                                                  3 « X

                                                  SS5

                                                  IS'

                                      2-6

-------



(Q
Z
CQ
Cd
OS
fjl
CQ
O

X
o
CQ
U
CO
3
a
2j
CQ
H
U
a
o
as
cu
j
u
w
C3
CM
•
Af. «-« —
-* ^-1
ii iii

-•
Is

l
»



1
J"5
iS
II

i. M
O JI
M 01
x:=
• u
TJ - ^ >
<• « -7 o
a t. 3 u
*• 8 3 ~
•• O » «3B & «
i if'il'l



1 i

1
w « «
I !!
o Jo
a. *- a,








.
i
5
S
?
^

5
u.
u
1 .
;.I
u «
> *
^
Mting* for Auton
, Encyclopedia '9
plications." PPG.
"85
u ^ „
> 35
*E5
" s
% «
!"-•"
•t -5
.j -» 
-------
2.2.1  Characteristics of Substrates
     The selection of a specific plastic for a particular
application depends on the part's function or end-use.  For
example, a golf bal-l must be impact-resistant, whereas an
adding machine housing would require a substrate that can
withstand day-to-day wear.  Other substrate characteristics to
consider include durability, heat sensitivity, chemical
stability, flexibility, and hardness.
     There are certain trade-offs in selecting a substrate.
For example, increased flexibility usually means a loss of
chemical resistance, weatherability, and hardness; increased
hardness almost always increases brittleness, which results in
loss of impact strength and resilience.2
     Most plastic substrates will distort if heated above a
certain temperature.  Therefore, the type of coatings applied
on a substrate must cure within the temperature limitations of
the substrate.  Low-bake coatings are designed to cure at
lower temperatures  (up to 194°F) and are used on substrates
such as acrylonitrile-butadiene-styrene  (ABS), Xenoy®
(polycarbonate and polybutylene terephthalate), polycarbonate,
and acrylic.2
     High-bake coatings cure at temperatures above 194°F
(normally between 250°F and 300°F) and are compatible with
such substrates as sheet-molded compound  (SMC), nylon,
polyester, thermoplastic urethane  (TPU), thermoplastic olefin
(TPO), and reaction injection molded  (RIM) plastics  (primarily
ABS) .2
     The flexibility of the substrate also influences the type
of coating required.  Substrates considered  "nonflexible"
include nylon, Xenoy , ABS, acrylic, and polycarbonate.2*3'4
Substrates that are considered  "flexible" and require flexible
coatings are TPO, RIM, vinyl, ABS alloy, and TPU.3*5   Flexible
coatings include higher-molecular-weight components and,
therefore, require higher VOC content than nonflexible
coatings.2
                              2-8

-------
     Table 2-1 and Table 2-2 show the physical characteristics
and applications of a number of thermoplastic substrates and
thennoset substrates, respectively.2  Table 2-3  lists the
abbreviations used in this section for each plastic.
     The type of substrate used to produce a plastic
automobile part depends on whether the part has an exterior or
interior end-use.  Typical exterior coated plastic parts for
automobiles and trucks are fascias, bumpers, grilles, side
panels, mirror housings, body panels, light housings, and
lenses.  Xenoy®' for example, is used extensively for car
bumpers.6  Xenoy  distorts  when  heated over 180°F,  so
low-cure-temperature coatings are required.  Typical
automobile and truck interior coated plastic parts include
instrument panels, glove boxes,  consoles, speaker grilles,
steering wheels and housings, and dashboard panels.
     In general, parts positioned lower on a car body require
more rigidity.4   Reinforced SMC  is  often  used  where  rigidity is
needed, as in bumpers, which absorb much of the impact of a
collision.  On the other hand, a RIM substrate is adequate for
fascias, which function more as decorative covers.
     Bumper reinforcements and fuel tanks are composed of
polypropylene.4'3  "Polypropylene  has been  used  in Europe  for  a
number of years, and it is expected to be used more in the
United States in the future.6 Polypropylene is  less  expensive
than other substrates but,  unlike Xenoy®, it requires a primer
to promote adhesion.7  Other substrates,  such  as TPO  and TPU,
are being used more frequently in cars because they allow more
flexibility, better design, and a flush fit to metal parts.5
     Substrates that are commonly used to produce plastic
business machines parts include ABS, polycarbonate,
polyphenylene oxide  (PPO) ,  polystyrene, and polyurethane.-5-7
Other resins used in this industry include Noryl® (a phenylene
oxide-based resin),  Xenoy®' and Cycloac®, all manufactured by
                              2-9

-------
              TABLE  2-3.  PLASTICS ABBREVIATIONS
ABS   -   Acrylonitrile Butadiene Styrene
ASA   -   Acrylic Styrene Acrylonitrile
Nylon »   Polycaprolactam
PBT   »   Polybutylene Terephthalate
PPE   =   Polyphenilin Ether
PPE   -   Polyphenylene Ether
PPO   -   Polyphenylene Oxite
PVC   -   Polyvinyl Chloride
RIM   -   Reaction Injection Molded
S-Ma  »   Styrene-Maleic Anhydride
SMC   »   Sheet Molded Compound
TPE   »   Thermoplastic Polyester Elastomer
TPO   »   Thermoplastic Olefin
TPU   »   Thermoplastic Urethane
Xenoy -   PC/PBT blend
                              2-10

-------
General Electric, and Geon®  (a vinyl-based resin) manufactured
by B.F. Goodrich.8  Other plastics,  such as  polypropylene and
fiberglass-reinforced SMC, are used less frequently.6
     The conductive plastics used in business machines are
thermoplastic resins that contain conductive flakes or fibers
composed of materials such as aluminum, steel, metalized
glass, or carbon.  Resin types with conductive fillers include
ABS, ABS and polycarbonate blends, PPO, nylon 6/6, polyvinyl
chloride (PVC),  and polybutyl terephthalate  (PBT).6
     Substrates used for parts in the miscellaneous category-
include ABS for telephones, acrylic for outdoor signs, and
polystyrene for toys and packaging.3  Polyurethane is used for
exterior window parts.9
2.2.2  Plastic Fabrication and Molding
     The molding technique used for a particular  substrate can
affect the type and amount of coating used.  Some molds
produce parts that require substantial surface coating to hide
flaws or defects; other types of molds produce parts that
require little or no coating.
     Plastics are generally fabricated by one of  two
approaches: either the product is machined from basic stock
forms  (sheets, bars, rods) or the parts are formed directly
from raw materials by molding or casting.
     2.2.2.1  Casting.  Nylons, silicones, epoxies, acrylics,
polyesters, and styrene are commonly cast by pouring resin
into temperature-controlled molds.  Casting is well suited for
short-run items such as prototypes because molds are
relatively inexpensive.2  Typical  products manufactured by
casting include toys and sporting goods.
     2.2.2.2  Compression Molding.  In compression molding, a
partially formed thermosetting resin is placed in a
temperature-controlled cavity.  As heat and pressure are
applied to the mold, the plastic material softens and flows to
conform to the cavity.  Compression molding is applicable to
virtually all thermosetting resins and is well suited for
large parts such as body panels for automobiles, doors,  and
                             2-11

-------
furniture parts, but not for intricate parts where tolerances
of ±0.0005 inches are required.4  Because compression-molded
parts are composed of thermoset resins, rejected parts cannot
be reground and recycled.  However, the surface of these parts
can be reworked to repair scratches, water spots, and other
superficial defects.4
     2.2.2.3  Infection Molding.  In injection molding, a
thermoplastic starting material (usually in granular form) is
heated until it becomes soft enough to be forced under
pressure into a hot temperature-controlled mold.  Following
the injection molding process, water is introduced into a
water jacket around the mold to cool the part.  Once cool, the
mold separates and the molded part can be removed.8  Most
rejected parts can be reground on site and mixed with virgin
materials for reuse.8  Production  rates can  be high,  and
intricate parts may be produced with a high degree of
dimensional accuracy.
     Structural foam injection molding and straight injection
molding are two techniques used to manufacture business
machines, medical equipment, and cash teller machines, among
other things.6  Structural  foam injection molding produces
parts with surface flaws that require a substantial amount of
surface coating to hide them, whereas straight injection
molding can produce parts with molded-in color and texture
that require little or no decorative surface coating.2  It
follows that finishing costs, when considered alone, favor the
use of straight injection molding.  However, tooling for
structural foam molds costs from one-third to two-thirds less
than for injection molds.1   Therefore,  molding costs favor the
use of structural foam injection molding, especially for
large, complex part shapes.
     Conductive plastic parts are usually formed by straight
injection molding.  Structural foam injection molding can
reduce the shielding effectiveness of these materials because
air pockets within the structural foam separate the conductive
particles.4

                              2-12

-------
     Reaction injection molding is used extensively to produce
fascias and other automotive plastic parts.2'4>3'7  The most
common RIM molding machines are vertical, i.e., the two halves
of the mold move vertically.  However, horizontal RIM molding
machines are available and are preferred for producing larger
parts such as fascias.
2.2.3  Molded-In Color
     In-mold coating  (applying the coating directly to the
mold) can be performed for some parts.  Insert labeling with
injection molding paper is a process that was developed to
replace a method using insert molding with a plastic film.8
     A molded-in color process such as that used to coat
tractor cab roofs produces a harder, glossier finish than is
possible with liquid spray application.*  The  coating is  roll-
coated on mylar and- then transferred to a thin compression
molded plastic part that has a shape close to the final part
shape.  Finally, the thin-coated plastic part is put into an
injection mold, where it is fused to injected plastic.8
     Plastic parts often need to match the color and texture
of metal parts or other plastic parts.  Color matching is
often difficult to achieve with molded-in color.  Color
reproducibility and color stability of plastic parts are
generally more easily controlled by spray coating the parts
than by using molded-in color.6  There is  also a move toward
molded-in texture plastic parts. This in-mold process is less
expensive, and can reduce or eliminate the need for painting.7'8
2.2.4  Parts Requiring Surface Coating
     The surface characteristics of the molded part and,
therefore, the amount of surface finishing required for a part
is influenced by the design of the part, the design of the
mold, and molding parameters such as injection rate, molding
temperature, and injection pressure.6   Many  surface  flaws  that
require sanding, filling, and application of coatings that
emit VOC's can be minimized by close interaction among the
part designer, molding and coating line personnel, and the
suppliers of equipment and materials.6  Reducing the number and

                             2-13

-------
severity of surface flaws can reduce the total film thickness
of coating necessary to hide them.
     Other molding advances have reduced the amount of coating
required.  For example, padded dashboards are produced by
placing large sheets of vinyl over foam and then heating them.8
The vinyl is precolored to match various car interiors so that
coating is not necessary.
2.3  CHARACTERISTICS OF COATINGS
     Coating plastics' can be more difficult than coating
metals and other substrates because chemical interactions can
occur between the coating and a plastic substrate.6  In fact,
the cross-linking reaction of plastic substrate and coating
can continue for some time after the coating is applied.5  In
addition to the resin, plastics contain plasticizers, blowing
agents, mold releases, conductive media, flame retardants, and
fibrous reinforcement fillers that can affect the applied
paint.7
     In the past, plastic parts were often coated with lacquer
coatings with very high VOC content, ranging from
85 to 95 percent VOC by volume.2  These  coatings  were fast-
drying, durable, and relatively inexpensive.  New resin
systems have since been developed that produce waterborne and
higher-solids coatings with similar characteristics.
Table 2-4 illustrates an estimate of emissions reductions
achieved from 1980 to 1988 by the automobile industry for
exterior coatings.  Keeping annual coating consumption
constant, and assuming a 1980 average VOC content of 6.0 to
6.5 Ibs/gal and a 1988 average VOC content of 4.85 Ibs/gal,
estimated emissions reductions range from 17,000 to 39,000
tons.
     Waterborne coatings contain water as the major solvent,
and contain 5 to 40 percent by weight organic co-solvents to
aid in viscosity control, wetting, and pigment dispersion.
They have a much lower VOC content than traditional coatings
with the same solids content.7  Waterborne coatings can have
lower VOC emissions and lower toxicity, yet they fulfill

                              2-14

-------
      TABLE 2-4.  VOC EMISSION REDUCTIONS FOR  	
                  AUTOMOTIVE COATINGS FROM 1980 TO 1988

1988*
1980b
1980s
Total VOC
Emissions
(tons /year)
11,470
28,400
50,750
VOC in coatings
(Ib/gal)
4.85
6.0
6.5
Solids in
coatings
(%, average)
33
17
10
aBased on Dames and Moore Report commissioned by the NPCA.

^Assuming the same production level as 1988 and assuming an
 average VOC content of 6.0 Ibs/gal.

cAssuming the same production level as 1988 and assuming an
 average VOC content of 6.5 Ibs/gal.
                            2-15

-------
color, gloss, impact resistance, and other requirements for
many substrates.2
     One limitation of waterborne coatings is that they are
incompatible with conventional steel delivery systems.  As a
consequence, stainless steel or plastic pipe fittings are
recommended for the application equipment.  Another limitation
is that increased control of booth temperature and humidity
may be required.  In addition, longer flash-off time may be
needed.2  Also,  some waterborne coatings  do not  adhere well to
certain plastic substrates.2
     Higher-solids coatings are solvent-borne and generally
contain a higher solids content than conventional coatings, up
to 50 to 65 percent by volume.  Because the solids content is
higher, less paint is needed to provide a given film build.
However, excessive viscosity can be a problem, and paint may
need to be heated to around 200°F to achieve sprayability.2
     One type of higher-solids paint is a two-component
polyurethane.  The two components (a color component and a
catalyst or hardening component) are mixed together
immediately before use and, once mixed, the coating must be
applied within several hours.2  Its  lower VOC content  and
ability to air dry  (because of the catalyst) make the two-
component polyurethane coating attractive for heat-sensitive
plastic parts.4'7
     Both solvent-borne and waterborne coatings are used in
electromagnetic interference/radio frequency interference
(EMI/RFI) shielding.  Solvent-borne conductive coatings
contain small flakes of nickel, silver, copper, or graphite,
in either an acrylic or polyurethane resin.  Nickel-filled
acrylic coatings are the most frequently used because of their
shielding ability and cost.6  Nickel-filled polyurethane
coatings are more expensive than nickel-filled acrylic
coatings, but are reported to give a more durable finish.6
     Nickel-filled acrylics and polyurethanes that contain
from 15 to 25 percent by volume solids at the gun  (i.e., at
the point of application or "as applied") are being used to

                              2-16

-------
coat plastic business machine parts.7  Waterborne nickel-filled
acrylics are being used less frequently than solvent-borne
conductive coatings.  Some coaters believe that waterborne
conductive coatings do not adhere as well to plastic as do
organic-solvent-based conductive coatings.8
2.4  COATING PROCESS
     Typical coating methods for plastic parts include spray,
dip, or flow coating, with spray coating being the most widely
used.  The type of coating used, such as prime coat, color or
base coat, topcoat, EMI/RFI shielding, and texture coat will
depend on the substrate and end-product.  The typical total
dry film thickness will usually range from 1 to 5 mils.3
     Because of their diverse properties, plastic parts are
coated in steps to ensure adhesion and finish quality.  The
general process for coating plastic parts is shown in
Figure 2-I.6  The  three basic  steps  in the process are surface
preparation,  coating, and curing.  Each step may be repeated
several times for a given part.  A description of these steps
follows.
2.4.1  Surface Preparation
     The surface preparation step may involve merely wiping
off the dust or residue left from the molding stage.  A
deionizer can be used with enclosed systems to eliminate the
need for the manual dust-removal step.8  Some  industries place
newly molded parts in ovens prior to painting to promote "gas
out," or the boiling off of impurities contained within the
substrate.4   Sanding and  puttying may be  performed to  smooth
                             2-17

-------

-------
the surface on some parts.  Parts may also undergo multi-stage
washing cycles using specialized soaps and rinsing with
deionized water prior to oven drying.4*5
     To make a part' conductive for electrostatic application,
a conductive coating (often composed of alcohol, organic salt,
water, and other proprietary compounds) may be sprayed on the
part and then dried, leaving the conductive salt residue.5'7
Metal plates located behind conveyorized parts can lend
conductance, eliminating the need for a conductive coating.4
2.4.2  Spray Coating
     To apply the coating, parts are often moved by a conveyor
through partially or totally enclosed spray booths.  Some
conveyorized parts are hung on paint hooks, whereas others are
placed on racks.  Conveyorized systems are most likely to be
found in large facilities because associated capital costs are
relatively high.
     Spray booths maintain air flow (usually crossdraft or
downdraft) to remove overspray in order to minimize
contamination and keep solvent concentrations at a safe level.
The spray booth exhaust, air flow, temperature, and humidity
must be monitored, as these factors can significantly
influence the finish quality.  Dry filters or water curtains
are typically used to remove overspray particles from the
booth exhaust.2   Incinerators  or  other  emissions  control
equipment can be installed on spray booths to control VOC
emissions.
     Some coating facilities apply tape or paper to parts to
shield or mask areas where coating is not desired.  Reusable
metal "masks" can also be placed over parts for selective
coating.7  A waterborne  acrylic resin is  often  used for reverse
masking.4  This  resin coating  is  used to  protect  an area  of  the
part that has previously been coated.   The coated part is
sprayed with the resin,  baked, and then the unmasked area of
the part is sprayed with a second or perhaps even a
                             2-19

-------
third color.  This additional color is added for style or
appearance.  The masking material dries into a thin film and
when it is peeled off, the initial color is preserved.
     In all spray coating operations, some coating solids
either miss or bounce off the part.  Coating solids that do
not adhere to the part are called overspray.  The greater the
overspray, the less efficient the application system.  The
efficiency of an application system is measured as transfer
efficiency.  Transfer efficiency is defined as the ratio of
the paint solids that adhere to a part divided by the solids
directed  (in this case, sprayed) at the part.
     Numerous factors affect how well paint is transferred to
a part, including the type of spray equipment used, the part
configuration, and the spray booth ventilation rate.  The
various spray techniques used to coat plastic parts differ in
the manner in which they break up  (atomize) the paint.  Some
methods are associated with inherently better transfer
efficiencies than others for a specific part.  The more common
spray techniques used to coat plastics are discussed below.
     2.4.2.1  Conventional Air Spray.  Conventional air spray
is the traditional method of applying coatings.  Compressed
air is supplied through an air hose to a spray gun, which
atomizes the paint into a fine spray.  The pressure supplied
to the fluid controls the paint delivery rate, with typical
pressures ranging from 5 to 25 pounds per square inch  (psi).2
The air pressure controls the degree of atomization, and is
usually 30 to 90 psi.2  One  of  the major problems with
conventional air spray is the overspray caused by the high
volume of air required to achieve atomization.  This overspray
typically results in relatively poor transfer efficiency.10
     2.4.2.2  Airless Spray.  With airless spray, a pump
forces the coating through an atomizing nozzle at high
pressure  (1,000 to 6,000 psi).  Airless spray is ideal for
rapid coverage of large areas and when a heavy film build is
required.  The size of airless spray paint droplets are
larger, the spray cloud is less turbulent, and the transfer

                             2-20

-------
efficiency is typically superior to conventional air spray.11
However, airless spray leaves a rougher, more textured
surface; therefore, it is generally used on surfaces where
appearance is not critical.
     2.4.2.3  Air-Assisted Airless Spray.  An air-assisted
airless system combines the benefits of conventional air  spray
and airless spray.  The system consists of an airless spray
gun with a compressed air jet at the gun tip to atomize the
coating.  It uses lower fluid pressures than airless spray and
lower air pressures than conventional air spray  (5 to 20  psi
versus 30 to 90 psi) .2>12  This fluid/air pressure combination
delivers a less turbulent spray than conventional air systems
and applies a more uniform finish than airless systems.
However, the amount of time needed to apply coatings is
greater because of the lower air pressure.10
     2.4.2.4  High-Volume Low-Pressure Spray.  A modification
of conventional air spray is high-volume low-pressure  (HVLP)
spray, which uses large volumes of air under reduced pressure
(10 or less psi) to atomize coatings.  Because of the lower
air pressure, the atomized spray is released from the gun at a
lower velocity.  Overspray is reportedly reduced 25 to
50 percent over conventional air spray.13'14'13  The air source
for the HVLP can be a turbine or a standard air supply, both
of which can handle multiple spray guns.14'13  Manufacturers have
constructed the fluid passages out of stainless steel or
plastic so that these guns are compatible with a full range of
paints, solvents, and waterbased materials.16  Many HVLP spray
systems are designed to atomize high-, medium-, or low-solids
coatings.  One limitation of this paint system is the learning
curve associated with the new spray technique.  When switching
to a low-pressure spray,  the painter must learn a new spray
technique and adjust to the different spray pattern.17
                             2-21

-------
     2.4.2.5  Electrostatic Spray.  In electrostatic spray
application, the coating and part are oppositely charged.  The
part is grounded and attracts the negatively charged coating.
Electrostatic spray systems are reported to have the highest
transfer efficiency of any of the spray application techniques
because of minimal overspray, which also results in lower
paint loss and lower VOC emissions.18'19'20*21'22-23
     One limitation of the electrostatic spray technique is
that the part to be coated must be conductive.  Plastic parts
not made of a conductive substrate are often made conductive
by applying compatible polar solutions to the surfaces and/or
placing the parts on a metal backing.3'6*7
     2.4.2.6  Zinc-Arc Spray.  Metallic zinc may be applied to
plastic to provide a conductive surface or shielding.  This
two-step process first roughens the plastic surface  (usually
the interior of a housing) by grit-blasting or sanding, and
then spray-coats with molten zinc, either manually or with
robotics.  The zinc-arc spray gun operates by mechanically
feeding two zinc wires into the tip of the spray gun where
they are melted by an electric arc.  A high-pressure air
nozzle blows the molten zinc particles onto the surface of the
plastic part.
2.4.3  Curing
     The curing process can be separated into flash-off zones,
cure zones, and cool-down zones.3  After a part  has  been
coated, it moves through a flash-off area, where solvent
evaporates.  The flash-off area may be vented by means of an
exhaust system to capture the organic vapors.  If the coating
requires heat to cure, the part is moved to a curing oven
after flash-off.  Some coatings that do not require heat to
cure may be heated to speed curing, thereby allowing the
production rate to increase.7  Oven temperatures will vary
according to the type of substrate and coating, but will range
from about 150°F to 300°F.2  The potential for distortion of
the plastic part by curing with temperatures that are too high
                              2-22

-------
is a concern for the coater.  Some coatings may require as
long as 72 hours after baking to be fully cross-linked.6
2.5  COATING SELECTION
     Coating selection for plastic parts depends on many
factors, such as the substrate, the technique used to mold the
part, end-use of the product, solvent selection, color-
matching, temperature, humidity, and paint adhesion.
Thermoplastics, for example, are inherently solvent-sensitive.
Often, the best reducing solvents for paints are also the most
aggressive in attacking sensitive plastics.6
     The specific end-use of the part determines which of the
following physical characteristics are most critical for the
coating:  color, gloss, adhesion, impact resistance, pencil
hardness, abrasion resistance, flexibility, ultraviolet (UV)
light stability, salt resistance, or solvent resistance.  For
example, durability and salt resistance is critical for a car
bumper, whereas stain and cleaning solvent resistance are
critical for a desktop computer housing.
2.5.1  Factors Specific to the Automotive/Transportation
       Segment
     Appearance and substrate protection are the major reasons
for coating plastic parts in the automotive/transportation
industry.  Color-matching various plastic parts to coated
metal and other plastics in automobiles can be difficult and
requires the use of numerous coating variations.  The
aesthetic quality of the automobile can also be improved by
the selective coating of parts.  For example, by masking and
spraying two colors adjacent to each other, a single part can
be made to look like two different parts bonded together.5
Textured molding is also being used more, such as on interior
door panels.3
                             2-23

-------
     The location and visibility of the automotive plastic
part will affect the choice of coating and even the number of
coats required.4  For example,  a  portion of  a bumper that is
partially hidden under the car needs to withstand weather
changes, impact, and other environmental stresses; however,
color-matching this part may be unimportant or even
unnecessary.
     Application of a waterborne base coat followed by a
solvent-borne clearcoat is used on some coated parts located
below eye level.4  Interior plastic  parts such as  consoles and
dashboard panels do not have to withstand the extreme
environmental stresses of exterior parts; however, durability
is important.  Resistance to cleaning solvents and color
matching are critical when selecting coatings for interior
parts.
     Both waterbornes and higher-solids  (especially two-
component polyurethane coatings)  are used extensively in the
automotive industry.  Although waterborne coatings  [with VOC
levels of 2.8 to 3.8 pounds per gallon  (Ib/gal), less water]
can be found in the automotive industry, some limitations are
associated with these coatings.24'23   Waterborne coatings
require curing to evaporate the water and sometimes the
plastic substrate cannot withstand the high curing
temperature.  In many instances,  "accelerators" can be added
to the coating to speed up the curing process.26  Adhesion and
finish quality are also potential concerns when using
waterbornes.
     The higher-solids, two-component polyurethanes are
gaining popularity for clearcoats and base coats.  Their
appearance, durability, and lower baking temperature are said
to be superior to those of waterbornes.26  Using a clearcoat-
bake-clearcoat process gives the final coated product a wet
look, which is often desired.4 A high-gloss white polyurethane
coating is used on the front grilles of lawnmowers with
headlights to improve reflectivity.8
                              2-24

-------
     Red and black automotive coatings often have unique
solvent requirements due to the nature of the pigment and
resin systems.  Red pigments are typically highly transparent
and have a tendency to flocculate  (form lumpy or fluffy
masses).  To control flocculation and evenly disperse the
pigment, higher volumes of solvent are required for red
coatings than for other typical colors.  Black coatings
generally use carbon black pigments.  The small particles
adsorb more resin than other colors.  To counterbalance the
higher resin loadings and higher viscosity, more solvent is
required for black coatings.
     Metallic paints for coating plastic automotive parts
present several challenges.  The thickness of the applied
metallic coating is crucial and varies depending on the type
of coat (base coat, topcoat, etc.).  If the coating is too
thick, the metal flakes will float, causing variations in
color.4 On the  other  hand,  constant  agitation of  the  metallic
paints in their containers or routing them through a paint
recirculation system is necessary to keep the metal flakes
floating so they will achieve proper orientation when sprayed.4
     Some coatings used in the automotive/transportation
sector have unusual job performance requirements and are
referred to as specialty coatings.  These products include
gloss reducers,  headlamp lens coatings, adhesion primers,
electrostatic preparation, resist coatings, stencil coatings,
ink pad coatings, texture coatings, soft coatings, vacuum
metalizing basecoat and topcoat, black and reflective argent,
and coatings for lamp bodies.  In some cases, the technology
is not available to formulate these specialty coatings with
reduced VOC content.  In other cases, the coatings are used in
such small quantities (accounting for about 4 percent of all
automotive plastic parts coatings)27 that reformulation would
not be cost effective.
                             2-25

-------
2.5.2  Factors Specific to the Business Machine Segment
     Plastic parts for business machines are coated for three
major reasons:  (1) to improve their appearance;  (2) to
protect the plastic part from physical and chemical stress;
and  (3) to attenuate EMI/RFI signals that would otherwise pass
through the plastic housing.
     Texture is often molded in to improve the appearance of
business machine parts.  Color-matching the plastic to coated
metal parts is often a requirement.  In selecting coatings for
business, medical, and other types of machines, resistance to
such items as correction fluid, surface cleaners, and inks
must be considered.
     The final coating thickness will vary, but the industry
standard is typically 1.5 to 2 mil dry thickness.4  Generally
speaking, this thickness is achieved with a three-coat system
(primer, color, clear coat) using conventional coatings, or
with one coat if a higher-solids coating is used.1  Higher-
solids coatings for decorative coating may more readily cover
flaws in the substrate.1
     The EMI/RFI signals emitted from enclosed electronic
components can pass through plastic housings.  The EMI/RFI
signals emitted from business machines can interfere with the
performance of other electronic devices such as radios and
televisions.  Conversely, EMI/RFI signals from outside sources
can  interfere with performance of the electronic components in
an unshielded plastic business machine housing.  The increased
use  of plastics for business machine housings and the increase
in circuit density afforded by advances in circuit technology
have resulted in a corresponding increase in EMI/RFI
interruptions of the airwaves.7  To combat  EMI/RFI propagation,
the  Federal Communications Commission has placed restrictions
on the maximum EMI/RFI emissions from computing devices.7
Coatings are frequently used to comply with these
restrictions.
     The two major performance specifications for EMI/RFI
shielding materials are conductivity and adhesion.  The

                             2-26

-------
EMI/RFI signals are best shielded with grounded, high-
conductivity coatings.  These coatings usually have a surface
resistance of less than 1 ohm per square area.  However,
protection is best achieved with grounded, low-conductivity
coatings with surface resistance of 2 to 20 ohms per square
area.  Although a high-conductivity surface may prevent a
spark from reaching internal electronic components in one area
of a housing, the spark may arc to the internal components in
another area as it travels to the grounding connection.  A
low-conductivity surface spreads the energy over a larger area
as it travels to ground, preventing a localized charge
build-up.7
     In some cases, copper shielding is used instead of nickel
because it achieves better resistance (5 ohms for nickel
versus 1.5 ohms for copper).*  Waterborne  copper shielding is
available, and sources indicate that it mixes better, sprays
better, and lasts longer than some solvent-based shieldings.8
One disadvantage is that when transporting the waterborne
coating in cold weather it must be kept from freezing.  Once
it freezes it cannot be used.7   In  addition,  when switching a
paint line from copper shielding to another type of coating,
the entire fluid line must be changed; otherwise, copper
specks appear in the other coating.8
2.5.3  Factors Specific to the Miscellaneous Segment
     The coating selections and requirements for the
miscellaneous category depend on the individual situation.  As
with the other categories, appearance and protection are the
most important considerations.   Plastic window frame and door
coatings must withstand the elements but must also be capable
of matching the numerous architectural and maintenance
coatings.  Coatings on sports equipment must be durable and
often impact-resistant.  Coatings used for toys must be
nontoxic and durable.
     Some substrates require multiple layers of paint for
protection and appearance.  For example,  the front panels of
gas pumps that frame the digital readouts are often made of

                             2-27

-------
Lexan* substrate and may have the following coatings:
(1) a clear barrier coat to prevent degassing of entrapped
VOC's from the substrate (degassing could distort the color of
the final product, producing a mottled effect);  (2) a black
barrier coat to seal off the paint from degradation due to
contact with gasoline in the field; (3) a spray fill, which is
a higher-solids paint used to remove surface imperfections;
(4) a black colorcoat; and (5) another coat of black color to
ensure a final gloss.  The more paint layers applied, the
greater the gloss.5
2.6  EXISTING EMISSIONS REGULATIONS
     Several States  (including Texas,  New York, Missouri,
Michigan, Maryland, and California) and local and regional
areas have adopted regulations to control VOC's from
facilities that surface coat plastic parts.  Table 2-5
presents a summary of State and area regulations.28  All of
these States and areas have adopted a limit on the VOC content
in coatings.  These limits range from 2.3 Ib/gal for a general
one-component coating to 6.7 Ib/gal for vacuum metalizing,
optical, and electric dissipating coatings.28  In addition,
Maryland and New York have adopted minimum efficiency
requirements in lieu of limits on VOC content if control
devices are used.  The Bay Area Air Quality Management
District in California allows add-on control if it achieves
equivalent VOC reduction.  Michigan restricts the use of
conventional air atomized spray.
     In addition to State and area regulations to control VOC
emissions from surface coating of plastic parts, federal
regulations exist to control emissions from the coating of
plastic business machine parts.  These New Source Performance
Standards  (NSPS), found in 40 CFR 60,  Subpart TTT, affect
facilities constructed after January 1986.
                              2-28

-------









M
0
M
6*
3
D
O
U
OS
6"
CO
IT)
1
CJ
00
^
E"i












IS
I


Report and
Recordkeeping
Requirements

o
e *•
.£ o
0 "^
o



•So
xi
K. U
».
« «I1
Ifal


X
t_
o
a>
u
a
u
f
i


~s
o -
3i
* 0
oc

0
a
Ul



"


I
> •• ** —
O O "a ^J v ^r
wi 3 £0i **• w
t» ^3 o C
O C C ** 01 41 O
(J « — C C U —
« 3 •— • **
u a o 5 « — «
xi - IS a.ii
.- S «- « ° "g a
O O u) •»».•&
a o 3 w o «• «

09
S




I- .?"S -3
a -^ S x a x 8
> O « « X « U

M in a in
IM m IM m


w ^
c c

o u o y
?!•«•«
*• "3 a | a S
w«>w t* w« 07
*•§ *o S «~ f 53 ol
o a*«- O«JM«*.£U o *^3
Cw C C O u au **
W-SflMM S V O *• u '" X *~ "
5 3 — a « U ^ JS $ 9 j| • 7 * S
i°ai8 i- 15 II s£ il
f m f o a i* — a
«*u '^H MU u w « u ^*^ <*B
(M « »- M C -* a 00 OC — C (MO
•^ « o -^ a N» «• at >. u— v«i »^ u

CO
s



& ? ?^1 w
Is^i °.5.§o 0
oo— 3 <- u o i. u
U ^ •« 0 O.'*- W .—
y a. u — ••- 5 >
Mo itS So 0 8-8

KHiN.N^ON»Ki/irooaa «-«*m



£
49 ***
C I«5 .. 3?
?3 |iz sfe s!
— & wo c s « a »i
MB — 2 I i _ a S >.
•o — c <• BO u i. o -. . «
v — .— a OM a O. u u
U 9 M ^ ~~ *«3 O 0. ^** "O
°-SS2 a 3" °.2Jsl
8S*"8-^^-^-i5 u 82
?£ • uo^Z-a-^3^ o «|
«T13u.— — u a u a « x — o a u
~*-*i>t--^*«0**c**c 0tkUoa^^
30 a — oa— u««u —
XX>Xa«OuiXi3X
-------



Q
U
D
Z
H
Z
o
c^
en
0
^
D
C3
U
(X
u
EH
en
•
i
(N
W
03
E*










41
O
Report and
Recordkeepina
Requirements

Q
C **
"" U
* i
o


o "o
hi
II
•— u


A *S
-••f-
5|||
J>

X
u
o
u
u
1
1



O "^
H

—
1


_

~Z «• | § -u £ ? 1
°ii o "I * S f°8 5 - &i I
1 5 - if o'Z £ sU* i § |u u
5 o c o 01 — S »• g « o u •• o u u tt
u - u ->cwa c ••— 09 3 j| a •
« «i .. w-te^e c y fi a. w evw g *< 3
ua u j» go** 99 v i > 3 « x» • u • u —
O C •Q O a 3 C > S— • u ^wlfl u • o
> — > 5 u o o 9-— o " ° S f ^ *- * •*• «
~« -—^ ** *< »*« /^<^ «i « e 1 •» . "^5 »»•
KI o ac — • e i\j o ^ %r •<- — u a  a, <• b
x i z .2 . ^ a
- ? 3 = » "
• e * "S ***
u S o «• x — <•
J u u x u* ae •
u
2 •
^9 ** CO *V
tf *** 4 3 iL 8 v
0K v 3v O U *•• Ck
. i
• •a i e *•
— « . • 3 —
e 3 -g i. « _.
ll li 1.1-
••c >»**.£tjua
— 3 i. — -g « «* «
• u o « c a • « i-
u >- X a • 3 0 Z •«
                            o o ^_
                            
-------







Q
W
D

w
EH
Z
8
(0
0
§
D
U
w
OS

u
g
eS
CO

•
m
i
(N

U
J
03
IS











S**


'II
Hi
««


o
e-
- i!
• >«•
^_
M ^*
• >"
a

00
ii

 9 « . -3
> fc X C U *• <-
in^iii i

o
s
^^
rt
^
(M


II S
*rf ^" w
s? s
o o u
u
^ 1

M
nj






^
^
U
h—
I
•
1 1
ft »
C ^
i ^
^
IsJu ^
*—•«*< m
S iJ • 55 "•
O 3 ^ V
i— 3 a •
T— a x —
u o « • a
^ a. at w at
^%
ll I

?S ?
2^ i
-!-
•>:.
5"8 S S"Z
•v M a c u
«"• — — "a.
^rSg-af
•- • v e >>
• ? 8
at ** «^ u
S •« » - « ~
5 u « o t» ij -o a «
ii s§ «£ 88 -. 8
i Ii IS ?! 11* *
8 sf s8 :i |s; -si
3 — un C w S w u M
3 »» « ^l! 2 3 €i8« S-S
i »8 i-2 lu «lxl ?°
• «—• -Jr— w «
^*> ^ «. ~ » w
S c 3
u 9 u
^ ^
• 2. «
u u u
>. • •*.
^ 4rf W
* f * «
35 * o
*tf U ** O
^ •**• ** • • • *« A v
JS 2S 3§S? 3§8
<• «- „* U U JQ <^ UUd
A X *•• W « • i C 4>* 41 A '
^g 5 S 3 S • S ? g S S ± S
al B u. zuaauxufiumuz
••* ••• * * &• i » — • M— A i i i
a: c. T < u • i^ & H>

^J'l
— «<•<•
*1a!«
Si2i1
U < »- .
««

a
u
»<
2-31

-------





1
M
8
%•»
W
o
H
EH
i
(6
»
g
£
CO
•
in
(M
u
j
00
E$



8
•*
o
«
**i
?ri
«* 9 •
HI
M **


o
e *•
-*
5»
IJUI
0
"So
1:1
t- U
5
u
•*
•
u
?
«rf
a
-i
« «
ii
» ?
«
w
•
4rf
M

«t* * MM
O M * * C *
Jc« S g? sSlu-sff*
ilil in ! ! « !, ii ^H»fi
i?«j !|| iji | i u if |j jif
a— fi _ <•&«<*< — -3 • a ^ • 8 « • c .- SlOu->!j«
^T O ^ O tf C ^ (A ^3 ^ 9 **• U ^ *^ 4 ^^ O ^* <^ *•• • ^ « fl 5
U b O 1. U — — « TI O. L. ^ C « 01 13 U — M->S.C'— -~«
Mb*< o • • 2. •«9 ft— w u u a~ • 9 M « »
•^ c i c o « J S1 UOB «•»— »»-« A « <~e3^ai— c^
N.8S5 5 « 3 6 eu>-8o «-B ni« K< 4 ^3 8-5 « e — u
wu*u MUMU — « au *< ^ 8 ^ o OSi Zufi-3.2 — i-,
IM
-


w KI ininmanaome
•o • >.
41 tm ^ M W
S T, ? ^ 8 S 3
-. S s~ .5 -S8. «S8
"O •• — K a o • •Q « o »
• a. — ^ Jl« o u • « SUM
•^7 •^^ -«.^ uujQ*«B uu£
u JJ K<»W«MIU - * • T
fl .c 2 « c • <• • c -3 «<••£
i u a^ « — 3 o • — 8r«o«— 8
— I 25 — t* ?i?v?iis.?"*
< >- sa T ' 'y'''! i
* 1
ii
< l-
>rf w



2-32

-------





TINUED]
|
TIONS
REGULA
U
EH
EH
W
in
i
(N
TABLE





i

Report and
Recordkeeping
Requirements
o
5S
a
*•• ^
o o
v **
Is
to U
-*„
T5 ^? s Q>
_~ ^J o S

41
Coating Ci
ii

M
<• • U M *J
I^SS'I i- I -
lllllj Hi Hoi- 1
•» oi —* 9 ^ 9 < fc- J5 fl -5 fl 3 3 ^ *
(A *^ & B ^ J3 Of &^ • * *** O A *< W
1 !] pljti ,1
fl 'Sw ? «i!c ?"o ^"So 2* 2
i» •• *— • i - «c * • *8 a So
<- M S.M 9L> 9 9 « 2L5lk S
•g Kg ^'i^'^i. S«— • 2." "2
^— ^8 ^S'S'5— **S — •§ ~8*
co
>.
u
v. M<"'~X'''**7M



• "O
O C
M '5 3" 01
2 8- - »
2 u £ 2
£ S 1 S 5
u - a. "• •.
8 Sggf^^i
c « o 3 3 ^ - - -
•^ 8u** uotai^rf
3— 4 x gi 5 S S 3
u JT « s 3 — — £
— "o "3 o o a5 »- c 3 ° i
s
l! P!
U O • • M «
'5 - x S « <
2-33

-------
a
w
o
CJ
•a £2

**f
*• 3 C

If
        o
        SJS
             kit
             ^ o >
              *• o
                   l ,
                    X
                   « o  "U
                  :$$  S
              Six
                  tl U •»
                  u  •»
              lKiiUii
                                    &

                                   . (M
                    s§*|1i»pg &-s
                    smjsihi If
en
z
o
H


|

U
u
OS

u
     o o

     X-
     l§
3
in
i
Ed

J
CD
4

6-"
                         2-34

-------
t and
acping
aMnts
      e
      e
8
CO
§
u
CO
in
i
U
J
CO


                 :lf
us
ion
              4V ** ^ •••  **
         O <*—
          31

          i-*l
          a. o i-l
                 i -i - a u
         S
0.

u
         I;!
         1 M
          a u x <
                            2-3S

-------
2.7  MODEL PLANTS
     This section describes the model plants developed to
represent the plastic parts surface coating industry for
purposes of assessing the effects of various VOC emissions
control options.  Model plants were developed for two general
categories of facilities:  (1) those that coat automotive/
transportation parts, and (2) those that coat business machine
parts.  Because of the variation in products, substrates and
coating requirements, and the small number of facilities of
each type, only general information is provided on the
miscellaneous plastic parts segment in this document.  No
specific model plants, or control alternatives are provided
for the miscellaneous segment.28
     Other parameters used in defining the model plants in
addition to coating types include facility size, degree of
automation and robotics, the type of substrates being painted,
end use, and types of spray guns and spray booths used.
     Both_the automotive/transportation and business machine
sectors were divided into various model facility sizes.  The
automotive/transportation category was divided into four model
plant sizes.  Because such a variety of substrates and end
uses are found in the automotive/transportation sector, each
size model plant was evaluated for three different scenarios
of plastic part substrates and end use: interior, exterior
flexible, and exterior non-flexible.
     The business machine category basically uses the same
substrate and types of coatings regardless of end use and
plant size.  Therefore, the business machine sector was
divided into three sizes, each using the same types of
coatings.
     This analysis includes 12 model plants representing
automotive/transportation and 3 model plants representing
business machines, as shown in Table 2-6.  The production and
process characteristics that define model plants for the
automotive/transportation sector and for the business machine
sector are described in Sections 2.7.1 and 2.7.2, respectively.

                              2-36

-------
w
E«
3"
cu
J
u
a
o
X
Cu
0
w
vo
1
CO











£
8
II
• u
— **"
«• u •
w o
— • u
3 3*
i I *s
* ft OJ
3 - Cu»
5 I Si I
« • oi~
8 3 2 j. •
I u o a.->
M v U x A
I S ill
S r 15 fe
i l ri*
a u o o o
i • • • •
a. -5 2 S

1 111


I
i* ^™ ^i >2
J




-•
-1
*rf U
33
u — •

JJ ^
"8
colorcoat)
(priawr, colorcoat
bla (priawr, color
ill
11 i
•S • •

ill
111



» 
U O O O
su s°
-Si -ssf
S .J « ..I
3 >. Z 3 b b
u « 4 u « a
w 0 <* b • v
_0 •" 3 »
~a i— "3 &~>
U •o^ U w^
JJ5 J±3
|5S 85C
•— X i — X i
w i w i
w •» e w*. c
.£S8 £25
sss
S5S *•«
b U b ** —



*•  5 ""
— *" 3 S " 33* 23^"
•39 O U X 0 U X UUX
3CU WU UJU 111
— jii-i. ji«.u Sfei; —
*J • O O ^J • O O TJ BOO ^J
3^ O O 4 ^OO4 W O O 4
OLUU o.u(j a o u

11 1 !


1
"a •< «• u
i




ts

8
•
•^J
.«
bu*ine»s «achirte/a
V
o
i

3
i
M
w
i
"a.
?
1
|
V
o
/
2-37

-------
2.7.1  Model Plants for the Automotive/Transportation Sector
     Model plants were developed to represent the major
equipment and techniques currently being used to surface coat
plastic parts for automobiles and other modes of
transportation, including trucks, motorcycles, tractors, and
lawn mowers.  The model plants presented in Tables 2-7 through
Table 2-10 were developed from (1) information collected by
the EPA from responses to Section 114 letters, during site
visits made to representative facilities, and through phone
calls to vendors,  (2) data compiled by the Michigan Department
of Natural Resources during its rulemaking process,
(3) information obtained from the State of Ohio Environmental
Protection Agency, and (4) information submitted to the EPA in
response to its presentation at the National Air Pollution
Control Technology Advisory Committee (NAPCTAC) meeting in
November 1991.
     Four sizes of model plants were selected to represent
small (Plant A), medium  (Plant B), large  (Plant C), and very
large (Plant D) facilities.  These sizes represent the range
of facility types in this segment, from small job  shops that
perform coating services exclusively up to very large plants
with fully automated facilities that perform both molding and
coating of plastic parts.
     The three basic types of plastic parts coated in the
automotive industry were used in the model plant analysis:
interior, flexible exterior, and nonflexible  (or rigid)
exterior.  A typical interior part would be a steering wheel
assembly constructed from ABS, a typical exterior  flexible
part would be a fascia or spoiler constructed from RIM, and a
typical exterior nonflexible part would be a deflector for a
truck cab constructed from SMC.
     Most plastic parts coating facilities, especially small
ones, specialize in coating only one of these types of
plastic.  Although some of the larger plants may have the
capability to coat two or even all three types of  plastic, the
analysis would become overly complex if all of the possible

                              2-38

-------



OS
w
CO

z
o
M
l<
Q£
2
W
JjR
3
os
5?
u
>
1
3C
B
OS
2
co
s
g
§
£K
J2
CU
1
CU
J
u
0
§
1
(0
^*
1
M
J
03
*"




1
•P
c


CU







fq
1
<
_y
c
CU




1

e
a
pH
CU






u
anete
Ij
id
CU


J_L
o
§
CM


in
CM
^
in



o"
o
o
CM
fl
**

in
CM
•
in

8
0
(^
i
in
CM
^
in
*

4J
«
•o
•
3
c?u
-4 >.
*l -*N
« -^
0 «
U 9
.
• ->^
•-4 •
e o >i
3 »*{
JJ ^ U
U « i
3 W ft
•00*
0 t4 0
VI
eu

(*t
o
en
•n


in

°»
en
o
CM

f^
OH

in
VO
v

S
•
CM
ft
£
,
**-^»
• **
u «
O 9

^
t-«
O
2.


VO
CO
^
00
^^
in


0?

CO
o
en
^^

CO
rl

5

en*
oo
, e -g
^"^ -4 5
*» « « u
0 9 U «
-$-
vo in o
ft in










vo in a
<-i in










vo in o — — in •>.
«-i in o o • o
in • in t*i
OB vo fl f
CM CM

co CM in in
to t+ • 1*1
r» • in t*i
0 °
<-l >-l
u
•o c ^
• 3-1
5- S • .
M S, 35 U 1
i ; !: 1 2
h c ja^.9 3 ft
a* -4 o e ^ •
u « — o > *J > u
O O Vi « 0
•*> U SH *» 9O > >
• vi ^. c j* u oa
U • 
« • • i « i o-«9 -• 1*^
TJ • >• • PU >» 3 Vl 4J «». 0 3 ^
^ J ^s. VI Vl ^4 >, 0 « 0 m <-4 9
2 V 3 2 8 ° §^ §8i * §2
1 1 i : s 5 •
. 1
• • • O M •
14
0»
2-39

-------
06
Cd
CO

z
0
M
as
2
CO
1
u
>
M
§
ae

05 -»
fa Cd
D
83
p*< ^»
U 6*
II
Ic *•••
2
04
04
HALL MODEL
CO
•
r*
PI
3
3
&«
. <*»
4J

0

04



M
«<

•g
0
A
O4

••4
y^
f-l
•H "•»
1
<
C co
0 f-4
04

•o
04
u ^
« IS
0 *••»
g» i«W ^^
5 o «
0 .2
04 f ~
1 14
-t >.
1
-
















** ** in —» — .
in • in ot . « & *
« 4| C » -4 U
S & 22 12 ? U 1
8 " :I 8 S • 1
•3 ? 5^» IS,.*
35 OC^« T3 U
4J  44 > O -1 — . -4
0 0 U 4J 0 O U U
-4 U >» 44 9O >» > • >t •
w ^.ej4 • 14 *4 f4 C
44 0 « 44 »<•» • O — « O « M
e o» c a** -a M 9
M 1" 85S. i 8^: 1^* J8
>, 1 U 4J-*. 0 l>-4 9 U 4
Q 0 *>» O 0 O O9O^> 1
> j > o> •» > ~ ><^ x
u o«
< i i ii i a












,




^^ ^^ c^ ^^ ^^
C9 ^f * ^^ ^^
in • . a> fH
• § 41 41 0
5 ^^c* •+ m -a it
44 «M Q-« O -1 O
«— O > 44 > O -4— -4
0 U « O 0 U W
U >» 4* O»O >» > • >» «
^% e M o ja -^44
« a— a
a o-^ 9 ~* 9^. a x
a u 44^.0 3-^ aw fi
"4 >• U • V • -^ « ^ >• OB
0"^ooo oaio*x i
>»J >O> •* ><•> >>H JS
c
II IIIS
•
2-40

-------
a;
2
cu
CO

2
0
H
OS
2
to
55
2
&4
U


£4
Q
jS
2
<<
«-»
22
w!
0$ H
H H
So
2 >-•
02
12
cu
cu

MODEL
|
03
*
r-
(N
3
1



1
4J
C
id

cu





• « 5» • -4 >,
4 C -4 J3 «
K -4 ja *j -a ^ -4 u
Cb'4'4 « « CU M CU
• « «— >, o. « •
Ol«i4 8 K h. — »
e ^^>9 3 cu • 14 e
-4 u c -< • -a u >, -4
* -» "o>W > o in— -^Z? «
8U « O 0 M U « O —
S 4J 0»O >•> •>< «9OU
•^CJCUA -« +> — >>
%4f4 •  >» *
a — o e « -4 •> • — ' u •»«. §a>
9 O-49 -4 §>>. 1 « .5,4 I —
3 u 4J^> o 3*4 3 h o« 4 3
••4 >• « « W a -4 « -4 >, 0) 14 *4 U
O^OOO 0 9 0-^. U I i 2 ><
>u >u> * >~ >^ o rj >£
U -4 b
i i ii i a sPt I
M
H •









* • -4 O
* ^^ 04 ^t
in 04 in 1-1
~" £ **



in o» p» O
>o • in oo
«n « va
O ^1 *
00











b
>*
3 *4 TJ •
• 9 • -4
e -4 .a
•^ ja 44 *a -4 -4
•Si • I S !
1ft. ! & : c
o e -4 a T3 b
•M 5-4 0 -4 0
0>4J > U .H — ,4
« O O b b
u 9O >• > a >. «
CM 0 J3 ^ 4J
• • a — • a 4J
o^ 9 * !, a u
"* 9*4
1 II ISO











o
o
o
£



(V|
i-l
«
C4












^
aprayad
I
0 —
U U

-------
              in  at
              


         •U 9O  >•
         C J< O  A
e ot^ -o
o e « -4
o -4 o> -^
  4J->k O

m:
                 u
                 04
              •o    «
              5    2

              I    5
•a   u
-4   o

  8"u  u
  X •
  -«• 4J

°s a
                    I  la
                       3- 0>S
                       ;& 1^8
                 e




                 4J
1^ Jl)t  82 SIj

1-6 ?2  Isi, 838
>^ »•  *j" *0>
                                      O
                                3
 •»   -^   ^-^

fl   -4   J3

•   0.   -4
                                >t

                                H
                                                     u
                                                     CU
                                - I - I
                                o 3-i 3
                                   •   hi

                                   3   u
                                   -4 — 0

                                   S& T!

                                     ^ 5

                                       H
-
               1
H

C
                                       I  I
            0 ••*  *J •—»
             «  e o»-^
            • at o e •
            |_ 0-4 0»

    ^ >, ^ u 5 u  o «u*

    «»J| siisi


    I   2 CU I    I
>


.c


T


*C
                                2-42

-------
05
U
W

Z
0
M
2
w
2
9*
^^
u
8
jjj
*•
SL
IS
|s
2 ^^
K
CU
04
J
U
a
i
a
2
co

i
rn
a
a
IS
n
*
e
|Q
r-l
04



cn
1
<
G
(0

flu
P"i
1
*
e
A
04



U
4)
4J
0)
8
id
u
-






in en or* • wo o» o w •
^ (^ O • OK O On o • O
00— 0 U^ fl <0 — 0 •* •»
** *>r fj f7 *"'
*•" ""•* "•*

^^ doo r*»oho • r» c* aoin •
i-t ft «• OKO«H r»« o
O f» » O *
«n r* >o m





. u
•a e "•» • TJ e
9 « 3 H « • 3
« • >i 9 ••>i«9
~~~4~44« » -4 -4 4 C
Ufljl 14 C 4J TJ <-4 ij 14 -4 Jl 4J
«>
    , cb x • • —
§-, 4 • •— f 4 4 • • «
>-44 ft 9 4 8 U fl 9 4 iJ I
09 4 m c 4 1-) 3 o. • IN e ja-x.9 3
>— -a -4 ja^.9 -4 • TJ -^ ue -4
-4 u .u ueo -^ w 41 *4 o -^ o
U M -H — O « — . »4 O -^ >Q ^4—0 4 — O > -U >
O >• 0 M -4 Q u 0 > -U O 0 M -4 0 U 4
>^.4>iU U>« 4><> 4 X 14 O X 4J 90 >.
fl ^»« ^ 4J 9 O J3 ">. 4 ^ C J5 U J3
IM IM ft 4J IM ft C Jtf U s. I • 4 § O-^ 9 fl
34 3 w j< o 3 u 0-49 o 3f» 3 vt Mo 3 u *i-^ o
•3S, « 2ti -3^: «ti^ • -3S -3^ 22 -34: ggg •
>• >- 43 ^J S8JI * §2 S" i| §J §8g '
1 1 iJ O 1 1 II 1 4 U 1 1 I
• •







M CM
9 0
in ft



OK >O
(^ oo
d *n
•,






u
^J ,
fl T3
«
•O ft
X S
4 4
-, 4
4 -a
o "o tl
^^
0 — O 4
u a
-H "4 fi >
i i
2-43

-------



0
w
CO

2
0
H
&^
g$
1
w
1
a"
>
|
«-*
D
03 Z
11
s^
04
04

LL MODEL
s
X
1
(M
3
1



7
<
e


flu





 w > o ^ -5
Ob « O 0 U
UX419O >» > • — > •
"*» e Jt o ja u *i
 M
O * 41 «•— e 0 — O^» M
9 e 9*4 ^ vi * a
• ~ o e 4 -4 •>, • « e «
§ 0-4 9 -4 1^. |9 J3 O
3S, olis? 8 1-3 3~ 2g
^^ g8i * $2 Si J:3
H 3*S
II IIIS
— — d — « —
§<0 • <-• d
• in 01 in
o * <*» in m
£ d


ui d in 01
d in . ^ o»
»H • in r» on
^ O ^ * *
• ^ ^4
d f«
d













* X
^ e •«».
1 !. a^ 3
Vl *4 A 4t IS ^
Ot •*•* « i a.
8~ i - 5
f £• ^ 9*° *» > • *•
O 4 V ••— e O — O 4
9 e 9*4 -a w 9
e-~ o c 4 -» • > § —
I 0-^9-4 1^. 1

























i~4
Nonflexlb
14
• High-Bake Bxterlo
Clearcoat
§~


d


VO
in
1
fj
,M4j














«*
•o
M
Q.
•4
0 14
U >
 ta)
1
2-44

-------




«
£*
M
CO

2
O
H
g
1
2
W
c*
r1
U
H
i
X
^t
<
§0
fa W
M
W X
SM
H
EH Z
is
2 ^*^
5
cu
cu
MODEL
J
M
p*
1
«N
H
J
03
g




n
l

jj
c


^• V
e >^ • ^
5 -H TJ XI
« 9 « -*
^X) «! TJ 2 8
?£ - ft a c
• 0 4 4 C
4 ij I U 0
xl^ 9 3 ft 4 SB
g c -H 4 -a
 XI > U ,H -. 0
4 O 0 U «4
XI 9O >• > 4 > U
cj< oxi ^. e
• tu *• * ^^ i i
*< •»< ^ 4*
xi . -« • 0—04 M
e 9«4 TJ M 9 H
0 C 4 -4 § X f "
0-49^ 8^.8 •
xfv.o 3 -H 3 u x u
y 4 y e ^4 >-i >» 4«
O o 5 09 0^ aa i
> o > * >— >^ 1-3
q CU
1 1 1 1 U
•
^^
o
o
a
«
^4



m
00
r»
«
(*>


















•prayed,
?
•^
XI
0 bT
U >.
1* . ^j
^< ^
0 4
9
3 si
s^
1
-. in -. -»
O • in ot
• in * «n
» •
e -x. • i-t
y * TJ A
29 • -4
. -^ X
•^ J3 4i TJ -H •
-H ^ 4 i cu -M
« — >. CU  U > O -l—O
4 O 0 U -4
•U9O X > • >, Vl
CM 0 J3 ^ •
9 'M *M ^*J 4J
xi »— • 0—04 M
e 9^ TJ u 9 w
0 C 4 -4 •>••<- XI
O-4 9 ^4 I-** I • 4
a«J S !* IS, IS
S8§ - §2 §^ ?8
i it i 3 o
•
-. — r»
§— f» .
at
am H
d



M ao r>
P" vO •
in • at
» O fH
p»


















* I
>. • &
u -^ ja xi
cu >-t -H a
• • —
9 4 J 1
C XI "v 9 3
-4 o e -•
xi >M a -* o
4 — 0 > xl >
Ob 4
U >> xl 9O >
•^. e M u -a
Ma ^^ ^
*4 »^ 9
O 4 xl «— •
9 C 9^4 -O
• — o e 4 -H
lb °U£ -3
«-5 838 '
> J > 0 > «>
1 1 1
2-45

-------



OS
i
09

0
M
frj
CQ
£••
w"


g
i
o a
b H
3
CO Z
Its
5§,
2?
04
e*
04
j

a
i
a
1


^
a

-» — . -. — CO -» — >
«a en o o tn M


(N
M(

4J
C o O «•» «n o
0U




1
^J
C O O f) fO O
(0
04

u u
•** « ^ -o -^.
^ • ja « e •-« •
»>4M«e §i»~4
•a -^ « u -^ -o ^
« a ^ a -i «ecu e
>. cu  04 e
4 « C • -4 « 4 4 5
U 0 O> 4 ^ 1 U &
0*eZCJ3 3 0« 4
l< • ^ -4 J -^ • T3 • >i
ffl -4 U *J  O -( C U
« O O -^ 0 U O -< O 0 -* • 4 0.
2 > 4 — U O > *J > 4J > > 4 -» *J ^ C £ 4
B u • ^sC4^ we •*+*
•J«4 •**>,« *4^ » O»O • 4 T) *4 0 -0 fl
U 0 — . O^s, X 04 4J J< O 4. 0 -. 0^ 8 • 2 » •
2 W ^ H -hi 0» C T3 b^&Mb^M M
« « >• « 4 4 4 — • O ••— -<4>««4-4-*4 ~4 ** ^4 ~4
0* l-< -» Siy>4Oie<^4^ M > 4 -• 4J C J
0 Ol 0 U 03 4 0^. O 4J^» 0 O» 0 Vi •JS^«!«> 4 O
>~>>*I«>»J>40*>>~>><<*>4' ' M B f
<^ 3 -H OO "» C C O  ^-^5 Q. *•-«-*
I I iJ I I II i 4t O at O < it
• o • • • •






























c
0>
>•
a.

u

Blectrosta
(50% TB)
•
2-46

-------
X
U
w

O
M
fr«
£
2
en
2
£7
U
>
I
•M
§
OS ^
0 0
fa U
D
co z
OS M
H H
SI
5 H.
3
cu
1
cu

J



a
i
(N
H
J
01

«
4J

§ ° °
CU





 o









O O CO O




^
«

0.
a
b a us b
3 js a o
a jj • 







a
,,,
-4







^
"a

*






- clearcoat

2-47

-------
OS
Ed
W
35
O
g
g4
PS
2
(0
t
Cd
>
^
§
|4
<
o a
fiu Ed
O
CQ a
Ed O
|1
3
CU
1
CU
Cd
a
i

^c
JP
CO
CM
Ed
ij
CO

2*

 > >



i
(4!
4J
§3 5 5.5
,H 8 A 0 A
04 e- * 3 3
U Vl U
> > >




1
4J
C *4 • • «
(0 -4 r4 fl *H
2 c* 333
- ^11



. i
« Vl
5 &
U o
ai -4 IM
.U .C 
1 < 1 1 1



O O O < <
u) in in •*»-x
M M CM XX








O O O «
r* in in ••^•v.
^ M CM X X

•






2T I? £7 W

-------



OS

IJ
u
to

o
M
i
2
to
5
^c
6*
w"

M
|
§
Of
0
b.
to
S
i
s
itC
04

—
2
04
M
Q
i
§
M
3
X
•
CO
p«
U
J
1





<*1
1
OQ
4J
e
a
.H
04




CN
|
0)
4J
C
a
^j
i^^
04




r4
GQ
C
<0
r-l
04






14
a
Paravet<



e?
in -
01
*
j^
--


01
in
i-t
0

-
in
»
^
~


ot
"I
O

Q
in
*
2.

c«
in

»
^^
o
d


1-
9 U
-4 «
I2
U U
'o j"
e "oTj
O 4 U
3 44
! ««
04
00
en
_,
o
ot

in
oo
in
en*
o
*
*

CM
in*
^|
00

en

V
%

in
00
CM
in
•H

in
<0
%
00
^
in


14
f
3
"o —
44 4
52

m
en
%
in

T.

in
in
m
5 2 « S
^
^
^
00
00
oo


. 4
•H 04 *4 ^» J ^» U
0 — 0 • *>. • 4
e u O) u e M 04
> c -a 3 > e
•*•-» -4 o o 4 i e
4^ 44 -^ JS -O 3 e
44 4 4 U e
S0» M • U
— i a. • • • o
U4 kl
0 0.


















.




— •
r» o CM
« <0 *


en
2 *** 01
•
^? ^A
* O



! s i
U) -4 44
I s- * ? •
9 4-44
5 ? 5^ 1
Ck«4 y o -*
8 Str *>- §
U °-5 ^Jf3 *
e  >^
04 > 3 14 44 0
u f 3S 832 •
0 >J >0^ *
14 -4
e 4 i i i
44
M •
























— »
§
^
<0

0
J
^
^*
~

N


aprayed.
87
> >•

•*»
%t~4
I*
i u
2-
>**
t



2-49

-------
o
Ed
3
Z
W CO
e* 1
Z GO
^ c
ifl
OS ^
o o<
ca
z
o
6*
§ 7
2 •
W -P
z c
2 10
&« 04
Ed*
M
I
£|
I
oJ , o, -3 • «e
• 9 S"'-? 15 - oJ 9 5»4^ 1
•^ O A ^ <• 3 Qt • C J3 •*» 4 3
0 •* 0 0 -• » TJ U -< UO'H
•U  > «— ^ — . -^ « -. o> >
o o u — 3 b o u u o u —
u -^ej<«ja •^ "» *j ^» c 4* « ja
e 9 e 9V 999 9 e 9V 9
u -^ > o « ja •^>i,ca'H>4U«ja •
9 O^v O 0 »^ O-^. 0 ">. 1 0 •>» O O <^
h •*• • "^9 "*
< i i i i i a i i i

-






















- ~ « - N
(ft * O • yj
SI *"* r? i •**
*••




-* « * 5 *!
^* ® • m
«n ° "


« *» 9 c
9 « • 3
• O > • 9

9* i-4 V« U -^ 44
• O4 0 O4 -19*
>, Q» ~* m • c
U O 9 S U ** |
• 9 M -4 ^5^0 -
«4 0 4t  >
OUObUOW /->
>>••>•• O >» ** 9
•>. "«»*» -^cj««ja

-------
1
D
as
H
2
8


OS

CO
2
O
H
ft1'
*c
os
2
CO

17
\3
06
H
U

I
as
|

OS
o
£

U]
B

5
0.
a,
£
1
§
M
s
X
00
1
r*
W

m
&5



n
CO
•P
C
10
iH
04






1
00
4J
e
 M" -. ~ * oT
<* 41 lit i* 00 t0 . CO rt
in « ^ •» co o . in49^
^— " «^ «* o» *» *** in" tH
"* ~" *" - -



co n _j to *o ._
com  in M^2
^ ^ • to ^*? in in. • ^ ~~
in o r«ot«* *> ^
ct ^ ift ^

-.
VO 3
<•* ^*
•




O f*
in r»
p*

* *
•o c » 73 e •
TJ ^ ^t 9 9 V ^ ^ 9 9 41
« ja«e - -» JQ « c -^
>iO« ^ • -4 • 4 4 .H ••^•44
44 tu OK 4 iJ 44 8 U IN O» 4 U 44 f M
U C jQ **» 4 3 Ch • C A •>» 4 3 CU •
• * 0 "* -M^O 3 " 44 *!8 * 3
o— »4 — u o u" — . o TT o iT u o w" M o IT *o v«
OUOU « O><44 9*4 >*>>••><• U>44 O»^ >» > >• • >
> 9* •> 44 ^ cx 4 jj ^ "•* 44 >^ ej<« oa ^ ^
^. ">. M , o 4^ • £><~4>«au -4 >• o 4 a • ^ >, ^ >
M *4 W *4 O
49Sfltl 1 II 1 SOI 1 II 1
1 1 4J
M
H • •

2-51

-------
a
D
2
M

2
O

0»>

06

a
en
2
O

f^
C^
06
2
w

1
^^
H
H
i
06
0


V)
06
a
U
0,
1
0*

2-8. MEDIUM MODEL
H
CO
&5



PO
•
03

4J
C
<0

o!






CM
1
CQ
4J
e
cu



i
GO

4J
C
» r^
in • gj r» M M. MotM9«. 0. -^ Q» -^ 9 « . ft-4 O. -^ O>
• • c >. a, x • • c >, a. x • • _c
hi 9 « «4 4J IK -19 « >4 4J I U ^49 «jl
e £*•>« 3 o. • t» e ja->.« 3 o. • *• c jj-^.«
Wl -4 O 0 ^ • -O -4 O O -^ • fl -4 OC
0 41  > W -» «^ — • O *— O> > W— "4— O «— 0>
U Oh — O M 0 U -4 Oh — O h O U -4 O U —
• O >, 4J 9-4 >«>>••>< U O >< *» 9*^ >,>>»•>, U O >, *J O<-^
*» ^s. CJ<« A -x. "*» • ^ CM* A -» ^ • ^ CJ<«
H 0 « 4* -**+ m 0 m Q « M O«4J «^> • 0 « O « X O « -W -^
a- s2 §*8 3 .2 .2 " .2 8S8 S .2 .2 "4. •*• § ?8
?S lh °i> -3 lu lu JS lu °2S "3 lu lu JSS lu ''i1*
a u -i >, o «.a • ^>,^>, « u *H >. o «ja • -i >, -4 >, « u -i >, o « ja
I h 0 ""^ O O r* 0 "** 0 "** "9 O "**• O 0 ^ O **» O ^ m U O "** O 0 **
]SS >J >0~ * >^ >r* 4j >ld >°~ * >-« >^ i^ >J >o-
soi i ti i 3 a. i i ii i 3 3 i i

• • •

2-52

-------
I
p
M

2
8

06
O
CM)
fj
H
2
0
H
EH
<
EH
OS
2
CO

a
EH
^^^
>
M
§
X
i
OS
o
fa

i
04
EH
04

W
Q
O
X
§
M
O
H
00
1
1
M
H
09
EH


r">
1
CD
4J
e
(0
 ^ ^ «» C . -4 •
4J T3 -4 J3 U -4 4J fl ^ -H
>i Q. X • « C > Oi C
15^5? SJ? 13^*
3 Oi • Eh C Jl*v.4 3 04 •
~t 4 TJ -4 00-44-0 LI
0 -1 14 4J ^ O 0 0 -<0
> o — -•— o 4— o> > g— ^— -4
OUOU-4 0 U — O U 0 U 14
>• > >t 4 >i U UX*I O»rH > > >< 4 >i •

• 0 4 0 4 X 0 *4 4J »*>« • 04 0*4 H
3 «£ «2 "^ «2 § e 8 3 2 «2
rH 1 ** 1"" «4 i "* O-^> FH 1" I"* M
O3u3hJiO9bt 4t oSuluii
• -I >, -4 >. 4 O ^4XU4jQ • -^ >. ^ >. « U
0 •*» O"**. 08 W 0^» O 0 •-« 0*^ 0"»» 1 f
* >* >^4 14 > ij > O -» «> > ^H >»H J3B
ii i 2 o i i ii i a a.

• •

—
3 £" *
" » 3
<• •*•
"


CO O CO
r>» M •
o
MO •*
r<
























« e
• 9
J S »

• 1 I *
9 4 J 4J 1
•5 ^ 0*0 -«
u- «8° §
8 £ v *:r >,
^ ejt 4 JQ
"0*4 v --^ •
• 2 § °*8 3
a w o-^ > ^H
3 w *» o
"3-5 8*3 *
•^ >J 1^ O ^" O
1 1 1



—
OD ^
% ^o
, -( >
*^ ^*4 ^ rH
i i



2-53

-------
CO
=
(0
             Irt
        3°
                                    CO
                                    8
                                         M
                                         M
                                          •

                                         O
                                                     *  S    s
                                                     «  «    5
                                                     -  3    «
7
CO

^
10
il
§
MEDI
CO
I
(N

M
J
03

IS
    A   TJ
    r*   •
U
«
4J
0
a
(0
V4

2
cu
    3
    i
    u
    5
    u
    u
    X
                                                  I
                                                            8
                                                        o.   ^
                                                        &   «4
                                                            I
2?
28
I I*
$2
x3
               *
               "* >  "*  1
               4J    O  9
                    •  *
                           3U  « O
                           •S^1  ?8
                           5>  iH
                           >^  js «
                                0» •
                                "* *^
                           ISU
                                                      0    h  3
                                                      •  ^ >•  ^
                                                             3
                                                             O
                                                             iJ
                                                                         -
                                                                        o -
                                     2-54

-------
1
w f^
E" l
2 00
8 4-
>- e
10
os ^
ecu


U
0
H
&4 
c
en 10
u cu
04
i
cu
1 U
X 0)
* 3
5 a
H <0
P h
U (0
X CU
•
CD
N
3
03
10 • *~ - M — C* £ ^
,
3 •a ja i a  • 6» «
» -4 M « e . -4
«• *0i* eu^a««« cu
>iOi, cu
a««c •-^«««
§U O 9 4ij4Jlw
3 a, • z c jj'-« 3 a. •
-« • -a -4 o o -^ • -a
O -^ U4J«4OUO -^
o tr "3 IT -4 SIT o>— * o »r "3*?
rt ^^ ^^ A ^^ g J^ 0 rt ^^ ^^
• 0*3 0*3 N <0<« 4J »•>> • 0*« 04
•a 9 a> H » e o»y -099
5 1" f .* p 85i i 1- |~
2 IS, IS, -S8 IS, 8 IS A S IS, IS,
o -^ o-^ a u o~>- o o -4 o •>» 0-**
« >*4 >•+ I 0 > *) > U <- « >-H >>^
j -H
II I J O I I II 1


? w • 3 3T
• » § • <•»
d ^* ^ ^^
*•* "*


in * »
* u« . o N
"I • ° » 1
CO « » « H

















• • B
a I . 9 i
825 4* T? S
«4 CU ^ 9 4 • CU
«M • • e >. a.
O 9 « d 4J I U
Z C A>s.490t •
-4 o o -4 • -a
U 4J  > a — -* —
•«4 OU — O Vl 0 Vl
b U >» *• 9^4 > > X • >

4^ %4 ^4 41 9 *M ^4 *M ^H
fl °2 gi1? 3 °» °5
54 1^* O-^> -^ I" I ""
O 914.U O 3 M 3 U
• U O^OO** O*^ O^»
M 	
id O 1 1 II 1


2-55

-------
o
ca
D
Z
H
g
8

as
*s
g*
o
OJ
2
O
H
*$
Q£
g
w

<
H
U*
M
§
X
as
o

2
S3
S
a*
cu
.3
N^
ca
MEDIUM MOD

•
03
1
N
TABLE



n
CO
4J
e
10
Q,
P*S




01
1
CO
4J
C
(0
04



r-l
CO

e
19
cu





Parameter





~






o o n no










o o n no








o o n no




•
1
• >»
8 2
* 3 1 fl •
-4 M b J3 M M
f~4 e -4 *4 -.4
hi Qi • B —. « *»
o e OM 9 o
>, • -4 M H C J3
0» » J3 -^ < 40
e > jj i * i b
-4 e 2 ** u -n









o o o o n










o o o o n








o o o o n



B ,
cue
9 9 «
& » -a
f 1 J
& ' P >.
?s 2
0 ^H A
-4 « "2 *
« M I O Mb
^ «^4 ^4 9 U' ^ *4 A
V ^* 4 ^ sn4 "^- •j »f tJ
0 M 9 O 0 3 0 -*
b H C^i > — :: .Q -4
4J «j 0 1 Cu 1 O "M
o * i b .c [j 3 u
JIO ^>> JN
M" • • S— • • Q









O










o








o

«
a. S
• «
b
ing waterwaah
de-draft for
spray, down-d
spray)
4J-4 -^
« «TJ «
*^ «-• 9
9 *» e
O • • i
bJ= 1 1
•4 4* O
O O JJ b
• 0 9 0
02 4s
?i









stf etf
>^>^ o
zz









•v.^. 0
Z Z






j* ff
•~^^. o
Z Z

e
4J
b
h ventilation
), m'/s (acfm)
curing ovena
4J T3
82 1
I -
5-5 V
b 3 •
M «— (9
































C
c
a
ication
anafer effici
~i b
0, ^
0«
< 4
o» «
c b
Coati
Ave
2-56

-------
a
D


5P»
8


05
£J
U
CQ
O
H
«
2
2
2
e«
w"
H
i
i
ts
0

w
OS
u
i
04
04
u
o
o
X
3
H
Q
H
X
00
1
(N
3
01



1
0

C
10
Ou




1
CO
c
<0
04



H
1
QQ

C
10
0!




4)
0)
8
(0
10
04



™





^4 ^4 ^4 ^ j j
* 3 a a a ? "9 "9 o o o «
in a .3 .2 .2 minin >^"*.
m inr«r> uuu N»i«i»
* 3'a'a'a 'S'9'9 -o-o-o «•«
s ^«:p!t: ass iii*»
^.^n 555 -««


: 1 I
VI • -O 4»
0 5 : ^ « ,-
« o • M e *
4» -4 e f « *
« je Ji Ot A
O 4» O • •
U -4+4 U
S 5 5 3 3 8
-1-4 1 « X
S«M a ^ vi •
41 4»4li-4 • 4>4lfC 41 4» >
tj>« 4 « -4 « « « &• « « C
vTovvioo «
• • U • 41
> > 3 G >-n

2-57

-------






OS
P-i
U
03
IM
0
M
EH
«
O
04
03

2J
2
S
w
HH

Q
as
o
t4
5
OS
o
fa
CO
S

JJJ
1
04

e_»
3
^•4
flu
J
a



w
o
-5
3
*
0>
1
U
03










«M
1
U
4J
C
10
/-I
04









01
0
4J
C
(0

04







f4
i
•U

(0
04









Li
Paramete





_ 3*
cT °*
S - in
141 *
. «
rC CM
* 1
*"" 2.

o
* 2
CM ^
CM ^
S 8
£


^
	 00
eT *
5 r-
"* «n
p^ "*
*•* CM


in
at J*
CM
Ct ^
to ®
*** »
^

o ?
in 'T,

pT f*
* *


(9k 1^
CM CM
CM •
• d
o» r»
^O ^D
CM


S
• — W
3 14 >
9"^ iJ
C *4
-*  * • U
-* 04 >•
V >H 4 -H'X.
U « O «^
3 -W 4> «
TJ 0 *» 09
0 fri * H —
14
04
0*
f-4
a

>o
in

^

CM
^
CM
% _ ^.
§ 2 « 2
o
f*


-^
1*1
co
m
O
CM
^


in
«M
«»
uT 2 « 2
1-4 t-i in
o»
in


CM
CO

at
CM
CM



S « „, 0
» M 4 f
3 5 ° 5 8 ?, 3
•3- * ? ^ ^ ^ 5
• g, ? « S 5, -S *
-1"-. -4 0 O 4 « •
4-t *j -4 js -a 3 •
4J 4 4 U «
O 9 14 « U
H~$a>*«oo
a. 14
O 04

































^ -« ^ —
2 o , -i 9 4 « >
J^ « e > ^.
-4 4 -4 f 4 -<
944h44JS W «
u c a» .0^4 3 at 49
ft-4*- OO»H • TJ —
44  > g -~ -i u
0 O > — O U 0 >
-4 U1^ -U 9^4 X > >» ••>.
14 >J GM 4 A ^ ^H
•  44 •->. m 0 4 O •
44 C T> C 9U TJ 9 TJ
14-4 f • OCO>4 f ~ S '
Cb > 1 4 44 O I U 1 ^
t4<-4i4 O 4 ja tie -i >i -i a
M TI ooiOOrH 3 o^^ o a
o >• > o — * 9 > -• >4
-4 14
14 -4
« < 1 1 1 1 1

e
M 4)

2-53

-------
a
D
Z
M

Sp
8

«
|
CO
2
O
H
6«
<
EH
«
2
(0
2
2
£1
•>*
u
>
§
X
<
§
s;

03
OS
M
2

1
"3
cu
Si
A
h4
Q
i

»
0
•
(N
U
CO




f)
1
u
4J
c
(0
,.4
cu








01
1
u
4J

(0
r-l
04





<-l
1
y
4J
<0
r— 1
0.





^4
4)
Paramet




™


















*








£~ S « «----.
A <^ M ^4 ^ ^ f% IWI
T. • • "1 M PH • _J d d
8 * "* S -^ ^2. S * i

^^ *^

^ p»
S S ^SJ 2s «2*
_T « ^ M ^ * **t 55
~ ^ ' ^* * * A Ma * ^
i^4O»« « >•! >, ^ O» « « >
u -^ « c > -^ -3 ^ « c >» -«s.
-^ 0» « * iJ 4J S U «CUO**flJjJS U 4
0 C 0* Jl ^*^ 43 CU fli O* fi 9 J3 ^** << 3 Qi • 9
o -^ — ' oo^ • •a-~u-*<~ oo^ • -a^u
4J » — o u o >. u o >. — o u o >• w
u ijej<«ja •>> ~* v *t GM * a **> ~* 4*
4I%4 419  O » 4* -^ • O«0*MO»4J «>^ • O « O » M
C -0 g 90 -0 ^9 -0 ^-0 C 90 "O _9 "O
-< •« o c o -^ S ~ 1 * !* o e o -< S "* i * * •"
>> 1 « 4« o iul^«i« 4J o 1 u 3 ^ « o
u «4i4 u«ja • c -i > -4 a m -* u o « jj • e ^ > ^ o. « o
^3 0 fli O 0 ^ 3 0 ^^ 0 Qi 1 0 Oto O O *"4 3 O *^* 0 flU 1 W
kl 9 O*^
^J ^J ^J Q
41 1 1 1 I S 1 1 I 1 IXO
• • •





























9 —
in vo
^ •
•• »
^ '*"*


\A
a in
% •
fl O
^

14 -•
> *4 9
*** « C
94 « J 4J
4 14 O S*
o >* ^^
Voluma of c
aprayad, L/
VOC contant
coating, kg
(Ib VOC/gal

i i

2-59

-------
a
w
3
Z
W
£4
SB
1


OS
2
u
CO
Z
o
M
e_*
PORTA1
w
1
t*
^^
u
>
M
1
5
OS
0
h

CO
Cj
U
p*4
X
*£

£4

04
J
U
a
i
Ed
O
•
at
fM

Ed
i4
S
6*




n
1
U
4J
C
10
,_4
a*




(N
1
u
-p
 S
2.




„ «-4 O)
. '* *
* 1 « o
"* CO CM

-W fl 14*
4 * >»
>« ->.
• 4 -4
i w 4
3 Qi • 9
-4 4 fl '-
0 -4
> O — -4 V(
Oh 0 >
>• > >. 4**«
A ^. ^
. -« a.
3 O"^ 0 CU b
* 9 >*^ > 4 0
•^
u
III*
M
X
u
















I * * | S
* « 3 CM* 2
•^ -4 3
"" -



^ *0 MK
o in * o 2
in «o • CM 2
» . !•» . °*
(MO CM O aT
o> r» *











«
— e » —
U -4 V fl U
>, -4 0» 4 « >,
^ « e >» ^
-< 4 -4 • 4 -1
944(4448 14 4
e 9 .a^-4 3 QI 49
U ~4 > UAP4J4
U U 0 >• -» O U O >.
«4 (!•>« *J 9-4 >• > >, 4-^.
•us N) cj< 4 a ^ f4
X-3 »4 «9 «M-4 «0-4>~4 i 1-4
4-434 41 0 3 U 3-4
CO .Q -4 U U4JB 4 C -t >i -4 Q,
1-4 0 Q. O O -4 3 0-^.OCU
£ X >• >0^ *9 >-• >4
9«
-4 -4
X Ou 1 | | | I
•
%




































W 44
O 4
-4 O
h-Bak4 Bxt«r
xibl* Color c
94
-4 -4
X fel
•
















eT
rt
in
«
CM
l»l



in
1-4
<
-4
II
Su
!«
i*
h


•

















_. •
4-44 4
4 «J 4J 8 M
xi^.4 3 a
00-4 4
 > O —
— 5 u
SS"3 j? >^
• 9 -M-"
V « -4 I
*> o 3 u
U 4^ 4 C -4 >
O O -4 3 O-x
> U ^ * 9 >>H


1 1 1


2-60

-------
O
U
D
2
5 n
i i
Z, 4J
C
« «
CM C*4
0
w
<
I .
U 1
3 o
0§ 4J
6* C
***• «J
U r-4
> 04
M
|

«
O
fa H
ca '
aj y
W .p
U ^"
2C *
1 *
04
|
04
J
U
a
i
E 2-9. LARGE
Parameter
i4
CO
&«

-









_^
^ o ^r ^*
ao S IT *
^3 fu ^^ ^^ Q^
QO • 09 *O
* 2 * n £ i
^^




O ^ CM * r» OK
rn m in « CM «-4
^ ^ O *^ ^ O
d 10 1*1 r^










« e
-» — C • — -4
5, & ^ 01 li i Si a
S ^ S 5 s 5- ^5
« 944k444§ U 4^4
• O) Cai^)^43 Qt • O» *•
•O — b 44 •* «- OO »H « T3 —
-4 O444  > 0«*~4b O
0 >i U 0 0 X — O Vi O >. -4
• "-. • b O^ 44 0»-4 > > >i «-^ b
*4444 J C J< 4 J3 ^N ^4*
« • Q * Q * H
TJ O -O C QIC TJ » « H
«e « «« o c o -« i ~ f •
i-^JSc a >. o-4> -4 I 1-4 e
3>^4^34 44 0 3b3*^J<
-< cu 00.0 -i w y «ua • e -• >, -4 a 4 b
o cu 1-4 ootOo^ a O^N o cu ca •
> 4 J8M >• > Q "~ * 9 >** > 4 Ifl
0* • * ••*
-4-4 Ob
i x *. i i i i i >Ja*

• •












j_^
*^ 4^ Q
w o" "J S « S
"* ' M « N .
• «e •* • m ..^
CO »» *"* i^Ot« « >>-4 >
~» « C >. — M --
-4 • -4 « « -1 • "•
Ot44ij44B W « -t Ol«
eo*ja*^43 Qi 4o>h> ca
^ -~ OO^ • TJ-» -4 —
44 > y — . -i u o 4b
>, -. ObON-4 0>
u "^ 44 o»*4 >» > > e ^« b O'*-
iJ GJt 4 A "^ ^4 • U
. e 04O»M 0 -
•a e o»y -a a* * H n
ei o c o -* 1 *- 1 • ** i «
I > 0-4? -4 I i-4 « 4 1 >
34 44 O 3b3-4J, -« 0. 4 U -I U
0 Ck O 0 •* 3 0 "*-. OOtOlb OO
> 4 > 0 — * S» >-4 >4 10 >•
j ^4
1 1 I t i J O t

•

2-61

-------
a
3
H
§
^

OS
o
&^
^J
64
CO
Z
O
fcri
£
OS
2
CO
1
§5
^^
Cd
H
UTOMOT
I
W
8
3
«p
1
fcri
0.
j
H
Q
C9
1
CN
W
CO


r»
O
4J
C
(0
s
B*








M
1
o
c
<0

04


1
y
G
(0
04



M
Paramete




1 - «
* » °
i



r*
O O CO
w in •
• . o
MO ^



— *" P 5" — 3" *"
i^ ^*2^ MC^ ^ocn
in SH,*^ 'tW o"^
^* «s ^ i ** f **
"



eo _. m o» _,
co r* o JT >o O co eo
O ^°^in cad ^eo*^







e ,-«^-.e »-• — c
— * 44V MJ3 U -4 4J ^ U V< -4 4J
«e >. -V.M -^ » c >» -s. ^ *• c
• -^ 4 4 -^ « ^ 4 -^ « 4 »4 -4 4 -^ «
4U4J § U 1 r! W4 4UM I U 4 0*4 4nJ-U g
£^••43 Qi « 0« fct CO«J3'>>43 Ot « 0» CO»ja*>>43
U 0 -^ • — • U U -4 ^- O O ~«
 > CJ — . -^ U O 4 U 0 > > O—^W-*S4UO> >
e5*4 5* >>««*^W O^.*» »^ >» >>4">.«UO'*»JJ O»^ >t
Sdlf 5 °S "T,* 2 %* loif 5 ^ft °T? fiJ5 ^^ lolf 5
85§ ^ 1- 15 .tJ 1?, 85g ^ p 15 53 15, 8-5S ^
** 0 3h3<^J. -< a. 4 u -t M U4j9 4 e -H > -^ a oa 4 -• u U4J3 • c
O 0 ^ 3 O^.OQ<(BU O Q4 O O »4 3 0 'x* 0 CU 1 »^ OCUOO^ 3
>U'"<»O>>>^ > 4 14 > 4 > O •» <» 9 > ^4 > 4 JS • >U"«Oi
0 -4 -»O
1 llliJCJII 1 1 1 B Z 1 | l
' •
2-62

-------
1
e"?
£J
8
^*
OS
g
w
CO
2
O
H
O
0,
M
3
S
6*
w"
M
OS
o
hi
CO
s

U
»
i
O4
&«
2
M<
j
u
a
i
U
at
i
(M
04
ta
£«

(*)
1
U
e
10
04




C4
1
O
4J
C
a



H
U
•U
G
(0
04





Parameter



O» 9»
^ 00
•o r>
« %
^ CL



* •»
2 S
« U)
m «-•





















^ 14
>» "-»
« -4 4t
Volume of VOC ipr
1/yr (gal/yr)
Volume of aolid*
applied, 1/yr (ga
gh-Bake Exterior
nflexible Colorcoa
-4 O
1 1 S Z
•

o
in
CM
nt



10
oo





















vT
^
Volume of coating
•prayed, L/yr (ga
i


—» C4 lO a
* « °. s
* m ^ •
*• ' fi 3,
•


in « | 3
in • . m
' M aT •
° W "* M




















e
^4 ^ T3 14
-1 0> « « >.
« e >. ^.
• -4 e « -^ v
« u -u i u « «
J3^. « 3 O, • O» 0
O O -4 • -O >- V4 O
** O O O «4 O M
0 > > O — . .* U -* «
~ O U O >. U •
G J* * A ^. -4 4J O
« 0» IH^  U «• * O> >>H >« JS«4
o»c
1 III 8Z
•

I « r 5 5
M gj CO «O
lA ^ O * *
I-* *"* ^* ^



»• * 0«
O 01 * O 00
f^t U) • CV^ W
• . en • .
MO m in in
at in -H

*


















- S .
W -W 41 •& V4
>« -H o» « e >
^ : 5 , sr ^
?3. ^^ 1 S, .S
•* — yo-< • -o —
•W  > U — ~4 U
>• — O 14 0 >
0*>. 4J 9*4 >, 5 >, »^
~* S^S ^ »4^ *4-
°i l?8 3 °2 °.r
§ « *3 'o S u 3^
^M u«j3 ee ^ >. -H a
ootoo*^ 3 o^ o a
> e > o— #9 >-• > «
ii ill


2-63

-------
s
D
M
H
Z
8
>^

OS
2
y
CO
o
M
OS
S
CO
I
>
o
X
OS
o
CO
OJ
Ed

04
04
w
Q
O
Ed
O
•
9.
1
Ed
00
&*


*"•
t
U
4J
C
•2
eu





i
c
£




CJ

4J



Parameter






























-Bake Exterior
flexible Primer
11
•


CM
-4
CO





«n
in
,
o














>,
f+
9«
e 9
44
« w
0 >,
O1^.
•4
t >»49«
• a >• -«v ^ e e

«,-)+> 8 U 4 « 94 « H) 44 I
JJ-^< 3 CU «9 0 69 A**** 1
00-4 m 13 ~ 0-4*- OO.-4
*4 O O 0 -4 141444 -M O O O
o > > g^<4uoo«uo> >
44 9^4* >i >>•->» U O O'** 44 9^4 >«
ex* A -^ -4 «u J ejtm j»
« 9 H4 »4 , -4 a « « ^u w «-fl ee
>oi «9 >^ >• i»4 >e > o ~ «9
1 1 1 I iJ Z 1 1 1
•

_^
if !'
*^ fH «?
^ ^ ^




^J *^ ^w
* o **
0» « 0*
^ " n
•













i I I
4 «™4 >4J ^
U « « 94
a • 9 o c 9
-4 U 14 44
O — . ^ U Q« « U
 -JO. «J« -414
O ^» 0 Ot m ** O U
1 1 3 X t
.

2-64

-------
o
w
a
g.
2



OS
p
o
0)
z
o
E-i
!
en
2
£4
•^
W
>
i
o
fa
w
g
«g
3
2
a.
a,
j
w
o
i

Ed

U
GO
IS



01
1
O
•U
e
10
cu






1
o
c
(0

a.


H
u
c
(0
o*





^0}
V
+J
a
(0
(4
(0
a.


-*• -i*
* « S S
W ° * *"!

*" i «^




01 ...
o •
« B >, -^
• -H f « -4 • •
4d44lb« • e b «
-a~x« 3 a « o« B 3 3 jc
O 0 <^ • TJ — 3 Ql • 4J
 > O — -4 b >• « O
— O b O >. « >• « b A
-U QiiH >. > > «^. ffl 4 b CU
• •*» ^ *4^ H-^ *J 5 « . S, ? i~ J
4^ «"x, •O40»C-4CJB« OH b
B g«o -o .°lJ.'0i« •*•**_ ° -^t* °
O C O -4 •^-•••B^'40'Q TJ -4 9  -4 § 1-4 a « o • • 4* • i* •
•P 0 3b 3-4 -4 M b J3 H M 4 M SO M b
U«.a«C'4>«<-4Ql3-*49 ^4 ^4 ^ 4J >-l -^ 3 OT «4 ->4 «
>o>-«9>^r>4«o 635>3go5'3g'o'~3giJ
> • -t w»4 6 2 UH B JO >— G 2 -4
0» • £ -4 < 4O4J 4Olfl«4O w i » • h o* a b £ .j a b
-4 B 0 *4 b Ul «O O»> >
4J O 0  • • X "- • • O
S
2-65

-------
Q
W
D
2
&4 C^
2 J
8 °
C. -U
C
os fl
| 0,
W
2
o
H
?s
OS
o
04 O|
«) I
5 °
i +>
H c
u* fl
> 04
M
Q
|
OS
o
s 2
u
S 4J
M C
2J 10

ffi
04
Ei
0,
iJ
H
a
i
M
H 0)
S ti
OS 41
5 a
14
«
04
1
H
J
CQ
i


_







—
m 2 no
o • *^ «o o
«*4 ^*











^
m 2 
44»> 4J*. JjJ CO
^5-2 g; ^7 5
o» i u a > • > b
e a fta •> * a
~4-qa usa f u
4J-4 »4 4JI 4J fl
4 • Q 4 0 • 09 'O
-4 -'a 3 o — ov a
3 jj «s ja-4 ja «* b
u a 4 4 4 1 -^
bjsea >• 3 xo » 44-^
-i b -Ob OO > >










a a a
444 000
•3 -3 •«! r» m m
b b b ^ CM w
444




a a a >, >, >
3*3 4 4 «

III 332

a
•3
^ 4^
3 1
& J

b a. u o -ua Q. o u
• b
> 3 e


2-66

-------
       n


       U
         z:
01
a

I
         •a
         «

         2,
o
o
         • 44
                                       2-67

-------
OS
Q
p^
o
u
03

56
0
M
&4
1%
&4
«
2
to
5
2
&^
H
E*
2
g
g

OS
2

to
OS
u
i
I
04

e«
ss
fC
04
J
W
Q
0


W
3
i^
cc
g.
x
CN

*
o
r-4
1
.
•W "X
srf
u »

oduction
Total volume of
uaed at capacit
(gal/yr)
u
cu
^
\J3
V0
0
o
ro
en
»
on
~~


.^
(*i
*
00
00
^
m
o
en

^
oo
O
en


olld> «p
L/yr (gal/yr)


— ^ m o
en 01 in
01
en
en
vO
01
%
^
^"


^
^
on
en
01
Ol
Ol
— * in o
O 01 in
*
VO
O
en
d


en
01
O

f^
f4
^
60
— •» m o
« 01 in
in
>o
 14 a 4 « • 1 4
-4^4 -O « >i 4 B>
04 0 • ^. • 4 U
4 o» o» u m M a» o
— c -g 3 >. « -4
-4 ^ 5 0 4 « • U
4u.tJ~4.fi-g > • •
44 > 4 VI • 4J
O"- H « 0 C
Q. U M
o a>
































*» — Ol
a o
in . *>
Ol vO
^ "^
p»
•**


r+ 01 01
^ P»
P» • ^
• O
en
01
Ol » «
a o» 01
-4 e e
4& *M •**) ""4 4i
u 4 u o ** ** e
O OX 4 J3 4 -
-4 O'X 4* O-* 0 XOI
u »] e u ~u A
•  4* 9 iJ -» • «
e TJ u c c^^ -a
M f « X 0«4U4 -4«
i x~>> u »« o a* -i £
X 3 4 -H •>-«.o:
UU ^4h4 O • O • -^
Of O Q. O> O * 9O O
J > 4 — > J3 J< > *>
-4 U
< a. i i i
•


2-63

-------
SECTOR
_
0
|
I
CO
Gd

1'
5 5
!< g
(X **
2§
CO *~
3
U
1^4
2
5
cu
fri
5
j
cu

^
u
o
i
u
05
T
NN
1
o
H
1
c\l

w
00
£5
r»
1
Q
4J
0
CU



•
M
0
4*
C
0
cu


•
Jo* P o" o" **! n o
in oo in • ^ t«> to
O4 OJ ^* 10 ^^ 00
co «H «n * «n
H VO *-• ^ O •— •
i ^^ W d
Q " "
4i
C
<9 f^ ^4 O€ O4 Ov ^B ^^
p*4 00 ^^ ^^ ^^ * ^P ^4
Oil^OO ~* • ^<*4
.
• C t3t O> •
fl -^ e e -o u
<«4 ^ %4 -*4 -*4 • ^4 Q
0 U ^14 U «U 04J.U SOU ^t U -^
o >• ox o o >» «ja « 5 o >» ox u
n >^ -^ 1J °^ S8i8 ^^ >^ '^ 5
ffl. M*J « • x o-to « -• • § •— f • x •
0 1 S1^ i^^1 xo i S^" °«5-5 ol l^x §3^ 4
14 ^u« rj 9«« wo ^u« u* 5i *"^ •* *•"** -»o«« a» u
M OOUWOtUWQU 0 CM O* O 4 O> O 0 0 CU*^ 0 CU 9 1 •
£ > • — > « ~ 0 >•<- >JO|J(> * > >•« >«*~ £B
* M^ 9 9-3
-40 -- -^ W
i i «o it 111 xeu

* *
















0 *
in
r- in
<»7 "*
"•*



in in
on \o

0
•H


C O> CT
-* c e

4 U 0 4J JJ
0*>. *l 0 2 0
j e o <»u
"^w 3s^
-^ u « u • u
§3-2 g«ii

1 1



2-69

-------
as
g
w
ca
§
H
61
«
O
a.
to
1
w
^>
M
|
P M
E 3
Sg
II
CO *"
8
ft
S3
tC
2
2g
a.

64
2
o«

J
&3
o
o
z
ca
(3
^•4
EXTRA
o
H
|

3
OQ

r*»
1
O
«
flu








Of
1
Q
4J
e
A
04







H
1
a
c
iO

a.







(4
«
•M
8
M<













o"
o
o
in



vO
o
co
.)r>i vO in c« <-t oo
• CA *d co in • 01 ^
m r» ^ m • in in ^

• c at ai • e
TJ 14 -4 ec •a u -^
4 ^4 O -«J *W "*4 •*•) * ^4 Q 44
c y u -• w -4 4 u o ** *i euw -4 w • -4 4 u
3 O >« 0 >. Ui 0 >» 4 JJ 4 3. O > 0>« Wi U O >
> >'*« ••^ « o->» 4* o -4 o >a> >"** m-^ «• o-^
J3 f* -4 4J iJCO^OD -4 -4 4J 8 U
4J4 — » • 4 O • O •— • H M 0 >
*o "O w ^ 14 Ttuec •>»»4 t> Q fl u 4J a> •o
-4 § ••>« I • >» « ** 2 « ^ o-< o « -^ • i « — !•>* w • i*
-4 I I >,•** § -4 -^ J« 4 § >^ 0 ^ O 0» -4 1 § > »4 1 -» ^s. « J<« i>,
O3 3 4-4 3-t^4 4Q 34-4 «>^. O3 3 4 >. 3-4^4 0. 4-4 d4
• -4 -4U« -4 0.4 OIO -4 U 4 0 • U «-4 -4 U^s. -4 Ot 4 ad -H U
0 OOiOi OOiO) Ib O O,O> O « OiO O 0 Q.-4 O Qi O» U 1-4 0 Q.
* > >«^->4— £0 > • — > J3 J<> * > > • « > 4 — 0 JC X >•
CII^^ 9 **^ 9 0
-40 ~ l«-4-4
ii i ao i i it i •Shi
M
• H •

2-70

-------
OS
CO
z
0
H
I
1
CO
2
EH

u
^
H
is
|« 3
Sj 3E
*^ hoi
11
CO ""*
OS
H
04

E-l
3
2
cu
J
u
o
o
ac
u
2
3
£
H
0
1
^

U
•J
03

O
4J
C
10
flu








i
a
c


&



fH
1
a
•P
e.
(0
a.








Paraaete













— (jt ^. _ -.-. o, _ ~~
*> • «O 9t O vfl • d 9»
* ^^ ^1 *4* O^ * lA 00 ^^
in  •» cir»^
oo in 91 ^ in



in 91 o o otin d'OOCN
to «d
• 1*1 9» CM CO • in009>
O CM • • » o m»«
in 9t r» r» in
i-* d W -^ -^ « -^ 044> «U -* -* « -^
O-W4J B U 14 -1 M -^Q4t4 O ** *J SOU -^ )4
4 jQ 4 5 O >» O >. UUO>i 4 JS 4 3 5 >. O >i
41 0 >^ O >9>'x. a-x, « U U-x. 41 O ^ 0 >*9>-x. ••>.
C O «-O JQ »« ^4 4JO iJ C O — '« J3 *4 ~l
24J "M .»H Q -o w ^ u
P'4Sa*'S it** I*!*'?- iS.** P-^8* "* S !•* !•>
O ^ O 9 -4 | § >,^ | ^ "v. j< • | >,x.. O -^ O 9 -J § I >^ I -4 x.
• >-x* O 3 34^4 3f4»4 4-4 34-4 •>•>>. 03 34-4 3-4-*
U • U «-4 -4 U 4 -4Q.4 OB jQ ^4U4 04 U •-» -4 U 4 ^4&4
O 4 9O 0 0 0.9 O 0*9 1 -4 0 Q. 9 O 4 9O Q 0 Q. 9 O 0*9
> AM> + > >•«• > m *- ji * > • — > a M> * > > 4 — >4 —
9 •

i ii i a to i i ii i
•
0

2-71

-------
OS
g
w
«J
2
0
H
%
at
2
CO
2
£4
^^
u
^
H
i'
i? o
2 2
*• 1^
osB
f* 5C
i~
04

g
*|
•04
J
0
o
ac
a
1
H^
2
1
*
O
H
1

1
o
4J
c
(0
0.









o
c

04


1-4.
1
a
c
<0
04






Parameter













-.-» .»-.-. -»-. «-,
O <*l • CO ^ OO • 09
1-4 • cncoeo en* in 1-1
o •* m CM ^ env0 ** ,H
O O CO ^ r^
in fi — • CM CM


COCM ^onen r» CM mm
oo u) • m en OB r^ • ^
CM* cn*ao M« uten
«O rn«% «O *^«
en ^ CM ^ en
oo ^ ««i en P-










o< . « w - «
e o» o» 4 e o» o»
u *j -4 ec TJ -« ee
04 4J « 4J34 9O> O >» -4 U 0 > 4 J3 4 3 O >« U
• h O^ 4JO-^O >.O» >^> ••>. 14 I O-*. *» O^ 0 >»O* >4>
4^4 ij c o --o ja -H m • a ij c o '-o ja u^.
M M %4 tt ^J ^M %4 ^1 *4 %4 0 ^J %4 ^lU^^
H^H O »— ** « J —> 44 O •— O «•*> M t4 O •-* 4J 4 J — 44 044
U TJ U C C'x.^ -Q -Oh *O U M 0* -Qh C C ^.^ T3 O<
• ««>«O-4U4«4««4>ifa>« 4«>»O-»0«-44«« —
4 -H §4^4* « >^> O9 34^ 3-4^ .5*4 3 4^4 « >"N. 03 I 3 U
OBJ3 -4 U * 04 O 4»« -I U 4 •* Q« 4 4 H -1 U 4 O • O • -4 -H ^ >.
1 -t 0 QiO» O 4 O«O 0 0 QtO» O 04 O» 08-^ O 0. 0» O 4 O»O O OO^
JSW > 4 — >jQJ<> *> > 4 ^- >4<* IX >4— > AJt> + > > > ~
99 * •
-4 -H 5-4
Shi 1 II 1 Ufeil 1 II
0 0

2-72

-------
OS
g
U
CO
z
0
H
Ei
OS
2
CO
2
t^j
^^
U
>
H
|
O 0j
CJ 23
< §
OS E-i
8g
i
cu
H
2
2
cu
J
U
a
o
X
U
fj

2
^•1
g
0
1
M
H
J
03

n
1
O
4J
C
0
p-l
CU









(N
a
4J
g
a
cu


H
a
-P
e
id
cu









U
Paranete














-. -.— r--.— — — co
in or* • en o en w •
\o -4 • en ^ ^ en • o
vo o m -4 in CM cn« »
^ O O * ^
— U) * —• N



»4 oooo f^f^en ^o oo
O 00*0 «*O*9 ^|tf) •
m c«>eneno <0*o
. » O »^ - » <• Q •+
vo en •-( vo ^
oo IA <-« . en













en o» • «
• e*« • c o> o»
tj 4J-«4 o»9 -a 41^ ec
-4 14441 eC« -4 U « 4* «4-4-^«
-• u o o « u  -i o o >i o 4» 4* i. 3 >» o >• -« o o >. «^« 3
•>» U U U^> * J3 * >tO» > "«• •*«. b>4 O ^. 410^40 >*O<
<-« «o iJ 4^oja ~t -^ • « »J e o — o ^
-• O 4* "M «4 4l**M • JJ
0 .— xq o «— • •« O »— O «— M^ o .-» 41 • iJ -» mm
•O U H O TJ Ui 4* • J — -O -O W *0 h H U IJ U C C >"< T)
««>i « • X C C *-.-4 ««• «•>« ••>• i • > ° -^ Si * ^ *
I -« ^ « • a >»*^ o -^ o « -i i 1 >.•»» i -^ *«. • • 9 >•*•» o ^ o o> ^ a
3-4-4 J<-4 5 « -4 U-4QOI 09 3 «-4 3-4^4 jif^ 34-4 •>•««. 03
-I Q.« 4 J3 -t Vi 4 «>*^ »-4 -4 H 4 ^ CU4 4J3 -4 W 4 U • O • -4
o Chen ea-4 o a,o» 040 o o o<9 o 0,9 pa 3 o Q.W o 4 o»o o
0-4 Q -4
1 iJhtl 1 II 1 iJ •» 1 1 1

• •

2-73

-------



OS
o
6
U
CO
2
0
s
E-t
06
2
ca
|
^^
u
g
O
•M ^^
If

< *
sS
CO *•*
8
cu

EI
2
J
cu
J
W
a
o
X
u
i
^5
H4
^
a
u
o
1-4
I
(N
U
ca
C_|





n
a
4J
C
id
cu







(N
1
a

(2
id
cu


i-t
i
o
4J
e
*
cu









h
Paranete



O W * **^ 1*1 O
•H • O 00 00 01
o * «* « r» o»

O O* 00 0*
in m — o»


«o O oo * m m
O in • «r 
^r ^r




f"| tf*
« •»
Ul v«O
U1 f-t








,





g> * « . j?
• G QV Ol • C
•o hu-4 ee 'Q u -4
-4 0 ffl JJ *<-» -^ « -4 0 4J
Ut« -4 ^ ^ g 4 Vl 04J4J (SUM -1 W -4 4 h
O >. O >l V4-3 0 > 4^J « ?5>t OX 14 OX
>^ «-^» «u o^» 4to-*o >a> >-+. m-^ • o^»
r* -I 4JQ« tj C 0 — O ^l 4
« « >1 i • >1 • J3 « « >l 0-< 0 * -4 f ••>! ••>• • J 4J •*>
i >^ §-*-. j<-i I >^ o^oo» ** I 1 >»^«» i-^-s. j*-^ « !>•**•
3 4-4 3-t^ «M 3 4-H «>>* O3 3 4-4 3^^ 4MO 3 4~4
^144 -I Q.4 0)* -t Wl 4 O 4 U 4-4 "I h 4 »l O> 4 CO • U >HU4
OQi9 OQ«9 1^4 OQiOi O49O O 00*0^ 00*9 1 •• 4 W OCbC
> 4 — >4— J8 4 <— > J J< > * > > 4 — > 4 — OS*4 O >4«-
Ot C O»C ^-4
-40 -HOP
1 1 S Z 1 1 II 1 B Z O 1


2-74

-------



OS

01
§

i
6*
OS
2
w
w"

I*
P H
5 o
*• 2
o|
CO ^
fl
cu

&4
3
2
cw
J
u
Q
0
w
8
05
^5
hJ

^
CL*
B^
O
1

a
00
6$




•• »O i«i • »
^ m ^ ^4 co
 *> eou >HU
• jQM 3O>« O >» b O >» « jQ « 3 O >» 0 >«
eo^-o ia ^ *^" 2 j" co~o a ^ *^"

** • j — • mm o •"- o -— M* o »<-» *• • j — •« o »— o -"-
e c^-4 TJ -o w -o u ^ TJ w c e^-4 -o -o u -o u
Q^U« -4 « • • >, 99>> «J3** • • * 0-404 -4 f f • >• «•>
o ^4 o 9 •* a i >••««. a -^ *«. j< -H « a >.-«. o -^ o 9 ^ a 1 >»-*. a -4 -*.
« >**. O 3 3 m~* 3~4~4 « M 0 3«"4 «>^o O 3 3«»4 3^4^4
u« u a~4 ^iu« -4A« ea • u ^» u m u« u a^ 4h4 ^cu«
O49O O Ofl<9 O Oi 9 \ f* It OO>9 O • 9O O 0 Qt 9 OQtO<
>&*> *> >•— > m «- jB«w « > • — >.Q.tf> «> > • «» > « —
-4 O -^
i ii i a z o i i ii i



2-75

-------



OS

&4
f\
fid
u
z
o

§
Of
2
w
l~
1"
*• M
(6 **
88
CO *•*
06
W
04

E?
2
0.
j
ca
a
o
X
w
o
**J
^5
i
X
w
o
1-1
1
M
W
a






n
I
a
4J
C
(0
£



CM
1
C
(0
o.




•-4
1
o
e
at
a*








Parameter


o o" • oT uT o £ *"•
Ot • in »H >O ,H . gi
9^ *o ^ **4 td O in *H
* ^^ * » % «w
•V * 'r4 0
n« (N — M
^^ ^* ^i*




r»f«i inrtf-i o> o> p«
40 ^ • ^i o co ^n •
m« incnm «M • at
«O !-(»» » O 1^
a» r» ao
^




















Ot • * Ot • «
C 0* Ot e 699
M«4 CC rj -^ G G
H 9 4i « « ja * 3 o >» o >» -^ o >» «jae 3
u u o^ wo-^o >«9 >^ e^. u o-». 4*0^0 >5t
ecu u c o "O ja M e JJ
Me o «<-» 4J e J — e « o •— o -•~ Me o -^ -w e J -~ e«
M^H T3 u e e*>>-4 -o Tib •on w-4 -o u e e-^^< -a
A « « >. o-i o « -* « BOX ee>i JIM i • >* o-^ue -4§
e-< i >«-^ u -4 o 9 «-4 i § >»"*. a-4^«. e-^ « S >^> 0^09 •* S
MM 3 «^ o3 le'H 3-^^4 j< M o 3«>H e>-«. 03
« e -i u * ge y • ^ -i u « -^ a* eeo -i u « ge g e^
CO ^ OO«9 O49O 0 OCb9 0 Qi 9 (Q~4M OQi9 O « 9O O
1*4 > » ~ > ja j« > •»> >e~ > « — I e — >JBJ«> «>
3 c S c^
2zi i ii i j z S i i i


-
•^

%
o

IMF




fl
<0
m
f-i























2-5
%-
e • >
0 04(
1


2-76

-------




X
o
i
J
i]
CO
z
o
H
Lj
s
2

s
o
04
U)
z
r"
a"
>
H

P H
• CD
<§
;|
r|
d
14
g
5
3
04
£
X]
Q
O
C
a
a
T|
^
U
o
H
1
3
a
-. -. ^ oo -. — .
O O CM • O> .-4
^ o • o oo Ok
 •» *^ *. »
* in * *
•—CM iH «-»
n — —
1
a
•P
c
(0 o\ mo aoinot o O n
»-l * cs in • r» «-t
CU O vo o at u?
» » o T » »
^9 ^* ^^ ^9
d 01 m rt





CM
a
4J

^k ^K MK
|Q O O 1*1
04
H
Q
4J
C
A o o in
04




Oi «. «
• c o» o> •
•o •* c c n •
-1 U *J t «A« COX OX -« • •
• -^ U U^s. 4JO-HO X9. >•«•> »^~ ** -^ C A
h * « J CU~0 J3 5« ^ H C •* 4J
O  ~ •• o »— o o'- i i o
t: • U H-4 TJ U C C-^r^ T3 TJU • U ft M 14 a
Z § • >• A4J ««X O-t 0 « ~4« § • X • • X -4 -4 f
S I~4*>^ « -4 « I X^. 0 ^ O O> ^ § § >»^ S -4 ^ 3. U ft •
to 3n^4 JZ x o 3«^ «>-^ 03 3*^ 3^rH & o e
^ ^ ft • « • O -1 U «S O • U Ht-l -4 U « -4 ft « H X • -4
O 0 ft O> CO <-* U O ft O> O •) OkQ O O ft W O ft O> • £ "-I
o* *c8 >•*• >-o-»<> *> >•— >«— J 5 ^ i
5 O ** -4 Q Q 
-------
Cd
ca

i
M



I
w
u
           o

           4J

           a
                     o   o
                                     oo
                                                                          O   
                                                                                          I
                                                                                          u
                                                                                          3
                          a
                         2S
                          O
                             _                fi          m Ht         m          **        v
                             3 <~             4       >»W •          41          4        C
                             O O.             U       4 TJ   U       4          b^_-4
                             -i -i        -o   o,     o«u i  -a o —     w             ••?   u
                               >         «•     ca«««M>,             jsc-»£   3
                             « S         M         -4 • fl 41   4JSC   ^.  41 O fl Ti   U
                             g ~»    ^  -4   U     41   -444IU4IO   ?  0 -^ • i
                             3        4  41   «     4.cai 3 H   4   0   -"4   0543-0-4     ^4^  >»-^ O *   -•
                               4     8   U   -Mi   V4 & £ 4 I 4  >»«4 3     4 41 4««^   **
                             e • ^             j_i   _< • j_i   n >^  M u 0     u <• a •   I
0
>3H
   •
   ««
a««o
«4bM
SO.—
                                                                    4 4J C
                                                                    u e 5.
                                                                    CU« i.
                                                                    M>— B
Spr
ven
(au
Ga
ov
                                                   2-78

-------
OS
u
ca
o
M
I
2
CO
w
g
Q
go"
|J 3

^5 »»
ce ^
O ^™
r
cu

&4
3
cu

J
w
a
0
1
1
u
a
(N
M
i-l
09
"
1
O
e
* «
cu *



(M
1
a
c
5 *
_^j ^^
cu *


H
1
O
"c
A *
f4 "1
cu *



0
e b u
o e b 41
-4 *4
4» << e i
3 .





.^ .4 ,4 .4 e e e
•^ -4 -4 >4 -4 J« J?
a a a a 3 3 A
r* U) in O -4-4-4
• • • b b b
•H f^ * 444





•
-4 -• -+ -4 e e e
-4-4-4-4 -4 .4 -4
a a a a 444
-4 in m o -4-4-4
• • b b b
, **:::: u u
b o o -M e -4 oo
vebuu Q«. •>.
ct d d Z Z







o o o < <
e» m in ">. ^
-4 CM 01 Z Z






^v 9>v 94 <4 4
b U U *•» -«.
•o «a  —
&e 4 4 e e
a -4 o o o -
1 b u o o a
*• 1 e b b *>
i a o 4 e 4*
01-3 -4-4 « 0» » > &-V
4oi i i < • a


2-79

-------
scenarios for each size of model plant were explored.
Therefore, the model plants for the automotive/transportation
industry were developed assuming that only one type of plastic
is coated.  By differentiating the model plants by the type of
plastic coated, a facility coating two or three different
types of plastics would be able to compare processes with the
model plants of the appropriate size and processes.
     The coatings used in the plastic parts industry have
different VOC and solids contents depending on their
application (i.e., primer, colorcoat, clearcoat, low-bake, and
high-bake).   Therefore, each type of coating was evaluated
separately for each of the plastic types coated.
     Because of the very low usage of specialty coatings,
their effect on emissions estimates is expected to be
negligible.   Therefore, specialty coatings are not included in
the model plant scenarios.
     The following sections describe the model plant coating
consumption, operating parameters, and baseline VOC emissions.
     2.7.1.1  Coating Consumption.  Annual coating consumption
data were selected as the basis for establishing the four
sizes of model plants. These data were obtained from
permitting information, which is more readily available than
data pertaining to the total surface area of parts coated per
year.  The total amount of solids sprayed is a function of the
coating formulation (which varies with each coating category)
and annual coating .consumption.
     The annual coating consumption data used to establish the
model plants were taken from permitting data supplied by the
Ohio EPA.  The data indicated that the industry could be
categorized by four size ranges.  These sizes coincided with
those reported in the response to the EPA's investigation.29
The annual coating consumption of the facilities that fell
into each of the four size ranges was averaged to determine
each of the four representative model plant sizes.
                             2-80

-------
      Transfer efficiency plays  a  Icey role in determining the
 annual  coating consumption  of a spray coating facility.   The
 lower the  transfer efficiency,  the more coating that is  needed
 to  coat a  given part.   For  the  model plants,  the volume  of
 solids  deposited at' baseline is based on an estimated transfer
 efficiency of 25 percent if sprayed using a conventional air
 atomized spray gun or  50 percent  if sprayed using either an
 electrostatic or an HVLP spray  gun.  These transfer
 efficiencies  are based on average values reported in the
 literature and by industries using the equipment,  and from
 responses  to  inquiries by the EPA.
      Because  each model plant uses a combination of spray gun
 types,  a weighted transfer  efficiency was estimated for  each
 model plant based on the type and number of guns assumed,  the
 expected transfer efficiency of the gun, and the assumption
 that an equal volume of coating passes through each gun.
      2.7.1.2   Process  Parameters.  Interior plastic parts are
 usually coated with a  primer and  a nonflexible colorcoat.
 Exterior parts require three different types of coating.  A
 primer  coat is needed  to ensure that the additional coating
 layers  will adhere to  the part.  If the exterior part is
 flexible (such as a RIM fascia),  the coating of choice would
 be  a flexible coating.  Flexible  coatings can better survive
 impact  and are less prone to cracking.  A flexible colorcoat
 would be applied to the exterior  part following application of
 the primer.  Finally,  an exterior flexible clearcoat would be
 applied.  If the exterior part  is not flexible, such as  an SMC
 body panel, then a flexible coating is not necessary; however,
 three coating layers would  still  be needed:  primer,
 colorcoat, clearcoat.
      The type of primer, colorcoat, and clearcoat selected
 also varies depending upon  the  substrate being painted.   Both
' high-bake  and low-bake coatings are used to some extent  in all
 applications described above.   The proportion of high-bake and
 low-bake coatings used in the model plants was determined
 based on national usage data for  high-bake versus low-bake

                              2-31

-------
coatings.  Interior parts coatings are primarily low-bake,
while exterior coatings are primarily high-bake.  Table 2-11
shows the amount of high- and low-bake coating used at the
three small model plants.  The ratios of high-bake to low-bake
coating usage for the medium, large, and extra large model
plants are the same as those for the small model plants.  The
baseline coatings used in the model facilities were selected
based on information obtained from coating facilities, coating
manufacturers, the National Paint and Coatings Assocation
(NPCA) ,  and previous regulatory investigations.2*27'30  The
corresponding amount of solids sprayed for each coating type
was calculated from this information, assuming an average
density of 7.1 pounds VOC per gallon (Ib VOC/gal) coating for
the coating thinner added by the coater before spraying.30
     Conveyorized lines require a large capital investment
that can only be recovered by facilities with high production
rates.  For this reason, only the three largest model plants
have conveyors included in their coating operations.
Likewise, robotized and electrostatic spray systems require
extensive capital investment.  For this reason, only the two
largest model plants have robotized, electrostatic spray
equipment.  In addition, waterwash spray booths are found in
use only at the larger, higher-production facilities because
this type of spray booth also requires extensive capital
investment.
     2.7.1.3  Baseline Volatile Organic Compound Emissions.
Baseline VOC emissions were determined based on the assumption
that all VOC's in coatings are emitted and that baseline
should reflect coating technologies currently in use.  The
baseline VOC content levels were determined for each type of
coating by considering available coating consumption and VOC
content data along with existing State regulations--in
particular, Michigan's Rule 632 and the South Coast Air
Quality Management District's 1987 limits.  A database was
developed with information on the VOC content of each coating
identified in this study.

                             2-82

-------
 TABLE 2-11.   AUTOMOTIVE/TRANSPORTATION MODEL PLANT COATINGS

 Modal                                                Usage
 Plant	Coating Type	(gal/yr)
   1     Interior
         Low-bake primer                             2,850
         High-baJce primer                              150
         Low-bake colorcoat                          8,550
         High-bake colorcoat                           450
   2     Exterior Flexible
         High-bake primer                            2,880
         Low-bake primer                               120
         High-bake clearcoat                         2,330
         Low-bake clearcoat                            670
         High-bake colorcoat                         3,400
         Low-bake colorcoat                          2,600
   3     Exterior Nonflexible
         High-bake primer                            2,750
         Low-bake primer                               250
         High-bake clearcoat                         2,330
         Low-bake clearcoat                            670
         High-bake colorcoat                         3,400
	Low-bake colorcoat	2,600
                             2-83

-------
     Information on VOC content was gathered from responses to
questionnaires sent to coating users, from material safety
data sheets (MSDS's) obtained during site visits and from one
coating formulator, and from background information obtained
from Michigan's regulatory development processes.  In
addition, significant data on coating usage and VOC content
were supplied by the NPCA.30  These data reflect a nationwide
survey of plastic parts coatings used for automotive and
transportation applications.
     Table 2-12 shows the baseline VOC content for each
coating category used in the automotive/transportation model
plants.  The weighted average VOC content was calculated from
1988 national usage data for each coating and was used as a
guideline for determining the baseline level.  These weighted
averages were compared to the ranges of VOC contents in the
coating database and adjusted as necessary to reflect current
reported usage.31
2.7.2  Model Plants in the Business Machine Sector
     Three model plants were developed to represent the major
equipment and techniques currently being used to surface coat
plastic parts for business machines  (including office,
medical, stereo, and telecommunications equipment).  These
model plants represent the range of facility types in this
segment, from facilities that perform coating services
exclusively up to large contractors with fully automated
facilities that perform both molding and coating of plastic
parts.  The three model plants developed for the business
machine segment were selected based on information collected
during the data gathering phase of this project and during
development of the New Source Performance Standard  (NSPS) for
Plastic Parts for Business Machines.T>32  The three model
plants represent small (Plant A), medium (Plant B), and large
(Plant C) facilities.  The model plant in each size category
is expected to apply all four types of coatings:  primer,
                              2-84

-------
             TABLE  2-12.  BASELINE VOC LEVELS FOR
             AUTOMOTIVE/TRANSPORTATION SECTOR
                                               Baseline
           Coating Category                  (lb VOC/qal)
Auto Interiors
  High-Bake Colorcoat                             4.6
  High-Bake Primer                                5.4
  Low-Bake                                        6.0
  Low-Bake                                        6.0
Auto Exteriors
  Flexible
         High-Bake Colorcoat                      4.6
         High-Bake Clearcoat                      4.3
         High-Bake Primer                         5.4
         Low-Bake Primer                          6.0
         Low-Bake Colorcoat                       5.7
         Low-Bake Clearcoat                       4.2
  Nonflexible
         High-Bake Colorcoat                      4.6
         High-Bake Clearcoat                      4.3
         High-Bake Primer                         4.2
         Low-Bake Primer                          6.0
         Low-Bake Colorcoat                       5.7
         Low-Bake Clearcoat                       4.2 	
                             2-85

-------
colorcoat, color/texture coat, and EMI/RFI shielding.  The
model plant parameters developed for business machines are
presented in Table 2-13.
     2.7.2.1  Production.  The baseline coating utilization
estimates presented in Table 2-13 are based on data used in
the development of the NSPS for Plastic Parts for Business
Machines as well as information collected during this study.
Because plant sizes used in developing the business machines
NSPS were felt to be representative of the industry, they were
retained for this analysis.  Model plant transfer
efficiency was estimated in the same way as described in
Section 2.7.1.1.
     2.7.2.2  Process Parameters.  The baseline coatings used
in each of the business machine applications were selected
based on information in the coating database.  The most
commonly used baseline colorcoats and color/texture coats are
solvent-based polyurethanes, and contain 13 to 80.6 percent
solids by volume at the gun.  The most commonly used primers
are also organic solvent-based polyurethanes containing 14 to
41 percent solids by volume at the gun.
     All three model plants have the capability to perform
EMI/RFI shielding, although not all plastic parts require it.
A typical EMI/RFI shielding would be either a nickel- or
copper-filled coating with an organic solvent base containing
27 percent solids by volume at the gun.33
     As discussed for the automotive/transportation segment,
conveyorized lines, robotized and electrostatic spray systems,
and waterwash booths are found only in the larger facilities
because these types of equipment require a large capital
investment.
     2.7.2.3  Baseline Volatile Organic Compound Emissions.
Baseline VOC levels selected for the model plants representing
the business machine segment are presented in Table 2-14.  The
baseline coatings used in each type of business machine
coating application were selected based on information
                              2-86

-------
    TABLE  2-13.    MODEL PLANT  PARAMETERS  FOR  BUSINESS MACHINES

                   Parajaatar                        Plant A          Plant i           Plant C
I.   Production
     A. Total voluaa of coating usad at            19,408 (5,127) 153,202 (41,000) 388,031  (102,507)
        capacity,  L/yr (oal/yr)
     I. Total solids sprayad, L/yr (oal/yr)         4,192   (954)  33,324  (7.626)  83,815   (19,066)
     C. Total solids appliad, L/yr (oal/yr)         1.048   (238)  11.733  (2,669)  32,595    (7,415)
II.  Oparating Paraa»tars
     A. Pariod of  Oparation
        1. hours/day                                          16               16                16
        2. days/Mas:                                           5                5                 5
        3. waaka/yaar                                         50               50                50
III. Procass Parajaatars
     A. Coaputar Cabinat
        1. Solvant-borna priaar
           a.  Voluaa of coating sprayad,  L/yr       4,852   (513)  38,800  (4.100)  97,008   (10,251)
               (Oal/yr)
           b.  VOC contant of baaalina coating.       0.68   (3.7)    0.68    (5.7)    0.68      (5.7)
               kg  VOC/L (Ib VOC/oal) coating
           c.  X solids by voluaa at out            20.0X   20.0X   20.OX    20.0X   20.OX      20.OX
           d.  Voluaa of VOC sprayad.               3.982   (410)  31,040  (3.280)  77,606    (8,201)
               L/yr (oal/yr)
           a.  V«lua» of solids appliad,              243    (26)   2,716    (287)   7,545      (797)
               L/yr (oal/yr)
        2. Colorcoat  - Solvant bssad
           a.  Voluai of coating sprayad,  L/yr       5,822 (1.538)  46.561 (12,300) 116.409   (30,752)
               (oal/yr)
           b.  VOC contant of baaalina coating        0.74   (6.2)    0.74    (6.2)    0.74      (6.2)
               kg  VOC/L (Ib VOC/oal) coating
           c.  X solids by voluat at gui            13.0X   13.0X   13.0X    13.0X   13.0X      13.0X
           d.  voluaa of  VOC sprayad,               5,065 (1.338)  40.308 (10,701) 101.276   (26,754)
               L/yr (oal/yr)
           a.  Voluaa of  solids appliad,              189    (50)   2.119    (560)   5,885    (1,555)
               L/yr (oal/yr)
        3. Calorcoat/Taxtura coat - solvant-basad
           a.  voluai of coating sprayad,  L/yr      4.832 (1,282)  38,800 (10.250)  97,008   (23,627)
               (0*l/yr)
           b. VOC cantant  of baaalina coating.      0.74    (6.2)    0.74    (6.2)    0.74      (6.2)
               kg VOC/L (Ib MC/gal) coating
            c. X sal Ids by  voluw at gun            13.0X    13.0X   13.0X    13.0X    13.0X      13.0X
            d. VoluM of VOC sprayad,               4,221 (1,113)  33.756  (8.918)  84,397   (22,295)
               L/yr (oal/yr)
            a. volust of solids appliad,              158    (42)   1.769    (466)    4.904    (1.296)
	L/yr (oal/yr)         	
                                               2-87

-------
TABLE 2-13  MODEL PLANT PARAMETERS FOR BUSINESS MACHINES
               (CONTINUED)
Parameter
4. ENI/MI Solvent-borne nickel- or caff
filled acrylic for EMI/RH Sheilding
a. Voluae of coating sprayed, L/yr
(gal/yr)
b. VQC content of baseline coating,
kg VOC/L (lb VQC/gal) coating
c. X solids by voluaa at gun
d. VolUM of VQC «prayad,
U/yr (gal/yr)
a. Volume of aoi ida appl ltd.
Uyr (gal/yr)
1. Coating equipaant
1. Conveyor lied linaa
2. lootha par Una
3. Off -Una bootha
4. Air atoaizad spray guna (25X TC)
a. Manual
b. Rabat izad
5. Elactroatatic spray guns (SOX Tt)
a. Manual
b. Robotized
6. High volume low pressure (HVLP) (SOX
a. Manual
b. Robotized
7. Dry filter spray bootha
8. Racirculating water-wash spray booths
(Sid* draft for automated spray,
down draft for •anus I spray)
9. Spray booth ventil. rate (••«.},
a3/a 
-------
TABLE  2-13   MODEL PLANT  PARAMETERS  FOR BUSINESS  MACHINES
                     (CONTINUED)
            Paraaatar                      Plant A         Mant 1         Plant C
   3. Average flaah-off period
     •. priwr                         Variable         12 min          12 min
     b. colorcoat                      Variable         12 min          12 min
     e. claarcoat                      Variable         12 min          12 min
   4. Curing taeperature and tlaa in baka «v«n <°C/»in)
     a. priaw                          air dry           140   30 min    140    30 min
     b. eoloreoat                       air dry           140   30 min    140    30 min
     e. claarcoat                       air dry           140   30 min    140    30 min
   5. Avaraga eanv«yor tpaad. •/• (ft/*in)      M/A           0.04           0.04
                                                        (8)            (8)	
                                     2-89

-------
TABLE 2-14.  BASELINE COATINGS FOR THE BUSINESS MACHINE SECTOR
              Type of Coating
                                               VOC Content
Ib/gal of coating
    less water
 Primer
       4.5
 Colorcoat
       4.3
 Colorcoat/texture  coat
       4.3
 EMI/RFI  Shielding
       4.9
                             2-90

-------
presented in the memorandum summarizing information from the
coating database.29  For colorcoats and color/texture coats, a
baseline of 4.8 Ib/gal, less water was chosen.  All
color/texture coats and the majority of colorcoats reported
also can achieve this level.  In addition, all State
regulations in effect as of 1991 are at least this stringent.
     For primers, the baseline was selected as 4.5 Ib VOC/gal
coating, less water; for EMI/RFI shielding, a baseline level
of 4.9 Ib VOC/gal coating, less water, was selected.
                              2-91

-------
2.8  REFERENCES


l.    Trip Report.  Norris, C. E. and.  S. J. Blackley.  Radian
     Corporation, Research Triangle Park, NC., to Kenkor
     Molding Division, Englishtown, NJ.  September 13, 1990.

2.    Technical Support Document.  Rule 632 - Coating of
     Automobile,  Truck and Business Machine Plastic Parts.
     Michigan Department of Natural Resources Air Quality
     Division.  Lansing, MI.  April 19, 1989.

3.    Lewarchik, R. J.  Low VOC Coatings for Automotive
    • Plastics.  Industrial Finishing.  November 1983.

4.    Trip Report.  Norris, C. E. and  C. R. Blackley.  Radian
     Corporation, Research Triangle Park, NC., to Autostyle,
     Incorporated. Grand Rapids, MI.  September 18, 1990.

5.    Trip Report.  Norris, C. E. and C. R. Blackley.  Radian
     Corporation, Research Triangle Park, NC., to Mack
     Molding, Inman, SC.  May 3, 1990.

6.    Trip Report.  Norris, C. E. and C. R. Blackley.  Radian
     Corporation, Research Triangle Park, NC, to Ford Motor
     Company Plant, Saline, MI.  September 19, 1990.

7.    U. S. Environmental Protection Agency.  Surface Coating
     of Plastic Parts for Business Machines - Background
     Information for Proposed Standards.  Draft NSPS,
     EPA-450/3-85-019a.  December 1985.

8.    Trip Report.  Norris, C. E. and C. R. Blackley.  Radian
     Corporation, Research Triangle Park, North Carolina, NC,
     to Ford Motor Company Plant, Milan, MI.
     September 19, 1990.

9.    Section 114 Response Letter and Attachments from Gates,
     G., Webb Manufacturing, Inc. to Farmer, J.,
     U. S. Environmental Protection Agency.  May 30, 1990.

10.  Levinson, S.  Application of Paints and Coatings.
     Federation of Societies for Coatings Technology.
     August 1988.

11. /3raco, Incorporated.  Product Information.  Paint
     Application Equipment for the Professional Painting
     Contractor.  1989.

12.  Graco, Incorporated.  Product Information.  Manual and
     Automatic Air-Assisted Airless Systems.  1988.

13.  Graco, Incorporated.  Product Information.  High Output
     HVLP Sprayers.  1990.

                             2-92

-------
14.  Sinks Manufacturing Company.  Product Information.  The
     Binks Approach to HVLP:  Second Generation HVLP
     Technology.  September 1989.

IS.  DeVilbiss Company.  Product Information.  High Volume Low
     Pressure System.  1989.

16.  Can-Am Engineered Products, Incorporated.  Industrial
     Duty Turbine Powered HVLP versus Portable Turbine Powered
     and Compressed Air Powered HVLP.  1990.

17.  Meeting notes with Kish, S., Graco, Incorporated., and
     Blackley, C., Radian Corporation.  May 16, 1990.

18.  Electrostatic Consultants Company.  Product Information
     and Letter.  April 10, 1990.

19.  Graco, Incorporated.  Product Information.  Pro Power -
     The Only Self-Contained Electrostatic Spray Gun.  1988.

20.  DeVilbiss Company.  Product Information.  EFX-100
     Electrostatic Spray Gun.  1988.

21.  Ransburg Corporation.  Product Information.
     Electrostatic Equipment for the Furniture Industry.
     1990.

22.  Graco, Incorporated.  Product Information.  High Torque
     Power Disc for High Solids Coating Material.  1990.

23.  Nordson Corporation.  Product Information.  RA-12 Rotary
     Atomizer.  1989.

24.  Telecon.  Blackley, C.  Radian Corporation, with
     Lamberty, P.  BASF.  February 5, 1990.

25.  Telecon.  Blackley, C.  Radian Corporation, with
     Ricky, K.  Akzo Corporation.  February 7, 1990.

26.  Telecon.  Blackley, C.  Radian Corporation, with
     Home, R.  Bee Chemical.  February 6, 1990.

27.  Dames and Moore.  Appendices for the Position Paper
     Recommending the Use of Michigan Rule 632 as an
     Automotive plastic Parts Control Techniques Guideline.
     Prepared for the National Paint and Coatings Association
     and the Motor Vehicle Manufacturers Association.
     June 28, 1991.

28.  Memorandum.  Miller, S. J. and J. Johnson, Radian
     Corporation, to Salman, D., EPA/CPB.  Ranking of Coating
     Data and Selection Baseline and Control  Levels for
     Plastic Parts Surface Coating Operations.  December 21,
     1990.

                              2-93

-------
29.  Memorandum.  Miller, S., C. Norris, and C. Blackley,
     Radian Corporation, to Plastic Parts Surface Coating
     Operations Project File.  Summary of Information Obtained
     from Industry Questionnaire.  November 16, 1990.

30.  National Paint and Coatings Association.  National Air
     Pollution Control Technology Advisory Committee Meeting:
     Comments on Surface Coating of Plastic Parts Control
     Techniques Guideline.  November 20, 1991.

31.  Telecon.  Johnson, J.,  Radian Corporation, to K. Schultz,
     DuPont. DuPont Plastic Parts MSDS's.  December 10, 1990.

32.  Memorandum.  McLean, J. and B. Ferrero, Radian
     Corporation to David Salman, EPA/CPB.  Coating and
     Category Revisions for Surface Coating of Plastic Parts
     CTG.  August 3, 1992.

33.  Standards of Performance for New Stationary Sources;
     Industrial Surface Coating; Plastic Parts for Business
     Machines.  Final Rule.   53 FR 2672.  January 29, 188.
                             2-94

-------
               3.0  EMISSION CONTROL TECHNIQUES

3.1  INTRODUCTION
     Volatile organic compound emissions occur when organic
solvents evaporate from coatings during coating and curing
processes.  This chapter describes techniques that are
available to control VOC emissions from the surface coating of
plastic parts.  The control techniques discussed are the use
of lower-VOC coatings, process modifications, and add-on
controls.  Section 3.2 presents a discussion of potential
coating reformulation options, including waterborne coatings
and higher-solids coatings.  Section 3.3 discusses potential
process modifications that could reduce VOC emissions before
they are generated and Section 3.4 presents potential add-on
control options to reduce the amount of VOC's that escape to
the atmosphere.
3.2  USE OF COATINGS WITH LOWER VOLATILE ORGANIC COMPOUND
     CONTENT
     One method to reduce the amount of VOC's emitted to the
atmosphere during the plastic parts surface coating process is
through the use of lower-VOC coatings.  The two principle
types of lower-VOC coatings are waterborne and higher-solids
coatings.  Although additional lower-VOC coating systems
exist, waterborne and higher-solids coatings have been
identified as the only technologies that are suitable to a
wide variety of applications.  They are, consequently, the two
lower-VOC technologies that are focused on in this document,
and are discussed in Sections 2.3.1 and 3.2.2, respectively.
For the sake of completeness, Section 3.2.3 describes some
other less widely applicable coatings.
                              3-1

-------
     In waterborne coatings, organic solvent is replaced with
water (producing either a waterborne or water-reducible
coating).   Higher-solids coatings increase the volume percent
of solids  in the coating, thereby reducing the amount of
solvent and the amount of coating required to apply a given
amount of  solids.
     The coatings discussed in this chapter were identified in
the data-gathering effort to support development of this CTG.
Information was obtained from questionnaires, site visits, and
from data gathered from States in support of their rulemaking
efforts.  This information was compiled in a coatings
database.   The development and use of the database is
discussed in separate memoranda.1'2  All  coating  contents
provided in the database are "as sprayed," and follow
recommended dilution instructions.
3.2.1  Waterborne Coatings
     Waterborne coatings are those that contain water as the
major solvent or disbursent.  A generally accepted definition
of a waterborne coating is  "a coating containing more than
5 weight percent water in its volatile fraction."3  Waterborne
coatings can contain 5 to 40 percent organic co-solvent to aid
in wetting, viscosity control, and pigment dispersion,
resulting in a much lower VOC content than that of traditional
coatings.   Waterborne coatings can be applied with the normal
application methods found in the painting industry, although
airless and electrostatic techniques are less common for
waterborne coatings.  In addition, all fittings on spray
equipment must be made of stainless steel to prevent
corrosion.4*   The major  advantages  of waterborne coatings  are
that they reduce VOC emissions, reduce fire hazard, tend to
lower toxicity, and use basically the same application
equipment as solvent-borne paints.  Color, impact resistance,
gloss,  weatherability, corrosion resistance, and repairability
characteristics are similar to those of conventional coatings.
Primary limitations of waterborne formulations  include:
                              3-2

-------
     •    Stainless steel or plastic pipe fittings are often
          recommended for the coating equipment;
     •    Some formulations must be protected from freezing
          (once waterborne coatings have frozen, they cannot
          be recovered);6
     •    Better control of booth temperature and humidity may
          be required;
     •    Longer flash-off time may be needed; and
     •    Some plastics  may be difficult to coat and may have
          poor adhesion.
     The performance of  waterborne coatings compared to
organic-solvent-based coatings is debated by coaters and
coating manufacturers.  Many coaters feel that the adhesion,
durability,  and gloss of waterborne coatings are inferior to
those achieved with solvent-based coatings.7'*  However,  some
coaters feel the quality of the finish obtained with
waterborne coatings is acceptable.9'10  One of the coaters said
that a waterborne EMI/RFI shielding coating outperformed its
solvent-based counterparts.9
     3.2.1.1  Waterborne Coatings for the Automotive/
Transportation Sector.  There is limited information on the
use of waterborne coatings in the automotive industry.
Waterborne coatings are primarily used in interior coatings
because of the more- stringent durability and gloss
requirements for exterior coatings.  Automotive industry
groups have raised several issues concerning waterborne
coatings:   (l) color matching with solvent-borne coatings is
difficult;  (2) waterborne coatings require increased drying
time and/or the use of plastics that can withstand drying oven
temperatures; (3) stainless steel piping and spray equipment
are required; and  (4) waterborne coatings have not been
developed to meet many coating performance specifications.11'12
The only waterborne coatings in the current database for the
automotive segment are five automotive interior colorcoats,
ranging in VOC content from 2.5 to 3.2 Ib VOC/gal coating,
less water.2
                              3-3

-------
     3.2.1.2  Waterborne Coatings for the Business Machines
Sector.  Waterborne exterior decorative/ protective coatings
that can be cured at low temperatures are presently used on
some plastic business machine parts, although they are not as
commonly used as organic-solvent-based coatings.  Waterborne
coatings are being used to coat structural foam parts that
require substantial coating films and to coat straight-
injection-molded parts with molded-in color and texture that
require films of 0.5 mil or less.  Several large business
machine manufacturers have approved waterborne coatings for
use on their products.
     The current plastic parts surface coating database
contains 12 waterborne coatings.  Each is discussed in the
appropriate section below.
     3.2.1.2.1  Primers.  One waterborne primer, manufactured
by Lilly, is available for use on business machines.  This
coating is reported, to have a VOC content of 1.19 Ib VOC/gal
coating, less water.13
     3.2.1.2.2  Colorcoats.  Eight waterborne colorcoats or
color/texture coatings are included in the current database.
These coatings are manufactured or distributed by Armitage,
Lilly, Komac, and Sherwin Williams and range in VOC content
from 1.06 to 2.25 Ib VOC/gal coating, less water.9*11
     3.2.1.2.3  Clearcoats.  Information was obtained on one
waterborne clearcoat manufactured by Lilly.  This coating has
a VOC content of 2.5 Ib VOC/gal coating, less water.11
     3.2.1.2.4  Electromagnetic interference and radio
frequency interference shieldings.  Information was obtained
on one waterborne shielding:  a waterborne nickel shielding
coating with a VOC content of 2.5 Ib VOC/gal, less water.9
3.2.2  Higher-Solids Coatings
     Higher-solids coatings are typically solvent based and
contain greater than normal amounts of pigment and binder.
Higher-solids paints can  reach the 50- to 65-percent solids
range, or higher.  Higher-solids  coatings reduce VOC emissions
by allowing less coating  to accomplish the same coating job.

                              3-4

-------
For example,  a coater using a coating that has 0.25 gallon of
solids per gallon of coating will need to use 4 gallons of
coatings to apply 1 gallon of solids (at a 100 percent
transfer efficiency).  Assuming that the remaining coating is
VOC, 3 gallons of VOC will be emitted.   If the coater switches
to a coating containing 0.5 gallon solids per gallon of
coating, only 2 gallons of the new coating will need to be
used to apply 1 gallon of solids, emitting only l gallon of
VOC.  As the transfer efficiency decreases from 100 percent,
the differences become even more pronounced.
     Higher-solids coatings have the following additional
advantages:
     •    Less solvent is emitted into the atmosphere;
     •    Less coating must be shipped, stored, pumped, and
          sprayed;
     •    Lower oven air volumes are required;
   _ •    Spray -booths may sometimes be smaller;
     •    Formulations may be less expensive to produce on a
          solids basis; and
     •    Less energy is needed for solvent evaporation.
Operating cost savings of 20 to 30 percent are common when a
coating process switches from higher-solvent coatings to
higher-solids coatings.14
     The limitations of higher-solids coatings include:
     •    High-viscosity coatings must often be heated to
          around 93°C  (200°F) to achieve sprayability;
     •    They may exhibit poor performance in dip tanks and
          flow coaters because of excessive viscosity;
     •    Films may be much thicker at the bottom of the parts
          than at the top;
     •    Difficulty in pumping and atomizing may be
          experienced, especially when cold;
     •    The cleaning quality of the coating may be more
          important than for conventional paints because there
          is less solvent present to "clean as it coats;"

                              3-5

-------
     •    Overspray is difficult to clean up because it
          remains in the uncured state and is sticky; and
     •    The added viscosity may preclude the use of some
          spray systems, which could lead to additional
          capital expenditures for new equipment.
3.2.3  Non-Volatile-Organic-Compound"Emitting Coatings
     This section describes lower-VOC coating technologies
other than waterborne and higher-solids technologies.  Most of
these alternatives are.applicable to specialized uses.
     3.2.3.1  Electromagnetic Interference and Radio Frequency
Interference Shieldings.  Alternative coatings that provide
EMI/RFI shielding but usually do not emit VOC's include zinc-
arc spraying, electroless plating, and vacuum-metallizing or
sputtering.  Considerations other than VOC emissions greatly
influence the EMI/RFI shielding techniques used.  Two
important considerations are shielding effectiveness and the
cost of a given technique.  Cost factors are discussed in
Chapter 5.0.  Simple comparisons of EMI/RFI shielding
effectiveness cannot be made among the different shielding
techniques.  Shielding effectiveness depends on the type of
material used for shielding, coating thickness, coating
uniformity, and the frequency of the EMI/RFI signals.
     The three methods of non-VOC EMI/RFI coatings are briefly
discussed below.  Techniques that provide EMI/RFI shielding
without application of any surface coating are discussed in
Section 3.3.2.2.
     3.2.3.1.1  Zinc-arc spraying.  Zinc-arc spraying is a
two-step process in which the plastic surface is roughened by
sanding or grit-biasting, and a coating of molten zinc is
sprayed onto the roughened surface.  Advantages of zinc-arc
spraying include high shielding effectiveness over a wide
range of frequencies and the fact that it is a widely
demonstrated EMI/RFI shielding technique.  Disadvantages
                              3-6

-------
include the need for special equipment such as a zinc-arc
spray gun, a spray gun air supply, a face shield and breathing
air supply or respirator for the operator, hearing protection,
and a waterwash spray booth or baghouse dust collector.15
     3.2.3.1.2  Electroless plating.  Electroless plating is a
dip process in which a film of metal is deposited from aqueous
solution onto all exposed surfaces of the part.  The plastic
parts are prepared for electroless plating by oxidizing their
surfaces with aqueous chromic and sulfuric acids or with
gaseous sulfur trioxide.  Following the oxidizing step, a
metal film (usually copper, nickel, or chrome) is
electrolessly plated onto the plastic part.
     Advantages of electroless plating include the ability to
coat the plated parts electrostatically, low materials and
labor costs,  and good shielding effectiveness.  One
disadvantage is the incompatibility of electroless plating
with molded-in color unless masking is used.  Another
disadvantage is the potential for VOC emissions if coatings
that emit VOC's are applied prior to the plating step so that
only selected areas of the parts are plated.16
     3.2.3.1.3  Vacuum-metallizing or sputtering.  Vacuum-
metallizing and sputtering are two similar techniques in which
a thin film of metal is deposited onto the plastic substrate
from the vapor phase.  Although no VOC emissions occur during
the actual metallizing process, solvent-based prime coats and
topcoats are often sprayed onto parts to promote adhesion and
prevent degradation of the metal film.  The VOC emissions
reduction potential of these techniques depends on the extent
to which VOC-containing prime coats and topcoats are used, and
the VOC content of the coatings used.  A disadvantage of these
techniques is the need to purchase additional equipment.
     3.2.3.2  Other Coatings.  Other coating technologies
that emit little or no VOC's are powder coatings, UV or
electronic-beam cure coatings, and vapor-cure coatings.  These
coating technologies are currently more limited in their use
on plastic parts than are waterborne and higher-solids

                              3-7

-------
coatings, but are growing in popularity for some coating
applications.  A description of the three systems follows.
     3.2.3.2.1  Powder coatings.  Powder coating is a coating
that is applied in the form of a finely ground dry powder.
The powder weakly adheres to a substrate by means of
electrical attraction.  After application, parts are heated to
melt the powder, which is then cooled to form a solid film.
The major advantages of powder coating are:
     •    No solvent emissions -and/or related costs;
     •    Less fire hazard;
     •    Less toxicity;
     •    No water pollution;
     •    No liquid mixing or pumping required;
     •    Less make-up air required;
     •    No flash-off time needed;
     •    Less tendency to trap air-borne dirt; and
     •    Less shrinkage stress developed during curing.
The most serious limitations of the powder coating process
are:
     •    Limited use on plastics because of the high cure
          temperature requirement;
     •    High-quality appearance often difficult;
     •    Powder must remain dry at all times prior to
          spraying; and
     •    Color change is a problem because overspray must be
          collected for reuse, and each color must be kept
          separate from the others.
     Because of the limitations of powder coatings, they  are
not used to a significant degree in the plastic coating
industry, mainly because many plastics cannot be heated to the
temperatures necessary to melt the coating.15
                              3-8

-------
     3.2.3.2.2  Ultra-violet and electron beam coatings.
Ultraviolet cure coatings involve the absorption of light
energy by an uncured coating material, resulting in a chemical
reaction that cures and hardens the coating.  The entire
process may take less than one second.  The advantages of
UV-curable technology is the high-solids nature of the coating
(80 to 100 percent solids) and the low temperatures at which
the process operates.  Disadvantages include the need for
specialized equipment for the curing process and the safety
hazards associated with this equipment.17
     In the electron beam coating process, high-energy
electrons are produced from an electron beam radiation source.
These high-energy electrons cure specially formulated
coatings.  Like UV-.cured coatings, electron beam coatings
typically contain low volumes of VOC's, if any.  In addition,
both UV and electron beam products have lower energy
requirements than a typical thermal cure line, and the rapid
cure time of these products allows for a high production rate.
     Disadvantages of this method includes its ability to cure
only what is in the "line-of-sight," higher material costs,
possible product hazards, and some problems with adhesion.
However, ongoing research is addressing each of these
concerns, and the increased emphasis on developing low-VOC
coatings is leading to the growth of both UV and electronic
beam coatings.1S
     The plastic parts surface coating category accounted for
approximately 36 percent of the $110 million radiation-cured
(including both UV and electronic beam) coatings market in
1989.  The primary use of these coatings is in the coating of
parts such as plastic cosmetic caps, containers,
ready-to-assemble furniture, speaker enclosures, and headlight
bezels for automobiles.  One industrial source projects a
12-percent annual growth for radiation-cured products.17
     3.2.3.2.3  Vapor-cure coatings.  Vapor cure coatings are
urethane coatings that are cured primarily by exposure to an
amine vapor.  The coated parts are exposed to the vapor either

                              3-9

-------
in a separate curing chamber, or the air to the paint spray
device is enriched with the amine vapor. . In the latter case,
the curing process is initiated as the paint-air mixture
leaves the spray gun.  Advantages of this coating system
include the ability to cure at or near ambient temperatures,
short processing cycles, and compatibility with many plastic
substrates.  The major limitation of this coating system is
the fact that it is" new, with only a limited number of
coatings currently available.2-3
3.3  PROCESS MODIFICATIONS
     Process modifications can also be employed to reduce the
amount of VOC's that are emitted into the atmosphere.  The two
major types of process modifications are changes in spray
equipment and process changes that allow finishing to be
completed without the use of solvent-laden coatings.  These
two modifications are discussed below.
3.3.1  Spray Equipment
     Changes in spray equipment can reduce VOC emissions by
increasing the transfer efficiency of the process.  As
discussed in Chapter 2.0, transfer efficiency is defined as
the ratio of the amount of coating solids that adheres to the
surface of the coated part to the amount of coating solids
used  (typically, sprayed).  Transfer efficiency is dependent
on many factors, including part configuration, spray
equipment, coating characteristics, and operating parameters
(such as distance from nozzle to part and spray booth
ventilation rate).
     Because equipment type is only one variable in
determining transfer efficiency, it is impossible to
accurately assign values to the transfer efficiency of
specific spray equipment.  A discussion of the various spray
systems is included in Chapter 2.0.  Although actual transfer
efficiency values are controversial, there is anecdotal
evidence that HVLP systems can reduce coating usage by 20 to
60 percent, with both turbine and non-turbine HVLP guns
regularly achieving 20 percent reduction.19

                              3-10

-------
3.3.2  Process Changes
     Another method of reducing the emissions of VOC is to
eliminate the coating process.  Several methods for
accomplishing this are discussed below.
     3.3.2.1  Molded-in Color and Texture.  The major non-VOC-
emitting technique employed to provide an attractive finish  on
plastic parts is the use of molded-in color and texture.  This
method is used primarily on business machines, office
equipment, and on the internal components of some machines
where color matching and finish are not of primary concern.6
This method relies on the use of straight injection molding
techniques in which pigment is added to the resin before or
during the injection molding step to provide the desired
color.  Molded-in texture requires that the mold itself be
tooled in such a way as to provide the desired raised texture
pattern on the molded parts.  Parts with molded-in color and
texture cannot be produced using structural foam injection
molding.
     The use of molded-in color and texture has been the
method of choice for some producers of plastic parts for
business machines and miscellaneous equipment.6-16  Some coaters
feel that the technology of molded-in color and texture does
not provide satisfactory color reproductibility and color
stability, and does not protect the plastic parts from
environmental stress.  Some coaters report that plastic parts
with molded-in color and texture still require some surface
coating.  If too much coating is applied, however,  the molded-
in texture may be masked.6'16
     Cost considerations also influence the use of molded-in
color and texture. " The mold used for straight injection
molding is more expensive than the mold used for structural
foam injection molding.  The reduction in finishing costs
realized by using molded-in color and texture (a straight
injection molding process)  must, therefore,  offset the higher
cost of the mold.  The cost considerations affecting this
choice are complex and depend on many factors, including the

                             3-11

-------
size of the part,  the complexity of the shape of the part, and
the number of parts produced from the mold.
     3.3.2.2  Electromagnetic Interference/Radio Frequency
Interference Shieldingg.   There are two types of EMI/RFI
shielding techniques that eliminate or reduce the need for
surface coating of plastic business machine components:
conductive plastics and metal inserts.  These are discussed
below.
     3.3.2.2.1  Conductive plastics.  Conductive plastics,
which are mixtures of resins and conductive fillers, are not
widely used for EMI/RFI shielding at the present time.
However, these materials are being studied extensively for
their usefulness in business machine applications, and some
conductive plastics are already being used to make business
machine enclosures.  Available resin types include ABS,
polycarbonate blends, PPO, nylon 6/6, PVC, and PBT.
Conductive fillers include aluminum, steel, metallized glass,
and carbon.
     Advantages of using conductive plastics include
elimination of the EMI/RFI shielding finishing step and
improved resistance to warping.  Disadvantages include high
materials cost; less effective EMI/RFI shielding, especially
when structural foam molding is used; and the addition of a
cosmetic finishing step to improve the surface appearance.
     3.3.2.2.2  Metal inserts.  The use of metal inserts to
house electronic components within a plastic housing is a
demonstrated EMI/RFI shielding technique.  The metal insert
can be a metal box within a plastic housing, metal foil
laminated between layers of compression-molded plastic, metal
foil glued inside the housing, or metal screens or fibers
placed within a plastic housing.  Shielding effectiveness is
comparable to that obtained with metal housings.  Many
equipment manufacturers are switching to metal inserts instead
of coatings.  The inserts are less expensive and provide a
consistent, known shielding ability.6
                              3-12

-------
3.4  ADD-ON CONTROL EQUIPMENT
     Add-on control- equipment such as carbon adsorbers,
incinerators, and condensers are presently being used to
control VOC emissions at many surface coating facilities,
including magnetic tape coaters, fabric coaters, and
automobile coaters.  Some facilities using add-on control
devices have been identified in the plastic parts surface
coating industry, including some automotive plastic part
coaters who-use afterburners on some curing ovens.20-21  Most
of the solvent-laden air in these facilities comes from the
application/flash-off area.  The concentration of VOC's in
this air is very low because it is diluted to protect workers
from exposure to harmful levels of organic solvents and
overspray.  One plastic business machine parts coater uses an
adsorption/incineration system to control VOC emissions from
the spray booths, flash-off areas, and curing oven.
     The amount of VOC's in the air exhausted from the curing
ovens is low because the majority of the solvent evaporates
before the coated parts enter the oven.  Therefore, only a
small percent of the total emissions can be reduced by ducting
oven emissions to a control device.
     The solvent -laden air from the application/flash-off area
can be captured and ducted to a control device, but the high
volume of air and the low concentration of VOC's make this a
costly method of control.  Volatile organic compound
concentrations in the solvent-laden air would typically range
from 10 to 100 ppmv.  The actual concentration in the exhaust
stream sent to the control device would be affected by
variables such as VOC content of the coatings and flow rate of
the booth exhaust, a function of blower capacity.
     In some cases, such as with automated spray systems, it
may be feasible to recirculate the booth exhaust to
concentrate the VOC's.  This would reduce operating costs of
the control device.  However, consideration must be given to
product quality and safety, thus limiting the applicability of
recirculation.

                             3-13

-------
     The general principles behind carbon adsorption,
incineration, and condensation are discussed in the following
sections.
3.4.1  Carbon Adsorption
     Carbon adsorption uses a bed of activated carbon to
remove organic vapors from an incoming airstream.  The
mechanism of VOC removal is complex, but the removal
efficiency is enhanced by specific characteristics of the
carbon. Its high surface-to-volume ratio and its affinity for
organics make activated carbon an effective adsorbent of
VOC's.
     The VOC adsorption efficiency across a carbon bed can be
at least 95 percent if the bed is properly maintained and if
inlet VOC concentration levels are sufficiently high.14
Because plastic parts coatings often contain ketones
(e.g., methyl ethyl ketone and methyl isobutyl ketone) in
their formulations, they pose significant operation concerns
for carbon adsorption equipment because of the potential for
ketones to cause fires on the carbon bed.  Safety precautions,
in the form of nitrogen blanketing, restrict the chance for
such occurrences but require a more elaborate equipment
c onf igurat i on.
     After a carbon bed has adsorbed a certain amount of
VOC1s,.a breakthrough is reached beyond which VOC removal
efficiency decreases rapidly.  The bed must be regenerated
before the. breakthrough is reached; otherwise, saturation will
occur and removal efficiency will approach zero.  Typically, a
carbon bed is regenerated by passing steam through the carbon,
countercurrent to the regular air flow, to atrip the solvent
from the carbon.  The effluent is either condensed and then
separated from the residual water by decantation or it is
incinerated.  The solvent collected by condensation may be
reused, sold, or disposed of as hazardous waste.
                              3-14

-------
     Figure 3-1 shows a typical carbon adsorption system.  The
two-bed configuration allows for continuous operation of the
coating facility because one adsorber can be regenerated while
the other is on line.
3.4.2  Absorption (Scrubbing)
     Absorption involves the scrubbing of soluble organic gas
components by a relatively non-volatile liquid.  The
absorption step is only the collection step.  After the gas is
dissolved, it must be .recovered or reacted to an innocuous
form and then reclaimed or disposed of.  Common adsorbents for
organic vapors are water, non-volatile organics, and aqueous
solutions.
     This control method is not demonstrated to adequately
remove organic solvents from an air stream.  Scrubbing towers
must be quite large to provide sufficient contact time to
solubilize, react, or condense small quantities of organic
compounds.  Because solubility is generally a function of
pollutant concentrations, large volumes of liquid may be
required, and this liquid ultimately requires treatment.
Because of the expense and limited efficiency of this control
method, it is normally not considered a viable control method
for reducing coating operation emissions.16
3.4.3  Incineration
     The incineration process converts incoming VOC to carbon
dioxide and water vapor.  The two main types of incinerators
are thermal incinerators and catalytic incinerators.  Heat
recovery may be used on both types of incinerators to reduce
operating costs.  However, capital costs increase as the
extent of heat recovery increases.
     3.4.3.1  Thermal Incineration.  A schematic diagram of a
thermal incinerator is shown in Figure 3-2.  In this
particular design, the solvent-laden air is preheated by
primary heat exchange with waste heat from the combustion
chamber.  A burner is supplied with additional fuel that
ignites the preheated air stream.
                              3-IS

-------
                                        CO

                                        I
                                       C/D

                                       _g
                                        a
                                        o

                                       I'
                                        CO
                                       O

                                       •o
                                        0)
                                       n
                                        i
                                       •o
                                        0}
                                        X
                                        c
                                        3

                                        6
                                       CO

                                        CO

                                        3
                                        a

                                       iZ
3-16

-------
                  V
i<
                                                                   O

                                                                   S
                                                                   
-------
     Three important design considerations of the combustion
chamber are time, temperature, and turbulence.  The residence
time, which must be sufficient to permit complete combustion
of the VOC's,  is typically 0.2 to 0.8 seconds.  The necessary
temperature range for combustion of VOC's using thermal
incineration is generally 760°C to 870°C (1400°F to 1600°F).
Turbulence facilitates the mechanical mixing of oxygen, heat,
and VOC's necessary for maximum destruction efficiency.  A
properly designed incinerator can achieve destruction
efficiencies of 98 percent if VOC concentration levels are
sufficiently high.22
     3.4.3.2  Catalytic Incineration.  Figure 3-3 shows a
typical catalytic incinerator.  The solvent-laden air enters
the device from the oven or application area.  It is preheated
to 260°C to 460°C (500°F to 860°F) and blown across a catalyst
site, where oxidation occurs.  About 98 percent of the
incoming VOC' s can be removed in this manner.20
     The catalyst accelerates the rate of oxidation without
undergoing a chemical change itself.  Typical materials used
are noble metals such as platinum or palladium, dispersed on
an alumina support.  Combustion temperatures are lower for
catalytic incinerators than for thermal incinerators.
3.4.4  Combination of Carbon Adsorption and Incineration
     This system is designed to concentrate dilute
solvent-laden emissions using carbon adsorption prior to final
treatment by solvent recovery or catalytic/thermal
incineration.  The key component of the system is a rotor that
consists of a honeycomb structure element made of activated
carbon fiber paper in a corrugated form.  The rotor is divided
into two sectors  (one for adsorption and one  for desorption)
and rotates continuously at slow speed.
     The VOC-laden process exhaust flows through tubular paths
in the honeycomb.  Hydrocarbons in the process exhaust are
adsorbed in the activated carbon filter in the adsorption
sector of the rotor.  A small air stream is used to desorb  the
VOC's from the carbon filter.  The desorbed air stream is only

                              3-18

-------
                                     SoJvent-Fr«
                                         Air
Catalyst Site
     Blower
Solvent-Laden
    Air
                                                                         Preheater
                       Figure 3-3.  Catalytic Incinerator
                                       3-19

-------
one-fifth to one-fifteenth the volume of the original solvent-
laden air stream entering the adsorber and, as a result, the
solvent concentration 5 to 15 times greater.  Therefore, the
costs to incinerate this desorbed air stream are lower than
those associated with the original solvent-laden stream.  Heat
from the incinerator is recovered and used to heat the air
used in the desorption process of the carbon adsorber--another
cost-saving feature of the system.
3.4.5  Condensation
     Condensation is a method of controlling VOC emissions by
cooling solvent-laden gases to the dew point of the solvent
and collecting the liquid droplets.  Liquid nitrogen and air
are typical coolants used in the shell and tube surface
condenser shown in "Figure 3-4.  Heat is extracted from the
incoming air stream as it passes through the cooled metal
tubes.  When the vapor condenses, it is collected and either
reused or discarded, depending on its purity.
                              3-20

-------
                                               BOWSOl*
                                                    CO

                                                    03
                                                    13
                                                    C
                                                    o
                                                    o

                                                    0)
                                                    o
                                                    CO-
                                                    t:
                                                    3
                                                    03
                                                    03
                                                    .0
                                                    3


                                                    •a

                                                    ca

                                                    "33

                                                    5
                                                    CO
                                                    a
                                  II
3-21

-------
3.6  REFERENCES
1.    Memorandum from Miller, S.,  and Johnson, J., Radian
     Corporation to Salman, D.,  U. S. Environmental Protection
     Agency,  Chemicals and Petroleum Branch.  Documentation of
     the Coating Database for the Plastic Parts Surface
     Coating Industry.  December 7, 1990.

2.    Memorandum from Miller, J.,  and Johnson, J., Radian
     Corporation to Salman, D.,  U. S. Environmental Protection
     Agency,  Chemicals and Petroleum Branch.  Ranking of
     Coating Data and Selection of Baseline and Control levels
     for Plastic Parts Surface Coating Operations.
     December 21, 1990.

3.    Glossary of Terms, Industrial Finishing Magazine.
     August 1990.

4.    Trip Report.  Norris, C. E.  and C. R. Blackley.  Radian
     Corporation, Research Triangle Park, NC, to Ford Motor
     Company Plant, Saline, MI.   p. 3-52.  September 19, 1990.

5.    Yaneff,  P. V., Coatings for Automotive Plastics.  In
     Proceedings of Finishing Technologies 1989.  Coatings
     Magazine, Toronto, Canada.   1989.

6.    Trip Report.  Norris, C. E.  and S. J. Miller.  Radian
     Corporation, Research Triangle Park, NC., to Kenkor
     Molding Division, Englishtown, NJ.  September 13, 1990.

7.    Letter and attachments from Gates, G., Webb Manufacturing
     Company to Farmer, J. R.,  U. S. Environmental Protection.
     Agency.   March 30, 1990.  Section 114 Questionnaire
     Response.

8.    Letter and attachments from Oyler; B., Fawn Industries to
     Farmer,  J. R., U. S. Environmental Protection Agency.
     March 30, 1990.  Section 114 Questionnaire Response.

9.    Letter and attachments from Reinhardt, D., Kenkor Molding
     Division to Farmer, J. R.,  U. S. Environmental Protection
     Agency.   March 30, 1990.  Section 114 Questionnaire
     Response.

10.  Letter and attachments from Sweetman, B., Spaulding
     Sports Worldwide to Farmer,  J. R., U. S. Environmental
     Protection Agency.  March 30, 1990.  Section 114
     Questionnaire Response.

11.  Letter and attachments from Bailey, B., Lilly Industrial
     Coatings to Miller, S. J.,  Radian Corporation.  June 4,
     1990.  Formulator Questionnaire Response.
                             3-22

-------
12.  Letter and attachments from Sirmeyer, C., Autostyle to
     Farmer,  J. R.,  U. S. Environmental Protection Agency.
     March 30,  1990.  Section 114 Questionnaire Response.

13.  Dames and Moore.   Position paper recommending the use of
     Michigan Rule 632 as an Automotive Plastic Parts Control
     Techniques Guideline.  Prepared for the National Paint
     and Coatings Association and the Motor Vehicles
     Manufactures Association.  June 28, 1991.

14.  Technical Support Document.  Rule 632 - Coating of
     Automobile, Truck and Business Machines Plastic Parts.
     Michigan Department of Natural Resources Air Quality
     Division.   Lansing, MI.  April 19, 1989.

     Bocchi,  G.  Powder Coatings:  The North American Market
     and Materials.   In Proceedings of Finishing Technologies.
     1989.  Coating Magazine, Toronto, Canada.  1989.

16.  Surface Coating of Plastic Parts for Business Machines -
     Background Information for Proposed Standards.  Draft
     NSPS, U.S. Environmental Protection Agency,
     EPA-450/3-35-019a.  December 1985.

17.  Schrantz,  J.,  Exciting Infrared and Ultra-violet
     Developments.  Industrial Finishing.  September 1990.

18.  Radak, William.  Chemical Business.  Radiation Curing:
     New Market Rx.   October 1990.

     Can-Am Engineered Products/Can-Am/Turbo Coatair, Ltd.
     Proposal to Amend the Definition of HVLP as Presently
     Listed in Rules 1136 and 1151.  Presented to the Southern
     California Air Quality Management District Planning
     Department.  May 18, 1989.

20.  Trip Report.  Norris, C. E. and C. R. Blackley.  Radian
     Corporation, Research Triangle Park, NC, to Autostyle,
     Incorporated.  Grand Rapids, MI.  September 18, 1990.

21.  Trip Report.  Norris, C. E. and C. R. Blackley.  Radian
     Corporation, Research Triangle Park, NC, to Mack Molding,
     Inman, SC.  May 3, 1990.

22.  Trip Report.  Norris, C. E. and C. R. Blackley.  Radian
     Corporation, Research Triangle Park, NC, to Ford Motor
     Company Plant,  Milan, MI. p.  3-52.  September 19, 1990.
                             3-23

-------
                   4.0  ENVIRONMENTAL IMPACT

     This chapter presents a discussion of the environmental
impacts associated with the control of VOC emissions from
plastic parts surface coating operations.  An analysis of VOC
emissions impacts was performed using the model plants
presented in Chapter 3.0 and three different VOC control
levels representing two control technologies--coating
reformulation and thermal incineration.  The VOC emissions
reductions achieved by each control level at each model plant
were calculated.  Other environmental impacts were evaluated
qualitatively.  Section 4.1 presents the three control levels.
Sections 4.2, 4.3, and 4.4 cover air emissions, water quality,
and solid waste impacts, respectively.  Section 4.5 discusses
energy consumption.  Health and safety impacts are addressed
in Section 4.6 and other environmental concerns are discussed
in Seciton 4.7.
4.1  CONTROL LEVELS
     Three control levels were developed to estimate potential
VOC emissions reductions.  Two of the levels, Level 1 and
Level 2, are based on reformulation  (i.e., use of waterborne
or higher-solids coatings); the third control level, Level 3,
is based on thermal incineration.  These technologies were
selected for analysis because of their availability and
feasibility for the" range of coating applications covered by
this ACT.  A detailed discussion of these control levels and
how they were chosen are presented in a separate memorandum.1
                              4-1

-------
4.1.1  Reformulation,
     Table 4-1 presents a summary of the coating reformulation
control levels for automotive and business machines plastic
parts, as well as baseline VOC levels.  Both reformulation
options represent VOC levels for types of coatings that would
achieve significant VOC emissions reductions and that are
currently available.  For more information on exterior
automotive coatings see Section 6.1.  For more information on
business machine coatings see Section 6.2.
     The technology is not now available to formulate
specialty coatings with reduced VOC content.  Since these
coatings are generally used in such small quantities,
reformulation may not be cost effective.  The recommended
control options for specialty coatings are therefore equal to
the baseline levels.  The baseline levels are based on data
obtained from trade associations, industry, and EPA's coating
data base.2-3-0
     One important exception is adhesion primers (adhesion
promoters) which are used in large quantities at some
automotive bumper painting facilites.  In the past year
several automobile manufacturers have approved waterborne
adhesion promoters for use by their suppliers.  These
waterborne coatings have been used in production by some
coaters, but there are still concerns about how coating
performance may vary with variations in the resin used to mold
the plastic parts.
4.1.2     Thermal Incineration
     Control Level 3 is the use of thermal incineration for
destruction of VOC's from surface coating operations.  As
described in Section 3.4, VOC concentrations in coating
operation exhaust streams are typically low--about 10 to
100 ppmv.  Auxiliary fuel is therefore required for
incineration.  For the purposes of impact analysis, 80 percent
capture efficiency and 98 percent destruction efficiency were
assumed for thermal incineration.
                              4-2

-------
TABLE 4-1.  REFORMULATION CONTROL LEVEL  (LOW-VOC COATINGS)
Coating category
Auto interiors
High -bake col or coat
High -bake primer
Low- bake colorcoat
Low- bake primer
Auto exteriors1
Flexible
High -bake colorcoat
High-bake clearcoat
High -bake primer
Low- bake colorcoat
Low- bake clearcoat
Low- bake primer
Nonflexible
High-bake colorcoat
High- bake clearcoat
High -bake primer
Low- bake colorcoat
Low-bake clearcoat
Low- bake primer
Baseline
(Ib
VOC/gal)

4.5
5.4
6.0
6.0


4.6
4.3
5.4
5.7
4.2
6.0

4.6
4.3
4.2
5.7
4.2
6.0
Control
level 1
(Ib
VOC/gal)

4.3
4.3
5.0
3.5


4.3
3.8
5.0
5.4
4.0
5.5

4.3
3.8
4.0
5.4
4.0
5.5
Control
level 2
(Ib
VOC/gal)

4.1
3.8
3.2
3.5


4.1
3.5
4.5
5.1
3.7
5.5

4.1
3.5
3.0
5.1
3.7
5.5
  For additional information on exterior automobile coatings
  see Section 6.1.

                            4-3

-------
 TABLE 4-1.
REFORMULATION CONTROL LEVEL  (LOW-VOC COATINGS)
            (CONTINUED)
Coating category
Baseline
(lb
VOC/gal)
Control
level l
(lb
VOC/gal)
Control
level 2
(lb
VOC/gal)
Auto Specialty
 Group A coatings:
   Black and reflective
     argent
   Air bag cover
     coatings
   Soft coatings
   Vacuum metalizing
     basecoats
   Texture basecoats

 Group B coatings:
   Gloss reducers
   Vacuum metalizing
     topcoats
   Texture topcoats

 Group C coatings:
   Stencil
   Adhesion primers
   Ink pad
   Electrostatic  prep
   Resist

 Headlamp lens coatings
                 5.5
                 6.4
                 6.8
                  7.4
5.5
5.5
6.4
6.4
6.8
6.8
7.4
7.4
                               4-3a

-------
    TABLE  4-1.
REFORMULATION CONTROL LEVEL (LOW-VOC COATINGS)
            (CONTINUED)
Coating category
Baseline
(Ib
VOC/gal)
Control
level l
(Ib
VOC/gal)
Control
level 2
(Ib
VOC/gal)
Business Machines2
     Colorcoat
     Colorcoat/texture coat
     Primer
     EMI/RFI shielding

   Business Specialty
           •
     Soft coatings
     Plating resist
     Plating sensitizers
                 4.8
                 4.8
                 4.5
                 4.9
                 4.3
                 5.9
                 7.1
3.5
3.5
2.9
4.0
4.3
5.9
7.1
2.3
2.3
1.2
4.0
4.3
5.9
7.1
     2 For additional information on business machine  coatings
see Section 6.2

                                4-4

-------
4.2  AIR EMISSIONS IMPACTS
     The air impacts of each control option are presented in
Section 4.2.1 in terms of VOC emissions.  Consideration to
other air emissions occurring during the coating process is
given in Section 4.-2.2.
                              4-5

-------
4.2.1  Volatile Organic Compound Emissions
     Volatile organic compound emissions can occur at several
points during the plastic parts coating process: in the spray
booth, in the flash-off area, and in the curing oven  (as
described in Chapter 2.0, some operations do not include a
curing oven).  The percent of total emissions occurring at
each of these points depends on a number of factors, including
the transfer efficiency of the operation and the amount of
time the parts spend in the flash-off area before entering the
oven.  However, in all cases, the majority of the emissions
occur in the spray booth.
     The percentage of emissions occurring at the spray booth
depends on the transfer efficiency because only the coating
that actually adheres to the part has the potential to dry
(and thus release VOC's) outside the confines of the spray
booth.  For example, if an average transfer efficiency for a
coating operation is 25 percent, at least 75 percent of the
coating remains in the spray booth or the overspray filter.
Therefore, at least 75 percent of the emissions- occur in the
spray booth.
     It is reasonable to assume that an additional percentage
of emissions occurs in the spray booth as the coatings
adhering to the part begin to dry.  Furthermore, coatings
applied to plastic parts must dry at lower temperatures than
metal parts coatings, so they often contain solvents with
lower boiling points.  The rapid evaporation of these lower-
boiling-point solvents in the spray booth and flash-off area
means that only a small portion of the VOC's are emitted in
the curing oven (if a curing oven is used).  According to some
estimates, 80 to 90 percent of VOC emissions occur in the
spray booth.6'7-8
     Emissions reductions are calculated from the difference
between the emission level at a model plant using baseline
coatings and the emission level at a model plant using
coatings that meet a given option.  Table 4-1 shows a summary
of the VOC content for two potential control levels for which

                              4-6

-------
emissions reductions are calculated.  The emissions reduction
over baseline and the percent emissions reduction achieved by
each option at each model plant are shown in Table 4-2.
Reductions range from a low of 21 percent for Level 1 controls
for automotive/transportation model plants applying exterior
coatings to a high of 86 percent calculated for each interior
automotive/transportation model plant using the Level 2
control option.
     Among the control options requiring coatings with reduced
VOC content (Levels 1 and 2), the highest reduction is
achieved using Level 2 controls for automotive interior
coatings.  All four sizes of model plants (A through D) show
VOC emissions reductions greater than 80 percent for
automotive interior coatings at Level 2.  Percent reductions
are greatest for automotive interior coatings because this
category includes coatings with some of the highest baseline
VOC content coatings.  Percent reductions are smallest for
exterior flexible coatings.  Emissions reductions from
business machine/miscellaneous coatings are equivalent at all
sizes of model plants, with Level 2 achieving the greatest
percent reductions for lower-VOC-content coatings.
     Emissions reductions would be even greater for the model
plants by replacing conventional sprayers with more efficient
sprayers  (e.g. HVLP) in addition to reduced-VOC-content
coatings.  By increasing transfer efficiency, HVLP sprayers
decrease overspray as well as the total amount of coating
used.
     As described in Chapter 3.0, coaters can achieve lower
VOC content by using waterborne or higher-solids coatings.  In
addition to containing a lower percentage of VOC's, fewer
gallons of a higher-solids coating are required to apply a
given amount of solids.
4.2.2  Other Air Emissions
     Other air emissions that occur during coating operations
include nickel particles from spraying nickel-filled EMI/RFI
shielding coatings, aluminum oxide particles from grit

                              4-7

-------
1
H
0!
O
b


cn
Z

O
H
cn

§
w
cn
cn
§

H
iJ
H
g


C
K


CO

A
             < »rf c
a

i
«1 C

  °
'*~ jQ

.H^!
e   •
IU



S   r
   §
  u
Si   -
S
LU
   U) N^ CJ
   §   C
   §
   U
     w 41

     st;
     u —
                i  XXX
                icootco
                                            ' X
                                            i^
                                0    > X
                               «•    19
                                                                        0    • XX
                                                                        ^    i^r*»
                i  O
                  o
                   •
                  o-
                  ^-^mc
                           O
    x^^o'o"   x
    in>» ~»m   u*
                                    O
                                    O
                                                                   oo    C
                                                                    *O
                                                                                O
                                                                                O
                                                           *£
                                                           ea
                                                       «««
                                                      

                                                        ^C
                               o o o
                               ooo
                                                                o
                                                                o
                                                                o
                               (O ~» o oo
                               tvjooru
                               oooo
                               m o o m
                               rvi o o roov*
                                                       ,'.   inoom
                                                                            o o <
                                                                              §o<
                                                                              o<

                                                                             §*•«*<
                                                                              >»<
                r

                  (M (MOO
                                             > XXX
                                             i ---ooo
                                              (VJK1O
                       00 -O
                       OCNJ O>

                        . .^   41
                       oeo  .   —
                                     i XXX
                                     i CM -o eo
                                      MM O>
                                                           01
                                                           —t

                                                           ^
                                               OOON-O   ^
                                                  OO«-
                                                  (\ioin
                    o
                    o
                                   o   ._
                                   -o   u
                nsr>rin
                               in^o
                            x  rn o
O   <_   O

O   n   O
   eo<2
                                                           4)
                                                           >
_,  OOOO   -n  OOOO   P
—  oooo   S  in o o in   «
g  O (M O O   ^  >M^^>

                        §"^•"00"
                         Kt in
                                       XXX
                                       v*OJOO
                                       NOOOO
                                                                  !§
                                                                                O
                                                                                o
                                                               Oin<\JO
                                                               ro «M(\J M
                                                                               XXX

                                                                               fMmOO
                                                                               -OOOO
                                                                             i §§S
                                                                              oo m
                                                                    eo-o
                                                                    r^--^
            £



            41
                OOOO   c   OOO
                oooo   _   ooo
           i   m o a i
                                Z  O O O <
                                c  o o o <
                                J:  oo o<
            i
                    
                             a
                             aa
                                            .i «-
                                             in
                                           w   O>-*MO>
                                     41

                                     01
                                      «*   —   oooo
                                                                  tin   ,    oooo
                                                                  •  "   a    «...
                                                                        0   Ov» —O
                                                                        ^j   O *T &• O
                                                                             41
                                                                             

                                                                                                    :8g
                                                                                                      inK




                                                                                                    i  O

                                                                                                    '§
                                                                              O O
                                                                                O
                                                                                                        ss
                                                                       41
                                                                       a
                                                                                             §§§§
                                                                                             o o 
-------
blasting prior to zinc-arc spraying, and zinc oxide fumes from
zinc-arc spraying operations.  Paint solids from powder
coatings are also emitted during spray application.  Although
free of solvent, the powder can be abrasive.'  Dry filters and
water walls in spray booths often have particulate removal
efficiencies in excess of 99 percent; therefore, emissions of
the above substances are expected to be minor.10
     Amine vapors are emitted during the curing of vapor-cure
coatings; however, special equipment and separate curing
chambers control and minimize emissions from vapor-cure
operations.
     Certain proprietary compounds are often used in
conductive coatings, but their emissions are not known.  The
conductive coatings are often composed of alcohol, water,
organic salt, and proprietary compounds that may produce air
emissions during the baking stage.  However, these emissions
do not appear to be significant.  Conductive coatings are
applied to the substrates by conventional spray.
Electrostatic spray technology may increase the transfer
efficiency of conductive coating application.
     Cleaning spray booths and spray guns with solvents also
produces VOC emissions.  Guns can be cleaned by soaking them
in vats of solvent.11  Manual guns can also be cleaned by
spraying solvent through the gun.12  Automatic spray systems
can be cleaned with internal solvent circulation systems.
Only the tips of the automatic guns or bells require manual
solvent cleaning, thus reducing air emissions.3    Another
method of reducing emissions is to reclaim the solvent used
for booth and spray gun cleaning through distillation.
Distillation can be performed on site or off site, with
recoveries of roughly 80 percent.5
     The following hazardous air pollutants  (HAP's) are
typically contained in some combination in plastic parts
coatings and are emitted during the coating processes:
formaldehyde, methanol, methyl ethyl ketone, ethyl benzene,
ethylene glycol, methyl isobutyl ketone, toluene, xylene, and

                              4-9

-------
glycol ethers.  All of these HAP's are VOC's and would be
controlled to some extent by each of the alternatives.
     Incineration may produce negligible amounts of nitrogen
oxides and carbon monoxide from the high temperatures and
incomplete combustion of hydrocarbons.
4.3  WATER IMPACTS
     Plastic parts surface coating facilities may use water in
waterwash spray booths, gun cleaning systems, and dip tanks
for electroless plating.  Waterwash spray booths are equipped
with a water curtain that removes overspray particles from the
spray booth exhaust.  Water pollution results from the
entrainment of coating solids and from the dissolution of
soluble overspray components into the water.  Water pollution
also results from gun-cleaning solvents in waterwash systems.
Some systems allow the captured paint and water  (oil/water
emulsion) to be routed to large vats, where chemicals are
added to deactivate the paint, forming a flocculent that can
be skimmed off through filtering.3
     Plastic parts may undergo multi-stage washing cycles that
require water in order to prepare the substrates for
coatings.3'13-14  Water is also used  in pressurized  systems to
clean paint build-up from grating and carriers.5  In addition,
metal conveyor rods are often dipped into salt water baths to
remove dried paint.3
     The types of water pollutants likely to result from spray
coating operations include organic solvents, resins, pigments
such as lead chromates and titanium dioxide, nickel particles
from EMI/RFI shielding coatings, and zinc from zinc-arc
spraying.l3
     Water pollution from electroless plating processes for
EMI/RFI shielding results from dragout, which is defined as
the volume of solution carried over the edge of a process tank
by an emerging piece of work.  This solution usually ends up
in the water used to clean the application area or in process
                             4-10

-------
drains.  Examples of water pollutants emitted from plating
processes are sulfuric acid and nickel and chromium
compounds.n
     Only Wisconsin has specific water pollution regulations
for the electroplating industry.  The Wisconsin Administrative
Code, Chapter NR 260, establishes effluent limitations,
standards of performance, and pretreatment standards for
discharging by electroplaters.  Federal water pollution
regulations for the electroplating and other industries are
governed by the Water Pollution Control Act.11  This Act
specifies several levels of control:  (1) for existing plants,
best practical control technology currently available and best
practical treatment  (BPCTCA/BPT) by 1977;  (2) for existing
plants, best available technology economically achievable and
best available treatment (BATEA/BAT) by 1983.  The Act allows
States to establish more stringent control levels than Federal
standards if desired.
     Methods currently employed by the coating industry to
handle wastewater and sludge include discharging to a sanitary
sewer, recycling, incineration, and hauling to a licensed
disposal site.  Facilities can reduce water pollution by
improving transfer efficiency and by using dry filter spray
booths and in-plant controls.  Use of dry filter spray booths
instead of waterwash spray booths will reduce the amount of
wastewater, but increase the amount of solid waste generated
by a plant.  Examples of in-plant controls include separating
process and non-process water and reusing and recycling water.
     The regulatory alternative of using higher-solids
coatings would not appreciably affect water usage or
contamination in waterwash spray booths.  Regulatory
alternatives such as HVLP and electrostatic spray methods
reduce overspray and, thus, can decrease the volume of
contamination in the wastewater from waterwash spray booths.
However, if a scrubber is used as part of an emissions control
system, water may need to be discharged into a sewer system.
                              4-11

-------
4.4  SOLID WASTE DISPOSAL IMPACTS
     The majority of solid waste generated by the surface
coating process is the coating overspray collected by dry
filter and waterwash spray booths.  Solid waste is usually in
the form of dirty filters from dry filter spray booths and
sludge from waterwash spray booths.  Paint also accumulates on
metal carriers, grates, and booths.
     Reducing overspray by using HVLP and electrostatic spray
techniques can decrease the amount of solid waste generated by
coating operations.  Paint recirculation systems that
constantly agitate and move the paint can also minimize the
amount of paint wasted.5
     Another means of reducing solid waste is a paint recovery
system.  In one type of system, paint overspray collects onto
baffles.  The paint solids then drop from the baffles into a
barrel, where they are recovered, reduced, and reused.3   Using
only zinc-arc spray for EMI/RFI shielding also reduces solid
waste production, if the zinc overspray is recovered and sold
by coaters.
     Using the reformulations control options, solid waste
from coating operations could be significantly reduced where
higher-solids coatings are used.  Fewer gallons of higher-
solids coating are needed to apply the same amount of solids
than are needed for conventional coatings.  Consequently, less
coating is sprayed, and fewer coating containers are disposed
of.  The use of HVLP's significantly decreases the amount of
overspray and, hence, the amount of dry filter and sludge
waste.
4.5  ENERGY IMPACTS
     Because coatings for plastic parts must cure at a low
temperature to avoid damaging the plastic, the energy
consumption for this process is lower than for similar metal
coating processes.  Many of the organic-solvent-based coatings
used on plastic parts can be cured at room temperature,  but
most manufacturers recommend a baking schedule to achieve
optimum finish quality.

                             4-12

-------
     Waterborne coatings generally require a low-temperature
oven cure.  Most coaters use low-temperature ovens to speed up
production regardless of the types of coatings used.  Some
coaters feel that increased oven air flows, and even
intermediate baking between coats, are necessary to produce an
acceptable finish with waterborne coatings.5   Regulatory
alternatives that require the exclusive use of waterborne
exterior coatings or waterborne EMI/RFI shielding coatings
might increase energy consumption at some surface coating
plants because of the higher air flow rates or longer curing
times.  However, waterborne coatings are cured at temperatures
in the range of 50°C to 60°C (125°F to 149°F), similar to
those used for organic-solvent-based coatings.  Therefore, the
energy impact of the regulatory alternatives specifying
waterborne coatings is expected to be negligible.
     Regulatory alternatives such as emission control
equipment and application equipment with better transfer
efficiency (e.g., HVLP and electrostatic spray devices) could
require additional energy in the form of electricity or fuel
consumption.
4.6  HEALTH AND SAFETY IMPACTS
     Some of the regulatory alternatives intended to reduce
VOC emissions may affect the health and safety standards for
workers at surface coating plants.  Worker exposure to some of
the materials used in the surface coating process must be
controlled through the use of respirators and proper
ventilation.  For example, vapor cure and powder coatings can
reduce VOC emissions, but worker exposure to the fumes and
particles must be considered.  Electrostatic spray devices can
also reduce emissions by improving transfer efficiency.
However, these applicators have greater potential fire and
shock hazards than conventional air spray.  Examples of
regulated materials that might be.affected by the regulatory
alternatives are listed in Table 4-3.
                              4-13

-------

2
3
ca
u
S
o
CJ

>H
EH
U
fc

K^

1
JJ
e
(11
Use of organic -solv<
based coatings



CO
jj
C
cu
>
rH
O
CO
CJ
•H
fi —
m u
Cno
rl >
O~














1<
o

o


•





^
O

o






Use of some two-
component
catalyzed urethanes





cu
jj
rd
C
- rd
CN >,
i CJ
CU O
a m
CU-H
3-H
rH T3
o •
EH 5f













•d
in — »
H in










o
i_f





o
JJ

Grit blasting prior
zinc-arc spray











|
d
•H
S
rH
4














in










in








Zinc-arc spray




cu

3
<
CU 5
Qi'r!
ca R
3 b
« S
w* CJ





H










H







m
Use of nickel -fillec
EMI/RFI shielding
coatings







rH
rd
jj
cu
S
rH
CU
X
CJ
•H
2
•gs
.2 en
u °
u r*
cu 5
QiTJ
CO P
3 LJ
CO ??
WW u





H
o









H
O




rH
o
UH

Electroless plating
EMI/RFI shielding





rH
CU
^
CJ
•H
c ca
T3
CD C
rH 3
X) 0
3 a
rH 2
0 0
CO CJ
jj
•H
.,-)
^

T3
rH
O
X!
CQ
0)
rH
Xi
E*

• •
CU
CJ —
rH O
3 o%
O en
CO H
K
• H
CU O
CnCJ
rd  CQ
rd JJ
53
T3 CU
cu en
jj rd

COi-H
•H rd
CU CJ
a -H
lue. An 8 -hour time-1
1 substances and phys
rd rd
> 0
•rH
^J €
-rt 0)
S X!
•H CJ
J
rH
•o o
rH H-l
0
X! CQ
CO 0)
CU 3
rlrH
XI rd
E" >
rd
,_!
rd
i_i
CU
T3
CU
b


• •
CU
O
rH
O
CO


•
0)
Ol
2
cu
>
rd

•o
CU
jj
X!
cn
•H
CU

1 "
cu
e
-H
JJ
rH
0
Xi
1
GO
S
jj en
•H CO
S i
O rH
ard
ST3
Cd (3
rd
QJ ra
rH
X) —
IT) rH
CQ CU
CQ JJ
•rH CO
g-H
en
cu cu
04 C^
X)



















^
CQ
T3
a
3
0
1
CJ

CJ
•H
M-l
•rH
CJ
CU
a
ry depending on the s;
rd
>

ca
jj
•H
S
•H
rH

CU
rH
3
ca
o
8*
w
o


































respirable dust.
rH
0
U-l

JJ
-H
S
•H
rH

CU
rH
3
CQ
O
S1
pa
T3
4-14

-------
     Regulatory alternatives that promote the use of
waterbome coatings could reduce worker exposure to organic
solvents and isocyanates.  Fire hazards could also be reduced
by use of waterbome coatings.
     Regulatory alternatives that promote the use of non-VOC-
emitting EMI/RFI shielding methods could reduce worker
exposure to the organic solvents and nickel particles present
in nickel-filled EMI/RFI shielding coatings;  however, other
occupational hazards are associated with non-VOC-emitting
EMI/RFI shielding methods.  Zinc-arc spray operators must be
protected from zinc oxide fumes and noise.  Electroless
plating techniques employ acids and soluble nickel and
chromium compounds that are toxic.  The EMI/RFI shielding
options presented in the regulatory alternative have different
types of health risks associated with them, each of which
should be evaluated accordingly.
     Guidance regarding fire and electrical hazards can be
obtained from the National Fire Protection Association.  The
Occupational Safety and Health Administration, the National
Institute of Occupational Safety and Health, among other
government agencies, provide specific guidance on worker
safety and health.
4.7  OTHER ENVIRONMENTAL CONCERNS
4.7.1  irreversible and Irretrievable Commitment of Resources
     For many of the regulatory alternatives, such as the use
of HVLP's and add-on control devices, additional equipment
would be required.  Manufacturing such equipment would consume
steel and other raw materials.  However, compared to current
coating industry use of these resources, the increase in
consumption would be insignificant.
                              4-15

-------
4.8  REFERENCES
1.   Memorandum from Miller, S. and Johnson, J.  Radian
     Corporation to Salman, D., U. S. Environmental Protection
     Agency,  Chemicals and Petroleum Branch.  Documentation of
     the Coatings Database for the Plastic Parts Surface
     Coating Industry.  December 7, 1990.

2.   Dames and Moore.  Appendices for the Position Paper
     Recommending the Use of Michigan Rule 632 as an
     Automotive Plastic Parts Control Techniques Guideline.
     Prepared for the National Paint and Coatings Association
     and the Motor Vehicle Manufacturers Association.  June
     28, 1991.

3.   National Paint and Coatings Association.  National Air
     Pollution Control Technology Advisory Committee Meeting:
     Comments on Surface Coating of Plastic Parts Control
     Techniques Guideline.  November 20, 1991.

4.   Plastic Parts Coatings Database  Radian Corporation,
     Research Triangle Park, NC.

5.   Letter and attachments from Nelson, R. J., National
     Paint and Coatings Association to Salman, D.,
     U. S. Environmental Protection Agency, Chemicals and
     Petroleum Branch.  March 4, 1992.

6.   Wilson,  A.  Methods for Attaining VOC Compliance.
     Pollution Engineering.  Page 15: 34-35.  April 1983.

7.   Industrial Surface Coating:  Appliances-Background
     Information for Proposed Standards.  U. S. Environmental
     Protection Agency, Research Triangle Park, North
     Carolina.  EPA-450/3-80-037a.

8.   Preliminary Review of 19 Source Categories of VOC
     Emissions.  U. S. Environmental Agency, OAQPS.  May 1988.

9.   Bryan, G. Bruce, Jr.  Powder Coating Safety is No
     Accident.  Industrial Finishing Magazine.
     September 1990.

10.  Surface Coating of Plastic Parts for Business Machines -
     Background Information for Proposed Standards.  Draft
     NSPS, U. S. Environmental Protection Agency.
     EPA-450/3-85-019a.  December 1985.

11.  Trip Report.  Norris, C. E. and S. J. Miller.  Radian
     Corporation, Research Triangle Park, NC., to Kenkor
     Molding Division, Englishtown, NJ.  September 13, 1990.
                             4-16

-------
12.  Trip Report.  Norris, C. E. and C. R. Blackley.  Radian
     Corporation, Research Triangle Park, NC., to Autostyle,
     Incorporated.  Grand Rapids, MI.  September 18, 1990

13.  Trip Report.  Norris, C. E. and C. R. Blackley.  Radian
     Corporation, Research Triangle Park, NC to Ford Motor
     Company Plant, Milan, MI.  September 19, 1990.

14.  Trip Report.  Norris, C. E. and C. R. Blackley.  Radian
     Corporation, Research Triangle Park, NC to Ford Motor
     Company Plant, Saline, MI.  September 19, 1990.

15.  Industrial Surface Coating:  Appliances-Background
     Information for Proposed Standards.  U. S. Environmental
     Protection Agency, Research Triangle Park, North
     Carolina.  EPA-450/3-80-037a.  pp. 7-1 - 7-14.
                              4-17

-------
                 5.0  CONTROL COSTS ANALYSES

   This  chapter presents  the  costs  associated with the VOC
emissions control options described iii Chapter 4.0 for the
plastic parts surface coating industry.  Section 5.1 explains
cost derivations for add-on thermal incineration systems and
for substituting currently used coatings with coatings having
lower VOC and/or higher solids content for the automotive/
transportation sector.  Section 5.2 presents the same type of
information for the business machine/miscellaneous sector.
All costs are provided in first-quarter 1990 dollars.  When
necessary, equipment and materials costs were updated using
chemical engineering cost indices.  Labor rates and utility
prices were obtained from recent publications by the
U. S. Department of Labor and the U. S. Department of Energy.
(See Appendix C for sample calculations of cost analysis.)
5.1    AUTOMOTIVE/TRANSPORTATION SECTOR
5.1.1  Add-on Thermal Incineration Systems
   As discussed in Chapter  3.0,  the use of  add-on thermal
incineration systems is an effective strategy for controlling
VOC emissions at surface coating facilities.  Thermal
incineration is the predominant type of add-on control used in
this industry.  Incinerator system costs were developed using
the methodology in Chapters 2.0 and 3.0 of the Office of Air
Quality Planning and Standards (OAQPS) Control Cost Manual.1
Scrubbers were neither required nor costed because the VOC's
in the coatings are not halogenated.
   Table 5-1 presents the operating parameters used for
thermal incineration design and cost estimations for the
automotive/transportation model plants described in

                              5-1

-------











IV*
MS
o
&.
CO O*
P5J O
W E-<
M a
H CQ
2 ss
2 o
0,H
2 <
3 E-<
S*
gg
CO CO
2 T
O g
LJ ^H
£^
s|
H Q
U 2
^S
*""* ^

j <
I w
2 a
M pH
t.
5C

^^

.
rH
i
Ul
W
1


















X —
> tj'is
*• w 1
« S a
3 Ji
u

u ^
§^e
* .5 7*
IF
^
|h
«il

i—


Number of
ncineratori
required0
'^

u
«•*
_, u *•
10 a ^
+* j ,•
—



Suo
Sfl-
A S
L. 3*-
3 0 0
•M -— «
(0 *^ ^i*
z

a
U ">
O CB ^
w -5 c
|3|


* 91
- 2S
i s's
2^^
CO

a
j
d
"c
4
1
3




5j£5j
•-«»»»
ooo





§(M«\J
CM(M
000


§O O
O O
O 0
KIKlrS




^*" *~


ooo
ooo





ooo






•o
KIKI »-
~*!^^



ill
ooo
KIKIKI






<<<
«<






K(MO
fMN-N.
OOO





(MON-
(MI^-O
OOO


§§§
OOO
in mm




(MOIOJ


ooo
ICICK





111







l-Q't
»- O«O
<— (MOI



ill
ooo
in mm






ca OB m
<«
-





Kl
>»•-»-






lo-S
OfMfM


Iff
to co co
»-^»-



KIKIKt


OOO
ooo
rvj c\jf\j
"~ — "




000
N.m in
x>>o >o
*- ^ ^






o
OKI IM
KIO O



OOO
OOO
ooo
(M(M (M






U U U
<«






«-«»»
(MtMOJ




OOO
•O ^3 -O
Kl KIKI







S^)^
KIKI
Kl CMCM



OOO
§§§
33^
(MCMO





Sac
<«








































9
e
3
jj
•H
O
01
rH
td

a1
•H
AJ
00
O
u
o
jj

jj
f+
I
G
M
id
(U
3

id
'W
0)
a
(U

01
a

fd
1
to
o
O
o
10
H
•d
c
(d
o
a

-------
Chapter 2.0.  Other information used as input to the costing
program included an operating temperature of 1,600°F and a
destruction/removal efficiency of 98 percent, as discussed in
Chapter 4.0.  The inlet stream heat value ranged from 0.044 to
0.344 British thermal units per standard cubic foot  (Btu/scf),
as determined from the heat value of the dilute VOC's in the
booth exhaust.
    The  cost-effectiveness  of  a  system using recirculation to
concentrate the VOC level  (and thus the heat content) in the
stream was also investigated.   For automated lines,
recirculation may be a cost-effective alternative.  However,
recirculation is not feasible on nonautomated coating lines
because worker exposure levels would be unacceptable;
therefore, on a plant-by-plant basis, it was not
cost-effective.2
    Annual operating hours  of  6,000  hours  per year for
automotive/transportation model plants D-l, D-2, and D-3 and
4,000 hours per year for all other model plants were used to
calculate the emission rates as well as operational costs such
as labor and utilities.
    Capital costs,  annual  costs,  and cost-effectiveness  are
discussed below.
    5.1.1.1  Capital Costs. The cost analysis followed  the
methodology outlined in the OAQPS Control Cost Manual.1
Equipment cost correlations were based on data provided by
various vendors.  Each correlation is valid for flow rates in
the 500 to 50,000 standard cubic feet per minute  (scfm)  range.
For flow rates above 50,000 scfm, additional incinerators were
costed.
    Equipment costs for thermal  incinerators are a function  of
total volumetric throughput (Qtot)• expressed in scfm.  Four
different heat recovery scenarios were evaluated in the cost
estimation procedures.  The cost algorithm includes systems
with heat recoveries of 0, 35, 50, and 70 percent.  The
equipment costs for each model plant size were calculated by
using the following equations:

                              5-3

-------
      Heat  Recovery (%)              Equipment  Cost ($)

              0                    10,294 x  (Qtot)  °-2355

             35                   13,149 x  (Qtot)  0.2609

             50    -               17,056 x  (Qtot)  °-2502

             7Q                   21,342 x  (Qtot)  0.2500

where Qtot ig tjtle sum °f all streams fed to the incinerator:
vent stream, auxiliary fuel, combustion air, and  dilution air.
    The amount of  heat  exchange that occurs is decided by an
economic optimization routine, with the least-cost system
being selected as the logical choice for a control device.
Total capital and annual costs are based on the most cost-
effective configuration.  The trade-off between the capital
cost of the equipment and the operating cost of fuel for the
system determines the optimum level of energy recovery.  For
each of the model plants, 70-percent heat recovery was
selected as the optimum level.
    The cost of  the"ductwork and fans required to carry the
vent stream from the spray booth  to the incinerator are not
included in the above equations.  The costs for this auxiliary
equipment were based on the assumption of 1/8-inch carbon
steel ducting, 2 feet in diameter, with two elbows per
100 feet of ducting.3  The fans were assumed to be 24-inch
diameter and able to produce the  pressure increase necessary
to move the vent stream.  The equations for these costs are as
follows:

      Duct Cost -  [(210 x d°-839)+(e x 4.52 x d1-43)] x 1
                  x (355.6/352.4)
where:
    d                *    diameter (in inches),
                              5-4

-------
    e                »    number of elbows per 100 feet,
    1                »    length of duct work  (in hundreds of
                         feet), and
    355.6/352.4      =    cost conversion from February 1989
                         dollars to Ist-quarter 1990 dollars.
    Fan Cost         -    NX  (96.96418 x Qv0-547'
                         x (355.6/342.5).
where:
    N                =    number of incinerators required,

    Qv              -    Vent stream flow rate  (scfm) , and
    (355.6/342.5)    =    cost conversion from 1988  (avg.)
                         dollars to Ist-quarter 1990 dollars.
    The sum of the incinerator,  ductwork,  and fan costs is the
equipment cost.  Table 5-2 presents factors used to calculate
purchased equipment cost.  The total direct cost is then
calculated as a function of the purchased equipment cost, as
is the total  indirect cost.  Total capital cost is the sum of
purchased equipment costs, direct costs, and indirect costs,
or 1.61 times purchased equipment cost, as shown in Table 5-2.
Table 5-3 presents a summary of total capital costs for the
12 automotive/transportation model plants
    5.1.1.2  Annual Costs.  Total  annual costs for the  thermal
incinerator system include annualized capital costs, as well
as operating  and maintenance costs.  The assumptions used for
determining annual costs are presented in Table 5-4.
Table 5-3 presents a summary of the annual costs of control.
    5.1.1.3  Cost-Effectiveness.   Cost-effectiveness is
defined as the total annualized cost per megagram of VOC
emissions reduction.  The information required to calculate
cost-effectiveness for thermal incineration is summarized in
Table 5-5.  The costs per emission reduction were determined
by applying the costing methodologies described in previous
sections to the individual model plant emissions reductions of
VOC.  The method for determining model plant emissions
reductions of VOC was described in Chapter 2.0.
                              5-5

-------
  TABLE 5-2.   CAPITAL COST FACTORS  FOR THERMAL INCINERATORS
	Direct Costa	

 Equipment  Costs  (EC) :

      Incinerator + Auxiliary
        Equipmenta                                          EC
      Instrumentation                                  0.10  EC
      Sales Taxes                                      0.03  EC
      Freight                                          0.05  EC

 Purchased  equipment  cost  (PEC)                   PEC »  1.18  EC

 Direct  Installation  Costs

      Foundation  and  Supports                        0.08 PEC
      Handling and Erection                          0.14 PEC
      Electrical                                      0.04 PEC
      Piping      •                                  0.02 PEC
      Insulation  for  Ductwork                        0.01 PEC
      Painting                                       0.01 PEC

 Total Direct Cost (DC)	0.30 PEC

	Indirect Costs  (Installation)	

      Engineering                                    0.10 PEC
      Construction and  Field
        Expenses                                      0.05 PEC
      Contractor  Fees                                0.10 PEC
      Start-up                                       0.02 PEC
      Performance Test                                0.01 PEC
      Contingencies                                   0.03 PEC


 Total Indirect Cost  (1C)	0.31 PEC

	Total Capital Cost  (TCP	

 TCC  -  PEC + DC  + 1C
           - PEC  + 0.30PEC  +
           0.31PEC
           - 1.61PEC
^Ductwork and fan(s).
                              5-6

-------
en
in
I
                 o



                 u
                 a
                 U4
                 at

                 8
                  l_
                  3
                  > L.
                  o >
                  ao
                  aj
                 u
                  a.

                  u
                            o
                            o

 ...    ooo
?   mmm
                                ooo  ££2=   eaeoco
                            l
                    l
                        (M
                        -O
  IM(M
  -O-O
v T-*-   OOO
OOO   mmm
mmm   ooo
§:
          ) O O
          >o o
          )O O
                        *-.-*-   £££
                        mmm   mm m
                         too   o o
                  ooo   ooo
            __   ooo   ooo
           oo   ooo   ooo
                                   >»«
                                   o
                                                  eoeo co
                         :§§   §:
                   too   ooo
                   I O O   OOO
                   too   ooo
                                 NOJ O4


                                 «•?«•? »•?  (\|"|M*C>4*
                                                    oo
                        «<   caaea   uuu  aoo
                        t— t— ^   Mf»^»   h-^H-  H*^H»
                                 §



                                 1

                           2T?
                           u a
                   in


                   fi
                   O
                   •H
                   JJ

                   U
                   (U
                   CO
                   a
                   01

                  •H
                   O1

                  •a
                   o
                                                            •d
                                                            a)
                                                            jj
                   u
                   rH
                   id
                   o
                   id
                                            i
                                           in

                                           0)
                                                                   rd
                                                                   a
                                                                  •H
 o

 o

Cb



 d)

 O
 o
 0)
04

rH
 id


"a
 c
 o

•0
 0)
 CO
 id
m
                                                 o
                                                 en
                                                 rH
                                                 id
                                                 c
                                                 •H
                                                 4J
                                                 tn
                                                 o
                                                 o

                                                 TJ
                                                 (U
                                                 N
                                                 d)
                                                 4J



                                                 Ol
                                                 O

                                                 §
                                                 •4-1
 3

 04
 4J


 5
U
             o
             •H

             id


             OQ


             -H

             I
             id

             •d
             a
             id
             
-------
        TABLE 5-4.
ASSUMPTIONS FOR CALCULATING ANNUAL
  COSTS OF THERMAL INCINERATION
 Annual  Operating Hours  (hrs)
      •    Automotive/Transportation Model
          Plants D-l, D-2,  D-3
      •    All  Other Model Plants
 Operating Labor Rate ($/hr)
 Operating Labor Required (hrs/8-hour shift)
 Supervisor  Cost (%  of Operating Labor)
 Maintenance Labor Rate  ($/hr)
 Maintenance Labor Required (hrs/8-hour
 shift)
 Annual  Maintenance  Material

 Utilities
      •    Electricity  ($/1000  KW-hr)
      •    Natural Gas  ($/l06 Btu)
 Overhead (% of Operation and Maintenance)
 Administrative Charges
 Property Taxes
 Insurance
 Capital Recovery Factor (10% interest,
 10-year lifetime)
TCC = Total  capital  cost.
                           6,000
                           4,000
                           15.64
                           0.5
                           15
                           17.21
                           0.5

                           100% of
                           Maintenance Labor
                           61.0
                           3.30
                           60
                           2%  TCC
                           1%  TCC
                           1%  TCC
                           0.16275
                              5-3

-------
TABLE 5-5.
SUMMARY OF COST-EFFECTIVENESS FOR APPLYING THERMAL
       INCINERATION TO MODEL PLANTS IN THE
        AUTOMOTIVE/TRANSPORTATION SECTOR
Total
annual
Model cost
plant ($/yr)
Ala 524,000
A2a 524,000
A3a 524,000
Blb 910,000
B2b 910,000
B3b 910,000
Clc 2,390,000
C2C 2,390,000
C3C 2,390,000
Dld 6,340,000
D2d 6,340,000
D3d 6,340,000
aSmall model plants.
^Medium model plants,
cLarge model plants.
Total VOC emission
reduction
[Mg/yr
31.7
26.4
25.0
71.9
60.1
56.8
257
215
203
791
661
625

»

(tons/yr) ]
(34.9)
(29.0)
(27.5)
(79.1)
(66.1)
(62.5)
(283)
(236) -
(224)
(870)
(727)
(688)



Overall cost-
effectiveness
[$/Mg
16,600
19,900
21,000
12,700
15,200
16,000
9,281
11,107
11,807
8,000
9,600
10,100



($/ton)l
(15,000)
(18,100)
(19,100)
(11,500)
(13,800)
(14,600)
(7,600)
(9,000)
(9,600)
(7,300)
(8,700)
(9,200)



dVery large model plants.
                             5-9

-------
    These analyses show that,  in general,  VOC reduction from
dilute streams  (e.g., the exhausts from each of the model
plants) requires significant investment of capital.  In
addition, large quantities of auxiliary fuel are needed, which
significantly increases annual operating costs.  Combining
these conditions with the emissions reductions achieved
produces high cost-effectiveness values, ranging from
$8,000/Mg ($7,300/ton) removed for the largest model plants up
to $21,000/Mg ($19,100/ton) removed for the smallest model
plants.
5.1.2  Substituting Lower-Volatile-Organic-Compound Coatincrs
    Using coatings with lower VOC and/or higher solids content
was discussed in Chapter 3.0 as an effective emissions control
strategy.  To develop control costs for this strategy, the
baseline and optional VOC levels were first selected as
described in Chapter 4.0.  Equations for estimating the cost
of coatings with varying levels of VOC's, were developed and
used to calculate the cost impact and cost-effectiveness at
both option levels for each type of coating used by the model
plants.
    5.1.2.1   Capital  Costs.   No capital costs were estimated
for the reformulation control options.  This is based on the
assumption that a facility's existing equipment can apply the
reformulated coatings without a capital expense.
    5.1.2.2   Annual Costs.  Total annual costs for
reformulated coating application is calculated from the
difference in annual coating cost between the given option
level  and the baseline level.  The equations used  to calculate
coating cost are  as follows:

    Colorcoat Cost ($/gal) - -14.43 x Cvoc + 99.76
    Clearcoat Cost ($/gal) = -12.98 x Cvoc + 89.79
    Primer Cost ($/gal)     =  -7.21 x Cvoc + 49.88

where  Cvoc is the amount  (Ib/gal) of VOC  in  the coating.
                              5-10

-------
The estimated cost associated with each coating was based on
information provided by the NPCA and coating formulators.*
All costs are provided in first-quarter 1990 dollars.
Representative cost estimates for each coating corresponding
to its level of VOC content are presented in Table 5-6.
Table 5-6 shows the VOC level and cost of each coating  for  the
baseline and both control options.  The total annual  coating
cost over baseline is estimated by the following equation:
                    n                n
             TAG =  £   [Ue x VOCC]  -   £  [UBx VOCB]
                   i = 1             i = 1
where:
       Uc     -  Usage of control  level coating in gal/yr.
       Ub     -  Usage of baseline coating in gal/yr.
       VOCC   »  VOC content of control level coating in Ib/gal
       VOCB   =  VOC content of baseline coating in Ib/gal.
The coating use for an  option was estimated based  on  the
assumption that the' total amount of solids applied remains
constant when substituting  the lower-VOC coating for  the
baseline coating.
    5.1.2.3  Cost-Effectiveness.   The cost-effectiveness was
calculated for each option  on a model plant basis  and on an
overall basis.  The equation for cost-effectiveness is:
                            TAG  ($/yr)
CE  ($/ton)
              [Emissions reduction  (Ib/hr)/2000(Ib/ton)]
Emission reductions for each model plant are  calculated  as  in
Chapter 4.
                              5-11

-------
CO
i
H

S
 CO
 w
 vo

 in

 H


*f»- C9
«M «MKI *-

o inKi KI
m KI ^ •**
SM«
KI «O KI °
»- KI




00-0 XT
•o-O-f in


ow-bake color
ow-bake primer
igh-bake colorcoat
igh-bake primer
utomotive Exterior
_J —i 3 S <
fcsn
S^2

^IS.

* CO»M I--
f^-O h-
MKI»- KI

-ro in
in-* in
«-^ »M
in CM *o
fw in *o
»-KI




r»OJ O


M 4-»
ss
u u u
«IJ
SoS.
41 « < -*
«^55
52SS
g-i-.--
u.
§
at
SS3
O-* PU

•-in co
•*« KI
*.-»•
o«-

KICOO

03 CO O
KI O1* ^
KIKIO
KIKI «-




^KIOJ

W 4^
a a
o o
u u ^
28.1
•3-2T
u o a.
41 41 41
J<^ -*
^^^
4|4
X Z =

JJ

I

en
GO
 a
   01
                                                 5-12

-------
    The results of the cost-effectiveness calculations are
shown in Table 5-7.  The cost-effectiveness for each  type of
model plant  (interior, exterior flexible, and exterior non-
flexible) was constant, regardless of size.  Table 5-7 also
shows the incremental cost-effectiveness, i.e., the cost-
effectiveness of the emissions reductions achieved by moving
from control Level 1 to control Level 2.
5.2    BUSINESS MACHINE SECTOR
5.2.1  Add-on Thermal Incineration System
    As  with the automotive/transportation sector,  capital
costs,  annual costs, and cost-effectiveness were calculated
using the methodology given in the OAQPS Control Cost Manual.1
Table 5-8 presents system parameters for adding thermal
incineration to the model plants for the business machine
sector described in Chapter 2.0.
    5.2.1.1  Capital Costs.   The costing equations and
relationships used to calculate total capital costs are  shown
in Section 5.1.1.1.  The capital costs  for applying thermal
incineration to the business machines model plants are
presented in Table 5-9, and range from  $590,000 for the  small
model plant to $1,870,000 for the large model plant.
    5.2.1.2  Annual Costs.   The costing equations  and
relationships used to calculate total annual costs are shown
in Section 5.1.1.2.  The annual costs for applying thermal
incineration to the business machines model plants are
presented in Table 5-9, and range from  $373,000/yr for the
small model plant to $1,490,000/yr for  the large model plant.
    5.2.1.3  Cost-Effectiveness.   The costing equations and
relationships used to calculate cost-effectiveness are shown
in Section 5.1.1.3.  The cost-effectiveness values for
applying thermal incineration to the business machines model
plants are presented in Table 5-10.  These cost-effectiveness
values range from $7,560/Mg removed  ($6,860/ton removed) for
the largest model plants up to $37,900/Mg removed  ($34,500/ton
removed) for the smallest model plant.
                              5-13

-------
   TABLE 5-7.  COST-EFFECTIVENESS OF APPLYING REFORMULATION
                             CONTROL LEVELS TO
                   AUTOMOTIVE/TRANSPORTATION MODEL PLANTS
                                $/Mg($/ton)
Model plant IDa
Interior
Exterior
coatings
Exterior
coatings
coatings
flexible
nonflexible
Level 1
694
674
735
(630)
(612)
(667)
Level 2
729
666
736
(662)
(605)
(668)
Incremental
332
655
737
(756)
(595)
(669)
aRefers to model plants described in more detail in
 Chapter 3.0.
                             5-14

-------










I
b
nJ
CO tf
OA O
HU
H W
i> w
3 2
S; o
04 H
E-"
s 
00
i
in
TABLE

















8§
> ti'i.
« ** E
— • £ &
sr
u


ifi
3 ~


w
u „
o UJ
_, 2 C
S*1^
•-


(A
o^
fc2.§
|2j
3 o .*

.-
L.
-••-'*
3
'-

0)
(0 CU
a^o^
III
IB H-
*


> cl
"c — -
—
J! u
c t«^
™* u i
U!
*5"*"
M



11^
ll2






** 0 M
K» "7 "5
o •" •"




5 S RJ
e a ~



o o o
§ i g
IM ^ r*i
(M in a







O 0 0
3 R S






588
r>j >o i>




in ro
in »» «-


§o c
o c
o* o* o
IM in c





- S .
1 ' -
vt x -j
^» *» «%
•< ca t.
^ ^ "*
01
!c
jj
o


•a
a>
05
3
0)
O
o
o

i
OP-I
U (0
rtj IT)

m


































j
s'
jj
•1-1
O
01
iH
(15

01
a
-H
JJ
01
o
o
o
JJ

JJ
3
01
C
H

A













,


















,
S
jj
•H
0
01
rH
ItS
01
G
•H
JJ
01
O
o
S
0
IM

JJ
Qi
jj
3
O

U
5-15

-------
CO
pd
H
K
CJ
jg

CO
CO
Ed
M
§
3

04
S
3
O
H
§
Ed

H
U

H
j
2
si
Ed
S
EH

JH
0)

J
o

CH
S
o
0
Et*
O
EH
CO
O
U

Ed
O

JM

S
5
g
CO


.
o\
1
in

j
2
EH


(A
O
U
TS **:
? >-
£ >
" W
a
o
•~


jut
\Z.
u*»
»2
5 *
ss


U
•M
S
u
** ^
'*" ^
•- JJ
f
u
01
IU

u
01
o
u
" X
^»
—J ts
3
a
z

n
I.

0 X
2S
— 4-1
w O
(0
u


^
^
fl

n
U
—
a
'a
a
u





Q
w
j
"a
—*
•o
2


0 0
Rl^
SQ






O O
§ §
3" 5






o o
o o
o o
rvi (M
(M in







o o
8 §
«-" o^
•• CM
IM in







§ 1

8 8







§o
, §

O ^D
m oj
^










- §
(A X
~> <-•
< CO


0
o
o
^r





o
§
a
Kl
*™





O
O
o
M
0







§
rj
o>









S







o
§

S
co
v-










O
at
u
a

,»
u



























,
H
•
H
,4
•
in

c
o
•H
JJ
U
(U
CO
G
•H

fl
(U
>
•H
01

T*J *
o

jj
S

^
43

•a

O

ca
rH
ftf
•H
^4
0)
jj

g
^
^
o

id
rH

ca
(U
1
rH
O
fl
M
TJ
5-16

-------
      TABLE 5-10.   COST-EFFECTIVENESS OF APPLYING THERMAL
                   INCINERATION TO THE BUSINESS MACHINE
                   MODEL  PLANTS
Model Total annual
plant costs
ID* ($/yr)
(A) Small 373,000
(B) Medium 867,000
(C) 'Large 1,490,000
Total VOC
emissions
reduction
11.9 (10.8)
95.4 (86.7)
238 (217)
Cost - effectiveness
$/Mg ($/ton)
38,000 (34,500)
11,000 (10,000)
7,600 (6,900)
aRefers to model plants described in more detail in
 Chapter 3.0.
                             5-17

-------
5.2.2  S.yta.s. fcitutinCT Lower-Volatile-Organic-Compound Coatincrs
   As  discussed in Chapter 2.0  and Section 5.1.2,
substituting lower-VOC- and/or higher-solids-content coatings
is a cost-effective control strategy.  The costs, emissions
reductions, and cost-effectiveness calculations parallel those
shown in sections 5.1.2.1, 5.1.2.2, and 5.1.2.3.
   5.2.2.1  Capital Costs.  No  capital  costs  were  estimated
for the reformulation control options.  This is based on the
assumption that a facility's existing equipment can be used to
apply the reformulated coatings without a capital expense.
   5.2.2.2  Annual Costs.  The  annual costs of implementing
coatings specified by an option were calculated as detailed in
Section 5.1.2.2.  The following equations were used to
estimate coating cost  ($/gal):

   Colorcoat,  colorcoat/texture coat,
    Clearcoat, and primer     = -9.04 x Cvoc + 62.57
   Solventborne EMI/RFI       =• -35.07 x Cvoc  + 247.20
   Waterborne EMI/RFI         = -36.09 x Cvoc  + 249.85

where Cvoc is the coating VOC content in Ib/gal.  Cost curves
were developed based on coating costs reported in the business.
machine surface coating New Source Performance Standards.3

   Table 5-11 shows the VOC  level and calculated cost  per
gallon of each coating at the baseline and both option levels.
                              5-18

-------




CQ
O
23
M
E-<
rtj
0
U
fa
O
CQ
W
O
U



o
o»
2
O
u

u
H
5
a
as g
pa f]
M W





m
CN


m
en
•
0
m




H
in



in
m
CO
H
.
en
H
CN
m


co




4J
recoa
Textu

1



CN 00
r> ^
H in
in CM





m in
CO VO




CN m
H CN


in ^«
m oo
• •
vo m
m in




CM ^*
in ^t«



(TV O
CN <*
cn o
co r»
. .
H in
CN <*
f~ H
CO f^


in CM





cn
C
H -H
i^ fc T3
(1) OJ rH
g ^ . a
fi J3
•H CO
oj m
CO CQ
o -a cn
0 -H C
rH -H
rH O 4J
rtj CQ ft!
cn o
^>. OJ O
U c
o a; ^
> o m
r-l CO
^3 CO ^>
(H Oi V>
ff* O M
5-19

-------
    5.2.2.3  Cost-Effectiveneas.  The cost-effectiveness of
each option may be calculated in exactly the same manner as
presented in Section 5.1.2.3.  Table 5-12 shows the results
these calculations.
                              5-20

-------
  TABLE 5-12.  COST-EFFECTIVENESS  OF APPLYING REFORMULATION
                        CONTROL LEVELS TO BUSINESS
                           MACHINE MODEL PLANTS
                                  $/Mg ($/ton)


Model plant	Level  1	Level 2	Incremental

(A) Small         517  (470)        529  (480)     1,199  (1,088)

(B) Medium        517  (470)        522  (474)       520  (481)

(C) Large	J317  (470)        517  (470)       518  (470)
                             5-21

-------
  5.3  REFERENCES

1.    U.  S.  Environmental Protection Agency, OAQPS Control Cost
      Manual.   OAQPS/EPA.  Research Triangle Park, NC.
      EPA-450/3-90-006.  January 1990.

2.    Memoradum from Ferrero, B.,  Radian Corporation, to David
      Salman,  U. S. Environmental  Protection Agency, Chemicals
      and Petroleum Branch.  Recirculation of Spray Booth
      Ventilation Stream.  February 24, 1992.

3.    Vatavuk,  William.  Pricing Equipment for Air-Pollution
      Control.   Chemical Engineering.  May 1990.  pp. 126-130.

4.    Memorandum form Fortier, G.,  Radian Corporation to Salman,
      D., U. S. Environmental Protection Agency, Chemicals and
      Petroleum Branch.  Sensitivity Analysis Performed on
      Coating Cost Assumptions. May 1, 1991.
                    #
5 .    Business Machine NSPS.
                                5-22

-------
             6.0  ADDITIONAL TECHNICAL INFORMATION

     This chapter presents additional technical information to
supplement the information on low VOC content coatings
presented in Chapters 3,  4 and 5.   Section 6.1 presents
additional information on exterior coatings for
automotive/transportation parts.  Section 6.2 presents
additional information on coatings for business machine parts.

6.1 EXTERIOR AUTOMOTIVE COATINGS
     The development of lower VOC content exterior coatings
for the automotive/transportation industry is a complicated
process involving product development such as new or modified
substrates,  coating performance (weatherability, durability,
etc.), and assessment of changing customer demands.  As
described in Chapter 2 and Table 2-4, the industry has reduced
exterior coating VOC content and emissions over the past
decade by developing many new lower VOC content materials.
     Improvements in exterior coating performance in some
cases has required higher VOC loadings than the lower VOC
content coatings in control levels 1 and 2 in Chapters 4 and
5.  Recent information presented by the industry indicate that
some of the lower VOC exterior coatings in control levels 1
and 2 were based on out-of-date or incorrect data.  Table 6-1
presents a new exterior coating option (control level 4) for
exterior automotive coatings.  The reasons for changes from
the options presented in Chapters 4 and 5 are:
          Red and black colorcoats require higher VOC content
          than other colors to achieve the same performance
          due to pigment particle size (see discussion in
          Section 2.3);
                              6-1

-------
          Flexible primers require higher VOC content than the
          initial lower VOC formulations to avoid masking
          problems for multiple color systems;
          Non-flexible primers require higher VOC content than
          the initial lower VOC formulations to provide smooth
          finishes to match other body parts;
          Primers with the initial lower VOC levels had poor
          weatherability.   Higher VOC levels are needed to
          achieve acceptable performance;
          Clearcoats with the initial lower VOC levels did not
          provide adequate acid etch resistance.  Recent
          clearcoats with slightly higher VOC content provide
          adequate acid etch resistance;
          The original colorcoat database did not span the
          full range of colors used in the industry; and
          The low-bake clearcoat data originally reported by
          the coating manufacturers did not reflect correct
          as-applied VOC levels.
     Tables 6-2 and 6-3 compare control level 4 with the
control levels presented in Chapters 4 and 5 for exterior low-
bake and high-bake coatings.  Emission reductions and cost-
effectiveness of control level 4 were determined as discussed
in Chapters 4 and 5 for control levels 1 and 2.  Table 6-4
compares the national impacts of control levels l, 2 and 4.
Other environmental impacts of control level 4 are equivalent
to those for levels 1 and 2, as discussed in Chapter 4.
6.2 BUSINESS MACHINE COATINGS
     The appropriateness of particular lower VOC content
coatings for business machine parts may be influenced by the
conditions in which the final product will be used.  Many
machines are used in a home or office setting, while others
are used in a more hostile factory or field environment.  The
coatings used on parts destined for factory or field use must
be able to withstand the conditions present in those
environments.  This may preclude the use of some of the lower
VOC content materials suitable for parts destined for home or
office use on parts destined for factory or field use.
                              6-2

-------
TABLE 6-1.  AUTOMOTIVE/TRANSPORTATION NEW EXTERIOR COATING OPTION
                         (CONTROL LEVEL 4)
 Low-Bake Flexible and Nonflexible Coatings
 Coating Type	
 Primers
 Colorcoats
     Red and Black
     All other colors
 Clearcoats
VOC Content
 (lb/gal)a
    5.5
    5.6
    5.1
    4.5
 High-Bake Coatings
 Coating Type
 Primers
     Flexible
     Nonflexible
 Colorcoats
 Clearcoats
VOC Content
 (lb/gal)a
    5.0
    4.5
    4.6
    4.3
* All VOC  contents  are measured as pounds  of VOC per gallon of
  coating less water.
                               6-3

-------
   APPENDIX A




LIST OF CONTACTS

-------
Pucci, Mike
AT&T
Rm B-2236
131 Morristown Rd.
Bushing Ridge, NJ  07920
Dougherty, David
ABB Power T and D Co.
Post Office Box 9533
2728 Capitol Blvd.
Raleigh, North Carolina  27604
Williams, John
AIMCO
Post Office Box 80153
Conyers, Georgia  30208
Marg,  Ken
Marketing Director
Accuspray
Post Office Box 391525
Cleveland, Ohio  44139
Swisher, Doug
Engineer
Advanced Plastics, Inc.
100 Main Street
Sherman, Mississippi  38869
Lowe, Ronnie
Air Power, Inc.
2304 Atlantic Avenue
Post Office Box 41165
Raleigh, North Carolina
27629-1165
Jurczyszyn, Robert
Corporate Manager
AJczo Coatings, Inc.
Regulatory Affairs
Post Office Box 7062
Troy, Michigan  48007-7062

Hickman, Bob
Executive Vice President
Alladin Plastics, Inc.
Post Office Box 129
Surgoinssville, Tennessee
37873
Maty, Joseph
Editor
American Paint & Coatings
Journal
2911 Washington Avenue
St. Louis, MO  63103
Walberg, Arvid
President
Arvid C. Walberg and Co.
Post Office Box 9055
Downers Grove, Illinois  60515
McConnell, John
Manager, Environmental Affairs
Autostyle Plastics, Inc.
5015 52nd Street S.E.
Grand Rapids, Michigan  49512
Bobowski, David
BASF Chemicals
Coatings and Inks Division
5935 Milford Avenue
Detroit, Michigan  48210

-------
Young, Barry
Engineer
Bay Area Air Quality
   Management District
939 Allis Street
San Francisco,  California
94109

Home, Reggie
Bee Chemical Company
Division of Morton Thiokol
2700 East 170th Street
Lansing, Illinois  60438
Chalikian, Peter
Director of Marketing
Sinks Manufacturing Co.
9201 West Belmont Avenue
Franklin Park, Illinois  60131
             Fair,  Paul
             Contour Technologies
             Design Engineering Group
             850 Stephenson, Suite 306
             Troy,  Michigan  48083
             Pond,  Bob
             Cook Paint and Varnish Co.'
             919 East 14th Avenue
             Kansas City, Missouri  64116
             Lumby,  Mick
             Vice President
             Croix Air Products, Inc.
             520 Airport Road
             Fleming Field
             South St. Paul, Minnesota
             55075
Rankin, Tim
Blue Ridge Hardware &
Industrial Division
P.O. Box 547
Bassett, VA  24055
Supply
Reese, Jim
DeSoto Paint Company
Coatings and Polymers Division
1700 South Mount Prospect Road
Des Plaines, Illinois  60017
Russel, Cheryl
Boeing Corp.
   Bunnell, Michael
President/C.E.O.
Can-Am Engineered Products,
Inc.
30850 Industrial Road
Livonia, Michigan  48150
Heuertz, Matt
Executive Director
Chemical Coaters Association
Post Office Box 241
Wheaton, Illinois  60189
             Robinson, Frank
             Director of Marketing
             DeVilbiss Co.
             Post Office Box 913
             Toledo, Ohio  43692
             McClinton, Roy
             Delta Environmental Services
             6701 Carmel Road
             Charlotte, NC  28226

-------
Coletta, Tony
DuPont
Automotive Products
Post Office Box 7013
Troy, Michigan  48007-7013
Turowski, Daniel
Project Development Engineer
Durr Industries, Inc.
Finishing Systems
Post Office Box 2129
Plymouth, Michigan  48170-4297
Schultz, Karl
Environmental Consultant
E.I. DuPont de Nemours & Co.
  Automotive Products
1007 Market Street
Wilmington, Delaware  19898
Lannefors, Hans
Flakt, Inc.,  Alpha Division
Environmental Research Dept.
29333 Stephenson Highway
Madison Heights, Michigan
48071
Lennon,  Joseph
Environmental Control Engineer
Ford Motor Company
Environmental Quality Office
15201 Century Drive
Dearborn, Michigan  48120
Scheaffer, Scott
Vice President
GET Plastics
4157 North Kings Highway
St. Louis, Missouri  63115
Steck, Paul
Manager
Exothermic Molding, inc.
199 West Clay Avenue
Roselle Park, New Jersey
0.7204
Bernhim, Ed
Sales Executive
Exxene Corp.
5939 Holly Road  '
Corpus Christi, Texas  78414
Oyler, Bill
Fawn Industries
Engineering Department
Hunt Valley, Maryland  21030
Peters,  Gregory
Environmental Activities Staff
General Motors Corp.
30400 Mound Road
Warren,  Michigan  48090-9015

Flores,  James
Districk Manager
Graco Inc.
7158 Open Hearth Drive
Keraersville, North Carolina
27284
Richter, Dick
Manager, Advertising
Graco, Inc.
Post Office Pox 1441
Minneapolis, Minnesota
55440-1441

-------
England, Kevin
Corporate Environmental
Engineer
Hasbro, Inc.
1027 Newport Avenue
Pawtucket, Rhode Island  02862
Bailey, Robert
Senior Vice President
Lilly Industrial Coatings
Corporate Marketing
P.O. Box 946
Indianapolis, Indiana  46206
Merrill, Ken
President
Hi-Line Plastics
Post Office Box 247
0lathe, Kansas  66062
Dionne, Edam
IBM
   Naisaith, Ann
IBM
Department 559, Building 002
P.O. Box 12195
Research Triangle Park, NC
27709
Jewett, Jim
Intel
   Armitage, Norman
President
John L. Armitage and Company
1259 Route 46
Parsippany, New Jersey  07054
Mullen, Marjorie
Kentucky Division of Air
Quality
316 St. Clair
Frankfort, KY  Allen, Andy
Marketing/Materials Engineer
Lexalite International Corp.
Post Office Box 498
Charlevoix, Michigan  49720
Chalfant, Bob
Lockwood Green Engineers
1330 West Peachtree St.
Atlanta, GA  30367
Beaman, Joe
Vice President
Luster Coate
32 East Buffalo
Churchville, New York  14428
Forberger, Steve
MXL Industries
Engineering Dept.
1764 Rohrerstown Road
Lancaster, Pennsylvania  17601
Steading, Dale
Finishing Manager
Mack Molding
Post Office Box 815
Inman, South Carolina  29349
York, Carl
Maryland Air Management
  Administration
2500 Broeing Highway
Baltimore, Maryland   21224

-------
Wagner,  John
Environmental Engineer
Masco Corp.
Suite 110, Westpark Center
5111 Auto Club Drive
Dearborn, Michigan  48126
Irvine, Robert
Michigan Dept. of Nat.
Resources
Air Quality Division
Box 30028
Lansing, Michigan  48909
Haddock, Bryon
Technical Sales Representative
Morton International, inc.
Specialty Chemicals Group
2700 East 170th Street
Lansing, Illinois  60438
Koreck, Joseph
Color Services Manager
Morton International, Inc.
2910 Waterview Drive
Rochester Hills, Michigan
48309
Praschan,  Eugene
Manager, Emissions and Control
Motor Vehicle Manufacturers
    Association
7430 Second Ave, Suite 300
Detroit, Michigan  48202
Schafer, Larry
NCR Corp.
7240 Moorefield Hwy.
Liberty, SC  29857
Nelson, Bob
Director, Environmental
Affairs
National Paint & Coatings
Assoc.
1500 Rhode Island Avenue, NW
Washington, D.C.  20005
Banks, Richard
National Semiconductor
   Reddy, Beth
New Jersey of Environmental
  Protection
CN-027
Trenton, New Jersey
08625-0027
Dalton, Kathy
New York Division of Air
Quality
50 Wolf Road
Albany, New York  12233
Waffen, Bruce
Director of Marketing
Nordson Corp.
555 Jackson Street
Amherst, Ohio  44001
Reinhardt, David
Director of Operations
North American Reiss Corp.
Kenkor Molding Division
Dept. I, Mount Vernon Road
Englishtown, New Jersey  07726
Lawson, David
Manager, Materials Technology
PPG Industries, Inc.
Coatings and Resins Group
Post Office Box 9  (JPCL5)
Allison Park, Pennsylvania
15101

-------
Suss, Naomi
PPG Industries,  Inc.
Automotive Technical Center
Post Office Box 3510
Troy, Michigan  48007-3510
Gregory, Ellen
Seyforth Shaw
55 East Monroe
Suite 4300
Chicago, IL  60603
Cyr, Dick
President
Plas-Tec Coating, Inc.
70 Mascola Road
South Windsor,  Connecticut
06074
Kirby, Art
Chemical Coatings Division
Sherwin-Williams Company
101 Prospect Avenue, North
West
Cleveland, Ohio  44115-1075
Rafson, Harold
Quad Environmental Technology
3605 Woodhead Drive
Suite 103
Northbrook, IL  60062
Ocampo, Gregory
Product Manager
Sherwin-Williams Company
101 Prospect Avenue, N.W.
Cleveland, Ohio  44115-1075
Brown, Kate
Ransburg-Gema,  Inc.
Marketing Department
Post Office Box 88220
Indianapolis, Indiana  46208
Lutterbach, Mark
Red Spot Paint and Varnish Co.
Post Office Box 418
Evansville, Indiana
47703-0418
Caine, John
Vice President Sales
Reeco Regenerative
Env ironmental
   Equipment Co., Inc.
Box 600, 520 Speedwell Ave.
Morris Plains, NJ  07950-2127
Bankoff, Barbara
Siemens
Ulrich, Darryl
Executive Director
Society of Mfg. Engineers
Assoc. for Finishing  Processes
Post Office Box 930
Dearborn, Michigan  48121
Thomas, Larry
President
Society of Plastic  Industries
1275 K Street N.W.
Suite 400
Washington,  D.C.  20005
Forger, Robert
Executive  Director
Society of Plastics  Engineers
14 Fairfield  Drive
Brookfield, Connecticut  06805
                                6

-------
Hopps, Don
South Coast Air Quality
  Management District
9150 Flair Drive
El Monte, California  91731
Sweetman, Bill
Senior Environmental Engineer
Spaulding Sports Worldwide
425 Meadow Street
Chicopee, Missouri  01013
Glenn, George
Technical Director
Speeflo Manufacturing Corp.
8605 City Park Loop
Suite 200
Houston, Texas  77013
Rosania, Stanley
President
Structural Foam Plastic, Inc.
Post Office Box 5208
North Branch, New Jersey
08876
Donahue,  Tim
Executive Vice President
TS Polymers
4750 Ashley Drive
Hamilton, Ohio  45011
Teten, Lance
Director, Research &
Development
Texstar, Inc.
802 Avenue J East
Grand Prairie, Texas  75053
Hynds, Jim
President
Turbo-Spray Midwest, Inc.
24047 Research Drive
Farmington Hills, Michigan
48024
West, Thayer
Union Carbide Chemicals and
   Plastics Co., Inc.
39 Old Ridgebury Road
Danbury, Connecticut
06817-0001
Gates,  George
Project Engineer
Webb Manufacturing Co.
Post Office Box 707
Conneaut, Ohio  44030
Lluch, Jaime
Wiggin & Dana
1 Century Tower
New Haven, CT  06508-1832

Labak, Larry
Environmental Engineering
Manager
Wilson Sporting Goods
8840 West Palm
River Grove, Illinois  60171
Ayer, Matthew
Environmental Coordinator
Worthington Industries,  Inc.
4219 U.S. Route 42
Mason, Ohio  45040
                                   Barefield, Larry
                                   YDK America
                                   P.O. Box 1309
                                   Clinton, GA  30114

-------
                            APPENDIX B  "
                       EMISSIONS CALCULATION

1.   BASELINE
A.   Automotive
     Baseline VOC  levels  were determined for each coating
category for each  model plant based on information reported  by
NPCA.  The volume  of  each coating used at each model plant was
multiplied by the  estimated baseline VOC level, to get an
estimate of model  plant baseline VOC emissions (see Example  B-l).

Example B-l;  VOC  Emissions Calculation (Model Plant ATA1)
Usaga VOC Content Emission*
Coating Csal/yr) (Ib VOC/oal) fib VOC/yr)
Highbake Colorcoat 450 x 4.6
Highbaka Priwr 150 x 5.4
loubake Colorcoat 8,550 x 6.0
Loubake Priam-
2.850 x 6.0
Total 12,000 gat/yr
• 2,070
• 810
» 51,300
• 17.100
71,280 Ib VOC/yr
(71,280 Ib VOC/yr)(1 ton/2,000 Ib) » 35.6 torn VOC/yr - 24.
                                                   VOC/vr
It was assumed that  100 percent of coating VOC content was
emitted.  Tables B-l,  B-2,  B-3,  and B-4 present the model plant
usage, VOC level, and  emissions for each category at baseline and
each option.  Options  1 and 2  are reformulation options, and
Option 3 applies incineration  as an add-on control.  Note that as
VOC content is lowered due  to  reformulation, total usage is
                                3-1

-------
CO

8

CO
CO
M

s

6H
u
a
o




I
(0
u
w

§
M

S!
2
01



E«

u
 I
a

s
03
      M 3 c
      11?
!J|
Hi
        N
      m

      i«i
      m
ji!


«
                8. 9 •»  -
                b b b  b
          5  = 53
          b  b •  ri  M
                r «
               532
               0  •»
                     ••  *
                     3  •
                  «  «
9  2  5


                                   2223  =  3
                                   b b  b  b  b  b
                                   3  «  S  8  3  3
                                           «1  ••  -
                                           O  •»  —
                                                           2  2  2  g  2 g  a
                                                           b  b  b  b  b b  •
                                            ?  S  S 55 S  5
                                            «  «  f« b <4  b  n
                                                           •  1
                                                                       »  - a
                                  <•  <«»  •»
                                                 -  9
                                                                          -  a
                                  a  a
                                  «  ri
                                        <«  b  «4
                                                                 -o  rt  —
                                  f»  •»  f»  O  f»
                                                 ••  •
                                                              •»«««"  —
                                                           ?  S  S
                                                           •*  ri  r*
                                                                    3  2  5
                                        I
                              j
                              d
                                  «  fl  M
                                                       t    ^«  i^  ••  B^  •«  B^


                                                       S    S  9  n  9  n  «
                                                                            1
                                      B-2

-------
CO

§
M
CO
(0
    «

    11!
J
w
o
a
Cd
w
w


o
o
cu
      o

      Ft
ill

lit
Z





<
 I
01


w
J
03
I
        I
         S  S  2  »
         3  X  9
         -  b  *
                                   s  a -s  s  s  T
                                   b  d d  b  b  —
                        s  a  s  s  5 s  «
                        o  o  o  b  b 2  -
P  S  5 S  S  S  !^      P  S  S  «  S  s  S
r»  «  « a  in  —  2      (-  •«  «  b  »i  _;  ^
             b  b  »>  —
                                «  •»  •»  9  •»  —
                                                        >o  •+  r\  o  •*  —  n
                   a  «  s
•?  ^
         »  M  —  S

         b  b  b  —  «
                                              -  a
                      2  5
                                        —  r-  n
                                                            •a  
-------
CO

o
M
W
to
w
Q
O


Cd
U
01



O
I
cn
&*

a
1
I
01

ca
>j
a
    1
   3s II
.31 A


lit
    !rt
'•II
1 si
i:
       r
       !
        a a a 3
        " S S 5
                      s  a  s  s  a
                      O  —  O  —  O  Wl
  S S 8 2 3 5
                                                 — o ^
am 
-------
W

O


w
&


Ok
a
3
X
O
6-t
OS
O
0*
CO
i
03

U
J
03

£
    it
    — u
    M
     »i
    Iff
      t
                               833?*
                               R « 3  2 |
                               8
5
                                      2 S
                                   2  —  a
                                   2  w  S
                                      - 3
           -o o
           M-
                                        2
                          * ??  3 3 8  P |
                          S »  P « 3  2 3J

                  3
                        -
                               ss
                               =
                                              £ S
                                              s s
               •*  «* >rt  «rt  Q
                                              o» «  *  — t»  «  •
                                              $ s
                                              S S!
                                                     S3??*
                                                     « 3 2  *

                                        i,
                               B-5

-------
reduced.  This is based on the assumption that the total amount
of solids required remains constant across the options (Example
B-2) .

Example B-2:   Reformulated Coating Usage
               (Highbake Colorcoat, Model Plant ATAl)
Reformulated Usage * Usage at Baseline x
                                              7.1
                                               vac
                                              7.1
                                                   option l»v»i.
Usage at Level 1
450 gal/yr x
                                     1-
                  4.6
                  771
                                     1-
                  4.3
                  7.1
                                                    402 gal/yr
                                            l«v«t 1
     The emissions from the add-on control  option (Option 3)  were
calculated from the assumption of 98  percent destruction
efficiency by thermal incineration.   Emissions are therefore
2 percent of baseline emissions  (Example  B-3).

Example B-3;   Emissions After Control  (Model Plant ATAl)
Emissions from Example B-l» 36 tons
Option 3 emissions        » Baseline  Emission * 0.02
                          » 36 tons/yr  (0.02)  - 0.7 tons/yr
                                3-6

-------
B.   Business Machines
     Coating usage and VOC levels were determined for each
coating type for each model plant size based on information
collected from the industry as explained in Chapter 2.  VOC
emissions from each model plant were then calculated by
multiplying gallons used by VOC content per gallon as in Example
B-l.  Table B-5 shows model plant coating usage, VOC level, and
calculated emissions for each coating at each option for all
three business machine model plant sizes.
     As in the automotive sector, add-on control was incineration
with a destruction efficiency of 98 percent.  Thus, emissions
were estimated to be 2 percent of baseline emissions (see
Example B-3) .

2.   EMISSION REDUCTIONS
     Emission reductions are calculated as the difference between
baseline emissions and the emissions at a given control option
for every case.  Table B-6 shows the emissions reduction for each
control option for both the automotive and the business machine
sectors.  Example B-4 shows the emissions reduction calculation
for ATA1.

Example B-4;   Emission Reduction Calculation
               (Model Plant ATA1, Option 2)
Emissions at Baseline =-36 tons/yr
Emissions at Option 2 =  6 tons/yr (from Table 1)
Emissions Reduction   » 36 tons/yr - 6 tons/yr » 30 tons/yr
                               B-7

-------
cn

O
M
cn
cn
o.

j
Ed
a
o


as
o
Ed
cn

cn

o
Ed
Ed
O
cn
Ed
Z
M

S
o
cn
cn
Ed
z
M
cn

oa
m
i
aa

Ed
J
00
      11!
      •5 i

      31'
      sil
      J-1A
       3 <•

       **
  5 I


  e||




  9-11
      - S€
^l.t
2 1 Sg
      s S c
      1.2 i-
      * 1 3
      a 1 1
  3=^

  I1S
                                b  6
                              2 8  3  S •
              f-l  ••  m  o V)

              b  O  b  — M
                                        o>  •» o> .0
                                         o. ^ »

                                        >o  >« >X — b
                                           —   « 9t
                 r>  « •• f>)

                 b  b b <•«
                   r«>o
                                     «tf
                                     •• 0
                                             ^k f^ ^^ ^K

                                             2 S 8 S 2
              O  O  O —
                 S  3 5
2. « 3  S  3
                                                 3
            •3
            hi
            1  £
                     i
                       .3

                       I

                                                      o
                                B-3

-------
       a *
       •» •?
       .si

o
5
0
CO
en
en
03


U

>J

03
<
   I
      i-§s
      | 1-5
      ill
      01 at •=•
 i
 DU *-
 e _
III
ill
01 06 •=>


 S -P
 .2 ^.


 II
                    - »


                  * a a    s
             "  -
                  « a a

   S
i!
      .2
     II
                              S
                                 -as
                                 s s s
                           58=

                                      3

                   s  a  ,   ||5
                                s s.  p
                                  S
            385   S 3 3  II
            iii

                                              9
                                        iii

                                        a <  a a a 
-------
                            APPENDIX C
                        COST CALCULATIONS

     Costs of control for both the Automotive/Transportation and
Business Machine/Miscellaneous sectors were developed in an
identical manner; however, the approach differed between the
reformulation options (1 and 2) and the add-on control
option (3).  Reformulation costs were developed from cost data
supplied by manufacturers.  The data was used to develop cost
equations based on VOC content.  To calculate the cost of a
reformulation option, the cost of each of the individual coatings
must first be calculated at both baseline and option levels.  The
cost equations are taken from Chapter 5.  Example C-l shows the
required calculations for model plant ATA1.
Example c~l;  Coating Cost Calculations
Baseline
Coating
Highbak* Colorcoat
Highbak* Prf«tr
loubaka Cotorcoat
Loubak* Priaar
VOC
Ub/gaL)
4.6
5.4
6.0
6.0
Cost
Equation
-14.43* (4.6) *
•7.21* (5.4) «•
-14.43* (6.0) *
-7.21* (6.0) *
Coating Cost
(VgaO
99.76 - 33.38
49.88 > 10.95
99.76 » 13.18
49.88 - 6.62
                               C-l

-------
Option l
Coating
Highbake Colorcoat
Highbake Primer
Lowbake Colorcoac
loubake Primer
VOC
(lb/gal>
4.3 -14.43*
4.3 -7.21*
5.0 -14.43*
3.5 -7.21*
CMC Coating Cost
Equation (S/gal }
<4.3)
(4.3)
(5.0)
(3.5)
* 99.76 » 37.71
* 49.88 » 18.88
* 99.76 » 27.61
* 49.88 » 24.64
See Table 5-6 for the VOC content and calculated cost of each
coating at baseline and both options.
     The total cost of coating is found on a model plant basis by
multiplying the total usage of each coating by its cost and
summing each cost as shown in Example C-2.
Baseline
Coating
Highbake Coloreoat
Highbeke Primer
lowbake Colorcoat
Lowbake Primer
Totals
Cast
(S/gal)
33.88
10.95
13.18
6.62
tlmm*^
**^^*^^i

-------
Table C-l shows the total coating cost for each model plant at
baseline and at both levels.
     The cost of controlling a model plant at an option may then
be calculated by finding the difference in total coating cost
between the option cost and the baseline cost  (Example C-3).
Table C-l presents the annual cost of control by reformulation
for each model Plant at both control levels.

Example C-3;  Annual Cost of Reformulation
Cost of Baseline (from Example C-2) « $148,200/yr
Cost of Option 1 (from Example C-2) » $161,900/yr
Cost of Control = $16l,900/yr - $148,200/yr = $i3,700/yr

     The cost of controlling model plants with add-on
incinerators was calculated by a computer program based on
Chapter 3 of the OAQPS Control Cost Manual.1  Table C-2 shows
the input to the program, and Tables C-3 and C-4 show the costing
output from the program.
      U.S. Environmental Protection Agency.  OAQPS Control Cost
Manual.  OAQPS/EPA.  Research Triangle Park, North Carolina.
EPA-450/3-90-006.  January 1990
                               C-3

-------












z
o
H
E-1
a

o
Ch
Ed
OS
X
03

0
OS
E-i
!
fiu
O
CO
O
U

r-l
1
O
U
03
•^
6-1
















CM
C
o
-P
Q
O














"
O
1>
o







0)
c
r-
U
09
(0
09








P 4j ^4
H to >i
§ y 
y *~






•5 *• "*•*
** o ^
g y 
u *•"





^ 	
*j sS
Q W V>
y ~




o» ^
^J lj
^* Q ^^
** u v>
y -




^_
5 ** "£
Tj o >i
Tj O °^<
2 y «>i
y ~

r-l 4J
4) C
so!



o
0
^
en
f-4






O
O
vO
P-
vO
•"*




0
o
r-
^
n
r-l




O
0
en

,_4
r-l





O
o
O)
»
CO
2



H
rtj
C^4
"^
0 0
0 0
in «
vo m







o o
O 0
\0 O
O* n"
O CM
P^ f^




O O
a o '
0 •»
^ n





o a
o o
r-l CO

CO O
en CM
CM n





0 O
o o
r-4 *T
% »
^ P»
en i-i
CM en



CM en
< <
H EH
< •<
a o
o o
r-l VO
* ^
•V rH






0 0
a o
r- in
O CM
00 CO
n vo




a o
o o
CM en
r-l CO
n




0 O
O 0
00 CO

r- vo
vo r**
n vo





0 0
o o
vo en
« *
*0 P**
n %



ft CM
03 QQ
6^ EH
< <
a
o
p*
m"
r-l






O
0
e*>
n
n
•"*




o
o
en
(•X





o
o
in
^
CO
(M





0
o
VO
^
a
CM
P»



m
03

*
O
o
o
CO
in






o
o
o
o
VO
n
1-1



0
0
o
CM

"



O
o
o

r-

rH




O
o
a
**
in
a
CM
T-4


r-4
U
EH
<
0
0
0
CM
in






0
o
o
en
^
*
CM



a
a
0
CM
n




a
o
o
^
en
CM
CM




O
o
0
^
rH
en
CM


CM
y

*
o
o
o
tn
**






0
0
o
in
CM
VO
CM



O
O
o
CO
CM




O
o
o

00
o
VO
CM




0
0
0
*
0
CO
in
CM


n
y
£4
*
o
0
a
VO
00
^
o
0
a
r-l
en
iH
*
^
O
a
a
in
^
n
a
0
o
a
in
o
^r
o
o
0
in
o
r»
r»
f-i
a
B
a
a
0
r-(
VO
r-l
O
o
o
•V
f-l
in
^
r-
o
o
a
CO
en

o
o
o
f-l
in
^>
r»
o
o
o
n
in
n
r>
CM
Q
§
a
0
o
r-(
1-
r-l
0
O
o
in
r-
o
^
CO
o
a
0
CO
CO

0
0
0
(M
CM
O
CO
0
o
o
^
n

-------
04
O
H
EH
CO
8
OS
g
H
2
H
u

H
a
H
 I
u
H

O
        S
        5;

        i;
       !»
       i^
        1
        ?
       II
       ^ ^
       r
          I
                  «**^«~»M«M<»JI«»«»»»l'»l'»««1^W-»
-»-»-*«c>»-»-»-»~r-o-o>o-»-»-»




















MMmwtmiA£<••»••»•>
          •       .a   •        .a    •       .a   «    y   «    u

     s   1       "il        "ii        sisss
     —    5       —5        —5       —   5    u   u    u

     *   *       "1   *        *    *       "   *    *   *    *
oo^oo_o_oo^^^^«   S    •
'u'C'C'C^TI^r'b'k'C'u'C    c   2    2

CXXCXxSxxSxx333
                                                                                              IM   a
                                                                                              0   >
                                                                                              §e*
                                                     C-5

-------
      I-
      Hi
      I!
O
O

1
a

CO

o
M
CO
ca
r»
 I
y

dl
j
aa
      « •
                     a  s   s  s  3  s
                                                            o  r\j
               o  o   a  o   a
               PI  PV   I*  lA   in
                            N.   >  O
                            (M   -O  
-------



Business
H«chln«/Mlsc.

W




I! !!
fi fl
<• «r
J> 0

IM d

l>» •»


1 7 J
3 *» •»
?i i
1-' °
» it
2
?
<•

o 


— 3m m
3 32 Z
* ?" *
* a? i"
2* *
<» i>
a
z
•

^4 Qk


— am
1 32
i ?i
' l?
2'
If


^*
Ut J*


S? 3
<^ f*
? ?
J '
^•J
1
er
•*
M M

IK M —

* m m «
8 2 X 3
li ! 5
15 « «
• Tt
1
^
*
- - -

li
-i a
r
5
o
It
u
0
T
"5*
*»
i"
|«
f »
• ^
s      2      "
%      -
S      §      *
*•      -o      o
                                                                                         Vl
                                                                                         UI
                                                                                         O»
                                    3      5
 v»   ^    o      e>    e§    o>
 333      333






i   i   i      §    s   §

»   t   X      S    2   »
IM   N    M      555





sis      333
         j   M
        XMVH
        0*O>
        ««
        0>Ot

        33
                                                                                                           UIUIW*
                                                                                                           o»   *   o>
                                                                                                           XtrSrS
                                                                                                               U4M
                                                                                                          SSI
                                                        »    *
                                           §      "5   5   S
                                           •
                                                                     fM    IM    IS»

                                                                                             M    M
                                                                                             uSvM
                   222
S
                                                       -OOi
                                                                    O    -O    0*

                                                                    '
          ^
Ok   VN   I'M
                                                                                            V    I'M      ^    4   9>

                                          S      5   '3   I      's   3    §     §   "s   i      §    1   S
                                                                                                                                    1
Incinerator
ltal Cost (
rlc
«/
                                         n *
                                           2»
                                         _

                                                                                                £3
                                                                                                I:
H
>
03
f
n

o
i
                                                   i
                                                   H

                                                   §
                                                                                                            8
                                                                                                            en
                                                                                                            "§
                                                                                                            cn
                                                                          C-7

-------
                          APPENDIX D
      CTG MODEL RULE FOR SURFACE COATING OF PLASTIC PARTS

D. 1 INTRODUCTION
     This appendix outline a sample rule to limit volatile
organic compound (VOC) emissions from the surface coating of
plastic parts.  The sample rule is for informational purposes
only; it is intended to provide information concerning factors
that need to be considered in writing a rule to ensure that it
is enforceable.
     This sample rule is general in nature; that is, the
applicability of the rule, and thus the stringency, are
determined when the emission limits are chosen by a State or
local agency.  As mentioned in Chapter 1, this document does
not contain a recommendation on RACT; therefore, no emission
limits are specified in the sample rule.
     The remainder of this appendix contains the sample rule.
Separate sections cover the following rule elements:
applicability, definitions, emission standards, compliance
demonstration, monitoring, recordkeeping and reporting.
D.2 APPLICABILITY
     The provisions set forth in this sample rule apply to any
facility that coats plastic components for the following uses:
          Automotive or other transportation equipment
          including interior and/or exterior parts for
          automobiles, trucks (light-, medium-, or heavy-
          duty), large and small farm machinery, motorcycles,
          construction equipment, vans, buses, and other
          mobile equipment; and
          Housings and exterior parts for business and
          commercial machines including, but not limited to,
          computers, copy machines, typewriters, medical
          equipment, and entertainment equipment.
                             D-l

-------
     This sample rule applies to in-house coating processes
located at the original equipment manufacturer  (OEM) site, as
well as, to coating contractors specializing in molding and
coating plastic parts, and job-shops performing coating only.
This sample rule applies to coating operations including
coating application, flash-off and drying/curing.
     This sample rule does not apply to plastic parts coated
on the main (body)  paint line in automobile or light-duty
truck assembly plants.  This sample rule does not apply to the
repair of plastic parts on fully assembled vehicles in
automobile or light-duty truck assembly plants.  These parts
are covered under regulations for automobile and light-duty
truck coating operations.  This sample rule also does not
apply to coating of. interior and exterior parts for aircraft;
coating of exterior of completely assembled marine vessels;
refinishing of automobiles, trucks or other transportation
equipment; and coating of internal electrical components of
business and commercial machines.
     The remainder of this appendix contains the sample rule.
Separate sections cover the following rule elements:
applicability, definitions, emission standards, emission
standards testing, monitoring requirements, and reporting/
recordkeeping.
D.3  DEFINITIONS
     Add-on control device.  An air pollution control device
such as a carbon adsorber or incinerator which  reduces the
pollution in an exhaust gas.  The control device usually does
not affect the process being controlled and thus is  "add-on"
technology as opposed to a scheme to control pollution through
making  some alteration to the basic process.
     Adhesion promoter  (primer).  A coating applied to
thermoplastic olefin  (TPO) parts to promote adhesion  of
subsequent coatings.
     Affected facility.  Any apparatus, to which a  standard  is
applicable, involved  in  the coating of plastic  parts.
                             D-2

-------
     Affrermarket automobiles.  Vehicles that have been
purchased from the original equipment manufacturer.
     Basecoat/clearcoat.  A two-step topcoat system in which a
highly pigmented, often metallic, basecoat is followed by a
clearcoat, resulting in a finish with high-gloss
characteristics.  It is often used on automotive parts.
     As applied.  The condition of a coating at the time of
application to the substrate, including any dilution solvents
added before application of the coating.
     Capture efficiency.  The fraction of all organic vapors
generated by a process that are directed to an abatement or
recovery device.
     Clearcoat.  A transparent coating usually applied over a
colored, opaque coat to improve gloss and provide protection
to the colorcoat below.
     Coating.  A material applied onto or impregnated into a
substrate for protective, decorative, or functional purposes.
Such materials include, but are not limited to, paints,
varnishes, sealants, adhesives, inks, maskants, and temporary
protective coatings.
     Coating unit  Cor line!.  A series of one or more coating
applicators and any associated preparation and drying areas
and/or oven wherein a coating is applied, dried, and/or cured.
A coating unit  [line] ends at the point where the coating is
dried or cured, or prior to any subsequent application of a
different coating.  However, a coating unit does not
necessarily include an oven or a flash-off area, and may
consist of any preparation and application areas.
     Electromagnetic interference/radio frecruency interference
 (EMI/RFI) coatings.  Coatings used in plastic business machine
housing to attenuate electromagnetic and radio frequency
interference signals that would otherwise pass through the
plastic housing.
     Flash-off area.  The area within a coating operation
where solvents evaporate from a coating during the interval
between coats or before the coated part enters a bake oven.

                             D-3

-------
     Flexible coating.  A paint with the ability to withstand
dimensional changes.
     Glosa reducers.  A low-gloss coating formulated to
eliminate glare for safety purposes on interior surfaces of a
vehicle, as specified under the U.S. Department of
Transportation Motor Vehicle Safety Standards.
     High bake coatings.  Coatings designed to cure at
temperatures above 194°F.
     Higher-solids coating.  Coating containing greater
amounts of pigment and binder than conventional coatings.
Solids are the non-solvent, non-water ingredients in the
coating.  Higher-solids coating usually contain more than 60
percent solids by volume.
     Low bake coatings.  Coatings designed to cure at lower
temperatures  (below 194°F).
      Non-flexible coating.  A paint without the ability to
withstand dimensional changes.
     OEM.  Original equipment manufacturer.
     Overspray.  The solids portion of a coating which, when
sprayed, fails to adhere to the part being coated.  The
applied solids plus overspray solids equal total coating
solids delivered by the spray application system.
     Plastic  Part.  A piece made from a substance that has
been formed from resin through the application of pressure or
heat or both.
     Primer.  Any coating  applied prior to the application of
a topcoat or  color  coat for the purpose of corrosion
resistance, adhesion of the topcoat, and color uniformity.
     Solids content.  The  non-solvent, non-water ingredients
in  the  coating, consisting of pigment and binder, that do not
evaporate and have the potential to form a cured  (dry) film.
The solids  content  can be  expressed as volume percent or
weight  percent.
     Specialty coatings.   Coatings used for unusual job
performance requirements.  These products include adhesion
primers,  resist  coatings,  soft  coatings, reflective coatings,

                             D-4

-------
electrostatic prep coatings, headlamp lens coatings, ink pad
printing coatings, stencil coatings, coatings  (automotive),
vacuum metalizing coatings, and gloss reducers.
     Topcoat.  The final coat of paint applied to a substrate.
Several layers of topcoat may be applied in some cases.
     Transfer efficiency.  The ratio of the amount of coating
solids deposited onto the surface of the coated part to the
total amount of coating solids used.
     Two-component paint.  A coating that is manufactured  in
two components that are mixed shortly before use.  When mixed,
the two liquids rapidly crosslink to form a solid composition.
     Volatile organic compound (VOC) content.  The amount  of
VOC in a coating as determined by Method 24.  The VOC content
can be expressed as pounds of VOC per gallon  (or kg VOC/L) of
coating, minus water and exempt compounds.
     Waterborne coating.  A coating that contains more than
five weight percent water in its volatile fraction.
D.4  STANDARDS
     (a)  Automotive/Transportation Sector.  The VOC content
of any automotive/transportation plastic parts surface coating
shall not exceed the applicable limitations as specified in
Table 1.
     (b)  Business Machine Sector.  The VOC content of any
business machine plastic parts surface coating shall not
exceed the applicable limitations as specified in Table 2.
     (c)  Daily Weighted Average Alternative.  The daily
weighted average VOC content of all coating used on a coating
unit that are subject to a single limit in (a) or (b) above
shall not exceed that limit.
     (d) A facility may use a capture system and control
device in lieu of complying coatings on any coating unit.  The
capture system and control device on a coating unit shall
achieve an overall control efficiency which is greater than or
equal to that needed to reduce the daily weighted average VOC
content of the coatings used on that unit to the applicable
emission limit on a solids basis.

                            D-5

-------
D.5  COMPLIANCE DEMONSTRATION, MONITORING, RECORDKEEPING AND
REPORTING
     For information on possible compliance demonstration,
monitoring, recordkeeping and reporting requirements, see
Model Volatile Organic Compound Rules for Reasonably Available
Control Technology. Planning for Ozone Nonattainment Pursuant
to Title I of the Clean Air Act. Staff Working Document, June
1992.
                             D-6

-------
               TABLE  1.   COATING CATEGORIES FOR
              AUTOMOTIVE/TRANSPORTATION COATINGS
                                                    Control
                                                    Level
                Coating Category                      (Ib
_ VOC/gal)a

 I.  Auto Interiors

   1) High Bake Colorcoat

   2) High Bake Primer

   3) Low Bake Colorcoat

   4} Low Bake Primer

 II. Auto Exteriors (Flexible and Nonflexible)

   1) High Bake
     a)  Colorcoat
     b)  Clearcoat
     c)  Primer -Flexible
     d)  Primer-Nonflexible

   2) Low Bake
     a)  Primer
     b)  Colorcoat Red and Black
     c)  Colorcoat Others
     d)  Clearcoat

 III.  Auto Specialty

     1)  Group (A)b

     2)  Group (B)c

     3)  Group (C)d

     4)  Headlamp Lens

aVOC content values are expressed in units  of mass  of VOC  (kg,
 Ib) per volume of coating  (L, gal) , excluding water and
 exempt compounds, as applied.


bGroup A - Black and Reflective Argent  Coatings, Soft
 Coatings, Air Bag Cover Coatings,  Vacuum Metalizing Basecoat
 and Texture Coatings.

cGroup B - Gloss Reducers, Vacuum Metalizing
 Topcoat, and Texture Topcoat.
       C - Stencil Coatings, Adhesion  Primers,  Ink
 Pad Printing Coatings, Electrostatic  Prep  Coats, and  Resist
 Coatings .
                             D-7

-------
       TABLE 2.  COATING CATEGORIES FOR BUSINESS MACHINE
                           COATINGS


                                       Control Level
	Coating Category	(Ib VOC/gal)a	

 I.    Primer

 II.  Colorcoat

 III. Colorcoat/texture coat

 IV.  EMI/RFI Shielding

 V.    Specialty
      1) Soft Coatings
      2) Plating Resist
      3) Plating Sensitizer

aVOC content values are expressed in units of mass of VOC  (kg,
 Ib) per volume of coating (L, gal), excluding water and
 exempt compounds, as applied.
                             D-a

-------