United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EPA-450/3-81-012
September 1981
vvEPA
Organic Solvent Use
In Web Coating Operations
-------
EPA-450/3-81-012
Organic Solvent Use In
Web Coating Operations
Prepared By:
George E. Weant
Robin R. Segall
ENGINEERING-SCIENCE
501 Willard Street
Durham, North Carolina 27701
Contract No. 68-01-4146
Chicago, Illinois
U.S. Environmental Protection Agency
Office of Air Quality Planning and Standards
Emission Standards and Engineering Division
Research Triangle Park, North Carolina 27711
September 1981
-------
This report has been reviewed by the Emission Standards and Engineering
Division Office of Air Quality Planning and Standards, Office of A r S
a*d Radiation, Environmental Protection Agency, and approved fo^pubS"-
bvnEpJ C °n °f C°mpanT 2 PrdUCt nameS d°eS n0t --titute endorsement
by EPA Copies are available free of charge to Federal employees, current
contractors and grantees, and non-profit organizations - as supplies permit
from the Library Services Office, MD-35, Environmental Protection I|en7y
VA 22161
' «'' ** ™? e °tane« or a fee' * *
^formation Service, 5285 Port Royal Road, Springfield,
U,S. Environmental Protection Agency
-------
TABLE OF CONTENTS
Page
1.0 INTRODUCTION
2.0 SUMMARY OF SURVEY RESULTS
2.1 Miscellaneous Categories f
2.2 Shoes and Handbags 2-1
3.0 DATA COLLECTION METHODOLOGY
3.1 Identification of Plants ;"J
3.2 The Plant Survey 3"1
3.3 The Questionnaire Evaluation 3"2
4.0 DATA EVALUATION METHODOLOGY
4.1 Data Reduction 4-1
4.2 Product Code Combination J"1
4.3 General Product Codes 4"2
4.4 Calculation 4'2
4.5 Growth Projection 4"3
4.6 Flexible Packaging 4"5
4.7 Vinyl Floor Covering 4"5
y 4-6
5.0 REFERENCES
5-1
* n " oUTy P*cka9e ^d Reminder/Thank You Postcard A 1
< 8 - Product Summary and Calculation Sheets £-1
LIST OF TABLES
2.1 Summary of Survey Data for Web-Coated Products ? ?
2.2 Miscellaneous Products Requiring Solvents in Their
Manufacture
2-3
3.1 SIC Codes Used for Plant Identification , o
3.2 Number of Plants Surveyed
0 — J
iii
-------
1.0 INTRODUCTION
During August of 1979, the U.S. Environmental Protection Agency
published a priority list of 59 source categories designated for the
development and promulgation of New Source Performance Standards (NSPS).l
This list ranked the source categories by their quantities of emissions,
health impacts, and mobilities.
Paper coating was ranked fourth, and fabric coating was ranked
tenth. Since both paper coating and fabric coating include an almost
infinite variety of products, EPA later decided that it would be impracti-
cal to write a single NSPS for the entire group of products. Rather, EPA
began to identify those web-coated products which require large amounts of
solvent for their manufacture and to prioritize these products for subse-
quent NSPS development. This report is part of the prioritization "Web
coating," as used in this report, includes the coating and laminating
of film and foil webs as well as paper and fabric; it does not include
printing.
This report presents the results of a study conducted to gather back-
ground information on the consumption of organic solvents associated with
the manufacture of web-coated products. The study began with a search
to identify products produced by coating or laminating web substrates.
Since data on solvent usage in the manufacture of these web-coated products
is not available in the literature, a survey was conducted to obtain
solvent use data directly from manufacturers.
To determine solvent use, questionnaires were sent to a random sample
of manufacturers identified in 13 Standard Industrial Classification (SIC)
codes, to all manufacturers of magnetic tape, and to manufacturers of
Photographic products through the National Association of Photographic
1-1
-------
Manufacturers (NAPM). The 13 SIC codes were chosen to cover the major
portion of industrial web coating and laminating operations.
The results of the survey are summarized in Chapter 2.0. Detailed
explanations of the survey methodology and data evaluation are found in
Chapters 3.0 and 4.0, respectively.
1-2
-------
2.0 SUMMARY OF SURVEY RESULTS
The survey yielded data on solvent usage and air pollution control
techniques and efficiencies. It also collected data on products that
do or do not require solvents in their manufacture, and it identified
web-coated products. Growth rates for the products were collected indepen-
dently of the survey.
Table 2.1 summarizes the data collected in this survey on solvent
usage, percent control, and growth rates for web-coated products. Data
concerning two products, pressure sensitive tapes and labels and flexible
vinyl coatings, were collected from other EPA studies2'3 and are included
in Table 2.1. Most of the solvent usage data in Table 2.1 are for the
year 1979.
Of all the estimated yearly solvent usage data, those for photographic
film and paper and magnetic tape are considered the most reliable because
of the high percentage (estimated 99%) of the total industry surveyed. The
other solvent usage data are not as reliable, but are reasonable estimates.
2.1 Miscellaneous Categories
Table 2.1 lists estimated yearly solvent usage for four miscellaneous
categories. A list of the products in these categories that require solvents
for their production is presented in Table 2.2.
2.2 Shoes and Handbags
Manufacturers with SIC codes specific to shoes and handbags were not
surveyed. However, one questionnaire was received from a shoe-fabric maker,
and the potential for a large solvent usage was indicated for this category.
Several other questionnaires were received from plants that make shoe soles
and heels and soling sheets. Solvent usage for these plants was also large.
Accordingly, a potential standard-setting category does exist, but a
2-1
-------
TABLE 2.1.
Product
Pressure Sensitive Tapes and Labels2
Flexible Vinyl Coating^
Flexible Packaging
Photographic Products
Magnetic Tape
Rubber-coated Fabrics
Vinyl Floor Coverings
Gift Wrap
Office Copier Paper
Inked Ribbons
Nitrocellulose Coated Products
Rubber and Plastic Belts
tiii •
Wai 1 coverings
Sandpaper
Carbon Paper
Metal Foil and Leaf (other than
packaging)
Polyurethane Coated Fabrics
Gaskets, Packing, and Sealing Devices
Shelf Paper
Manifold Business Forms
Oil, Waxed, and Wax-laminated Paper
Rubber Hose (except garden hose)
Other Hose and Belts
Subtotal
Miscellaneous Categories
Miscellaneous Coated Products
Laminated or Coated Rolls and
Sheets (paper)
Other Coated Fabrics
Miscellaneous Laminated Products
Other Fabricated Rubber Products
Subtotal
TOTAL SOLVENT USAGE
— —---.. , v , , rvwfe' w W f I 1 L« U 1
Estimated Yearly Industr
Solvent Usage all Per
(Metric Tons) Control
i\uuuv< I j
y Over- Annual
cent Growth
1edm Rat»C%\
600,000* unk 10.0
68,670* Unk 2.0
41,200 7.1 i r,
38,000 46^4
32,710 46.4
31,190 18.6
23,090 19.7
20,780 0
t.u
9Q
. y
13.3
8.0
7 ?
/ « o
o o
wwj/wvy \J C»O
15,550 90.0** 2.5
14,860 57.0 5.3
9,130 40.2 1.5
8,580 43.8 ft.fi
6,690 7.1
3,260 0
2,670 7 2
i— > \j \j / • t
2,550 41.7
2,380 0
U510 7.9
790 0
90 0
— w \j
80 0
40 o
10 Q
923,830
38,990 16.2
15,670 3.2
5,300 11.7
1,270 10.0
1,050 0
62,280
986,110
>2.3
4r
.0
5.3
11.3
n!o
4n
• U
1.5
7.6
?
1 5
x . j
4 5
~ • w
2.5
Estimated annual emissions, from References 2 & 3.
Percent controlled number based on data from one plant.
probably high for the entire industry.
Unk = unknown
This number is
2-2
-------
TABLE 2.2. MISCELLANEOUS PRODUCTS REQUIRING SOLVENTS
IN THEIR MANUFACTURE
Miscellaneous Coated Products
Acetate color filters
Acrylic-coated book covers
Adhesive-coated papers
After-exposure label paper
Aluminum pigment coated cloth
Automatic transmission plates
Automotive clutch and filters
Barrier-coated papers
Bottle capliners
Car sound-deadening materials
Chemical sterilization indicators
Coating of closed-cell foam
Coatinq of polyester film with foil
Decorative laminates
Dry-gum adhesive paper
Flexo-print envelope paper
Flocked board
Friction plate
Impregnated chemical test paper
Industrial textiles
Kraft paper
Kraft paper honeycomb
Laminated glass/asbestos/polyester
Mimeograph stencil paper
Paper plates
Polyethylene and nylon films
Polyurethane foam
Raq (100%) tracing papers & vellums
Reflective sheeting for highway signs
Reproduction papers (data graphics)
Supported and unsupported transfer
adhesive
Transparentized paper
Typewriter ribbon cover-up
Varnish coating
V-belt thread
Waterproof writing paper
Other Coated Fabrics
Adhesive-coated glass-cloth
Aircraft insulation
Buffing wheels
CAB lacquer on fabric
Card cloth foundations
Flocked fabrics
Friction materials
fabric
of cotton,
Phenolic-coated
Polishing buffs
Scrim coat
SRM-nonwoven fabric composite
Table covers
Vinyl organasol-coated fabrics
Window shades
sisal, etc,
Other Fabricated Rubber Products
Blood pressure bags
Custom molded rubber goods
Fabricated latex foam rubber
sheets and shades
Friction materials
Laminated shoe soles and heels
Molded rubber to metal
Rollers
Perimeter sealing devices
Rubber and plastic linings for tanks,
pipes, and valves
Synthetic rubber-soling sheets
Miscellaneous Laminated Products
Cable wrap
Plastic and captan film to metal
Polyester/paper for printed circuit
boards
Pressure sensitive adhesives on foam
rubber
Reinforced plastic and rubber
Various materials (vinyl, cotton,
foam, fabric, Tricot, etc.) for
shoes and handbags
Vinyl plastic to particle board
Vulcanized fiber
2-3
-------
negative growth rate (-11.9%) ha, been projected by the U.S. Department
of Commerce for the "rubber and plastic footwear" category.*
2-4
-------
3.0 DATA COLLECTION METHODOLOGY
Data collection was completed in three steps: identifying the plants
to be surveyed, conducting the survey, and evaluating the questionnaires.
3.1 Identification of Plants
The basis for the plant identifications was 13 Standard Industrial
Classification (SIC) codes. These codes were chosen by examining a list
of SIC codes and selecting those codes in which web coating and laminating
operations were likely to exist. In addition, magnetic tape producers (no
SIC code) were selected as directed by EPA.
Dun's Market Identifiers file, a product of Dun and Bradstreet Corpor-
ation, was used as the primary source for plant identification. The file
was used to generate mailing labels for plants in each of the 13 SIC codes.
All plants with total employment of less than ten were ignored.
Some operational restrictions can arise from the use of Dun's Market
Identifiers as a complete sampling frame. For the purpose of this survey,
a Plant (i.e., business establishment) is a unit record in the Identifier's
file. The file contains approximately four million unit records. However,
its completeness is unknown in regard to a total defined population of
business establishments.
Plants producing magnetic tape were identified by talking with people
who were knowledgeable of such plants and by calling firms listed in the
Thomas Register under the categories of video, audio, and computer tapes.
This procedure identified twenty one plants.
Plants producing photographic film and paper (SIC 3861) were identified
in a different manner. During discussions with environmental representa-
tives from several large film producers, they all agreed to cooperate if the
3-1
-------
survey were conducted through trie National Association of Photographic
Manufacturers (NAPM). The NAPM was contacted and agreed to assist. Thus,
the listing of representative plants was not necessary. The Dun's file for
SIC 3861 was used as a supplementary source of plants not included'in the
NAPM survey.
The SIC codes surveyed and the number of establishments in the Dun's
file with 10 or more employees are listed in Table 3.1.
, TABLE 3.1. SIC CODES USED FOR PLANT IDENTIFICATION
SIC Code SIC Descriptor.
2295 Coated fabrics, not rubberized ?ifi
2641 Paper coating and glazing 5 to
2649 Converted paper and paperboard products 669
2761 Manifold business forms
2771 Greeting card publishing
3041 Rubber and plastics hose and belting
3069 Fabricated rubber products
3291 Abrasive products
3293 Gaskets, packing, and sealing devices
3497 Metal foil and leaf 54
3861 Photographic equipment and supplies** 551
3955 Carbon paper and inked ribbons 101
3996 Linoleum, asphalted-felt base, and other hard 22
surface floor coverings
Magnetic tape
TOTAL 5084"
^Number of plants with ten or more employees.
National Association of Photographic Manu-
3.2 The Plant Survey
A two-phase design using four-digit SIC codes as the stratification
variables was used for the survey. The survey was approved by the Office
of Management and Budget (OMB No. 2000-0122). During the first phase, a
total sample of 1402 plants (27.5 percent of the 5084 total) was to 'be
allocated to the strata in proportion to their relative sizes, as measured
by the number of plants in each SIC code. However, all of the plants in
the smaller categories identified by SIC codes 3497 and 3966 and magnetic
3-2
-------
tape producers were surveyed, but the total number of plants was kept at
1402. Using this procedure, 26 percent of the plants, other than those
in SIC's 3497 and 3996 and magnetic tape producers, were surveyed. The
breakdown of the number of plants surveyed is shown in Table 3.2.
The first phase of the survey was conducted by mail. A questionnaire,
a product code list, instructions for completing the questionnaire, and a
covering letter were sent to randomly selected plants named in the Dun's
file. A copy of the survey package is in Appendix A.
After approximately 21 days, a postcard was sent to all respondents
who had not returned the questionnaires. The postcard served as either
a reminder or as a thank you (in cases where the plant had returned the
questionnaire but it had not been received). The postcard is reproduced in
Appendix A.
Phase one netted 1094 completed responses, or 78 percent of the total
originally sent.
TABLE 3.2. NUMBER OF PLANTS SURVEYED
SIC Code
2295
2641
2649
2761
2771
3041
3069
3291
3293
3497
3861
3955
3996
SIC Descriptor
Coated fabrics
Coated paper
Converted paper
Business forms
Greeting cards
Hoses and belts
Fabricated rubber products
Abrasive products
Gaskets, packings, and seals
Metal foil
Photographic equipment
Carbon paper and inked ribbons
Floor coverings
Magnetic tape
TOTALS
Number of Plants
Total Surveyed
216 56
518 135
669 176
478 124
141 37
160 42
1376 360
301 79
376 98
54 54
651 171
101 27
22 22
21 21
5084 TOT
Phase two of the survey consisted of telephone calls to nonrespondents
of phase one. Calls were made to the company official (usually the president
3-3
-------
or plant onager) Hsted on the Dun's printout. An effort was »d. to get
,nformat,on needed for the survey while on the phone; if this was not
possible, a deadline for return of the questionnaire was agreed on
deadhne was monitored, and the plant was called again if the questionnaire
was not received on the promised date. "'onnaire
2761 rM D n°nresP°nde"ts *™ •« called. For SIC
2761 (Mamfold Business Forms), on.y 2 of 101 responses showed so.vent
use so nonrespondents were not called. For SIC 3069 (Misce.laneous Rubber
Products) and SIC 386! (Photographic Eo.uip.ent), respondents were called
'' baSlS
POPS ™ P".
For SIC 3069, many nonrespondents were molders or fabricators of rubber
parts, d,d not use webs or solvents, and thus were not called. For SIC
3861, .any nonrespondants manufacture camera equipment, design electronic
components of camera equipment, or make movies, so these were not called.
Of the H02 questionnaires sent out, 1274 responses (or 91%) were
recewed. Some respondents sent questionnaires from all of their plants
so considerably more questionnaires were received from sore companies
than were sent out.
3'3 The Questionnaire Evaluation
The data from each questionnaire returned were first recorded on a
sugary sheet for each product code and then examined for completeness and
reasonableness. Data inconsistencies or deletions were checked by telephone
with the person listed on the questionnaire. Those questionnaires on
which no web coating or solvent usage (Item II) was checked were tallied
by product code and were filed separately from those showing solvent usage.
A common occurance was the combining of the solvent usage data for
two or more products. In these case,, the respondents were asked to break
down the data into separate product codes. If the respondent could not do
this, the usage was assigned equally to each product code.
3-4
-------
4.0 DATA EVALUATION METHODOLOGY
Data evaluation was conducted as four steps: data reduction, product
code combination, calculation, and qrowth projection. Due to the avail-
ability of a previous survey of the flexibile packaging industry, data
from this group of plants were evaluated differently as explained in Sec-
tion 4.6.
4.1 Data Reduction
Data from the survey responses were grouped according to product code
and recorded. A product code is a numerical designation arbitarily assigned
to various products (see Product Code List in Survey Package, Appendix A).
Because emission estimates for flexible vinyl coating and pressure sensitive
tape and label manufacturing have already been made as part of a NSPS back-
ground study, questionnaires received from these industries were not includ-
ed in the survey. After all the responses were received and logged, the
data for solvent usage under each product code were recorded on the product
summary and calculation sheets (shown in Appendix B). In addition to
information on the quantities of solvent in or added to the coatings and
adhesives, used to process the reported products and for equipment cleanup,
the sheets also include data on the number, tyoe, and efficiencies of
pollution control devices used, and the total quantity of solvent that
entered the control devices, the total quantity exhausted from the control
devices, and an average control efficiency for all the control devices in
use.
Other data recorded from the questionnaires included the total number
of plants surveyed and the number of plants using and not using solvents.
In cases where the survey respondent selected one of the general product
codes (e.g. "other coated fabrics" and "other laminating"), the specific
product as indicated by the respondent was listed under the remarks portion
of the summary and calculation sheets.
4-1
-------
4-2 Product Code Combination
As the survey responses we-e accumulated and the data recorded it
became apparent that several product codes needed to be combined to properly
evaluate the solvent usage data. For example, the original Product Code
List provided in the survey package (Appendix A), included codes for
"nitrocellulose bookcovers - fabric substrate" and "nitrocellulose book-
covers - paper substrate." Since only one questionnaire was received for
fabric substrate, these two codes were combined. Several respondents
specified other nitrocellulose coated products such as photomounts under
the "other coated or converted paper products" category. These responses
were also combined, and a new category entitled "Nitrocellulose Coated
Products" was formed. Other product codes that were combined are listed
below:
1. "Wallcovering - fabric substrate" and "wallcovering - paper
substrate" became "wallcoverings,"
"giftwrapP '-^ " ^"^ f°n" 3nd "9iftwraP ' ^11 " became
"Coated carbon paper" and "carbon film sheets" became "carbon
paper ,
r-1KbKb0nS ,: fabMc" and "1nked ribbons - «lm" became
n boons,
5. ''Gaskets and gasketing materials" and "packing and sealing
devices became "gaskets, packing, and sealing devices,"
6. "Capacitor foil" and "other foil or leaf" became "metal foil
and leaf,
7. All photographic film, paper, and cloth became one category
and 3 '
8' Zln!?< tJPe§" Kllaud1°«tape>" "comPuter tape," and "other
magnetic tape" became 'magnetic tape."
4.3 General Product Codes
To accomodate the listing of otherwise non-classifiable and/or unique
products, twelve genera) product codes were included in the survey's product
code list. These were:
4-2
-------
other coated fabrics other coated or converted paper products
other carbon paper other hose or belts
other abrasive products other fabricated rubber products
other foil or leaf other film paper or cloth
other floor coverings other magnetic tape
other coating other laminating
Except for those codes combined with other product codes as mentioned
previously (Section 4.2), each general product code was treated separately.
The general product codes were frequently chosen by respondents at
plants that operated as custom job shops. These plants produce a wide
variety of products, many of which were difficult to categorize.
4.4 Calculation^
The control device performance figures and the estimated yearly solvent
usage figures were obtained by calculations. They are recorded on the
product summary and calculation sheets.
The equations used to make the performance data calculations are
presented below. The left side of the calculations correspond to the
headings on the data sheets in Appendix 8. The terms used in the calcula-
tions are:
A = Total solvent usage (i.e., total in coatings as purchased, added to
coatings, and for cleaning) summed for each product category from
the questionnaires,
B = Quantity of solvent entering each control device (reported as Item
IV B on the survey questionnaire),
C = Quantity of solvent exhausted from each control device (Item IV C
on the survey questionnaire),
D = Total quantity of solvent entering all control devices on exhaust
mSro( a11 surveyed Plants producing products in the category
(u - LB), and
E = Total quantity of solvent exhausted from all control devices on all
surveyed plants producing products in the category (E = s C).
Control Device Efficiency (%) = (1 - £)(100)
8
Average Control Device Efficiency (%) = (1 - I) (100)
4-3
-------
Proportion of Total Solvent =2 (100)
Entering Control Devices (%) A
Overall Industry Percent Control (%) = Q-E (ioo)
^»
The estimated yearly solvent usage (Y) was calculated for each product
category by two methods. The first method assumes the solvent usage of the
sample is typical of the industry and uses as a multiplier the ratio of
total plants in the industry to plants surveyed:
where: Y = the estimated yearly solvent usage for the product (tons/yr),
M = the number of plants from the Census of Manufacture.
M = the number of plants included in the survey, and
A = the total solvent usage.
In the second method, total solvent usage was scaled upward by 3.85 the
sampling proportion of the survey (i.e., 100% * 26.0%; see Section 3.2).
These procedures were not used for photographic film and paper and
magnetic tape because of the essentially total industry coverage afforded
these two categories by the survey. It is estimated that solvent usage from
99 percent of the plants in these categories was included in the survey.
Estimated yearly solvent usage values calculated by both of the methods
described above are reported on the product summary and calculation sheets
in Appendix B. To prepare Table 1 (Section 2.0), the higher of the values
was chosen because of the survey methods. In explanation, the list of
Plants surveyed was generated from a file of plants (Dun's Market Identi-
fiers) classified by four-digit SIC codes; 26.0 percent of the plants in
each SIC code listing (with exceptions noted previously) were randomly
selected to receive the survey package. Ideally, 26.0 percent of the
Plants producing a specific product would also be selected, however, this
did not occur due to two factors. Primarily, four-digit SIC codes are
broad and thus not specific enough to select for the products which were
to be examined in the survey. Additionally, it was discovered through
tabulation of survey data that many plants in Dun's file were misclassified
4-4
-------
(i.e., plants that were listed in one SIC category actually produced web-
coated products that belonqed in another category) and that often the file
was incomplete. This resulted in the decision to use listings in the
Census of Manufacturers which include a breakdown in number of plants up
to six-digit SIC codes as the reference in determining the total number of
plants producing a specific product. Obviously, in many cases, more or
less than 26.0 of a particular product's industry were actually surveyed.
To arrive at the most conservative figure, the scale-up method which
provided the higher value was used to calculate the estimated yearly solvent
usage. In cases where the number of returned questionnaires was consider-
ably less than 26.0 percent of the CM reference number of plants, the
first scaleup method described above was used. In cases where the number
of returns was considerably more than 26.0 percent of the number of plants,
the second scale-up method was used. While the assumptions that were made
could lead to some errors, the results obtained are considered to be reason-
able estimates of estimated yearly solvent usage for the manufacture of
the product listed in Table 2.1.
4.5 Growth Projection
Growth projections for various products were obtained from several
sources.4>5»6,7,8,9,10 Growth predictions were used if available; if not,
however, historical data were projected to 1985. In projecting historical
data, quantity data and value data in constant dollars (i.e. adjusted for
inflation) were preferred over unadjusted value data. The projections are
shown on the product summary sheets (Appendix B).
4.6 Flexible Packaging
Questionnaires from 32 plants engaged in the manufacture of flexible
packaging were received and evaluated in the same manner as the data on
other products. Additionally, the results of a 1978 emissions studyll of
the flexible packaging industry were included in the analysis for compari-
son. The Flexible Packaging Association (FPA) checked the 32 plants survey-
ed against the list of plants that participated in the 1978 study. Thirteen
4-5
-------
of these plants had not been included in the 1978 study, so the solvent
usage data from these were added to data from the 1978 study.
The results generated by the two data evaluation methods are shown
below:
Method 1
Total Solvent Usage from Questionnaires - 5273 metric tons
Number of Plants in Survey — 32 metric tons
Total Number of Plants in Industry -- 250
Estimated Yearly Solvent Usage:
A. By ratio of FPA total plants (i.e., 250) - 41,195 metric tons
~3T
B. By factoring upward by 3.85 - 20,301 metric tons
Method 2
itsir j;™ .:vurvey -- 32-°24 ™M< *»»
Total Number of Plants in Industry -- 250
Estimated Yearly Solvent Usage --' 250 x 32,024 = 75,528 metric tons
106
For Method 2, the total solvent usage (Table 2 of the 1978 report4)
includes solvent used for coatings, varnishes, adhesives, and cleaning,
but not printing. The number of plants in the survey (i.e., 106) is the
total number of questionnaires received in the 1978 survey (i.e., 154)
minus the number of plants showing greater than 90 percent of solvent use
in printing operations (i.e., 48). The estimated yearly solvent usage
was obtained by multiplying total solvent usage by the ratio of the number
of plants that coat or laminate (Reference 9) to the number of plants in
the survey (i.e., 250 x 32,024).
4.7 Vinyl Floor Covering
The solvent usage number for Vinyl Floor Covering in Table 2.1 is the
smaller number (23,090 metric tons) of the two numbers calculated by the
two methods explained in Section 4.4. The smaller number was chosen because
it was closer to the number (18,700 metric tons) generated in another study
done for EPA.1^
4-6
-------
5.0 REFERENCES
1. Federal Register. August 21, 1979, page 49222.
2. "Pressure Sensitive Tape and Label Surface Coating Industry-Background
Information for Proposed Standards," U.S. EPA, EPA-450/3-80-003a
September 1980, pages 3-2 and 3-3.
3. "Discussion of Aerosol and VOC Emissions from the Flexible Vinyl
Coating and Printing Industry," meeting report, Radian Corp. to U.S.
EPA, July 25, 1980.
4- 1981 U.S. Industrial Outlook. U.S. Department of Commerce, Bureau of
Industrial Economics, Washington, D. C. January 1981.
5- Predicast's Basebook. Predicast's, Inc., Cleveland, Ohio, November 1977,
6. Predicast's®, Issue No. 78, 2nd Quarter, Predicasts, Inc., Cleveland,
Ohio, January 18, 1980
7. "Converting Industry Could See Moderate Growth in 1980 " Paper Film
1980F01'a e McLean"Hunter Publishing Corp., Chicago, February
8. Telephone conversation between Mr. Tom Dunn, National Flexible Packag-
ing Association, and Mr. George Weant, Engineering-Science, May 26
1981 .
9< Census of Manufacturers. 1977. Bureau of the Census, Department of
Commerce, Washington, DC.
10' The Industrial Fabrics Market (U.S.). promotional bulletin, Frost &
Sullivan, Inc., New York, Spring 1980.
11. Boies, D. B., E. K. Schumann, and F. S. Scofield, "Overview Assessment
uL™fniTC EmirSnSAionS of the F1ex1'ble Packaging Industry," report by
WAPORA, Inc., EPA Contract No. 68-03-2580, 197s!
12. "Source Category Survey Report, Resilient Flooring Industry," draft
report, to U.S. EPA, OAQPS, Research Triangle Park, N.C., June 23, 1980.
5-1
-------
-------
APPENDIX A
SURVEY PACKAGE AND
REMINDER/THANK YOU POSTCARD
A-l
-------
** n \
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
Office of Air Quality Planning and Standards
Research Triangle Park, North Carolina 27711
c/
February 16, 1981
Dear Sir:
^J"^™^^™!!?"?" *?enc? of *"e Unfted States
directly applicable to this work are Sections 103, 111 and 114? '
The information supplied in the questionnaire will be receivpri *nH
-
William L. Johnson
Web Coating Survey
Emission Standards and Engineering Division (MD-13)
Environmental Protection Agency
Research Triangle Park, North Carolina 27711
A-2
-------
-2-
Sincerely yours,
Jon R/> Goo\dwin
Director
Emission Standards and
Engineering Division
Enclosure
A-3
-------
OMB No. - 2000-0122
Expires - October 1, 1981
General Instructions
Clarification of items in this survey my be obtained from Mr. Willia
Johnson, EPA, by telephone at (919) 541-5305.
This questionnaire is concerned with coating or laminating operations
on fabric, paper, plastic film, or metallic foil that result In emission of
"
re e r d tn Us <*
referred to collectively as web coating and includes coatings applied by roller
reverse roll, blade, air Knife, rod, dip or rotogravure coater.
Fill out the questionnaire for each type of product code manufactured at
your facility. Product codes are identified in the enclosed Product Code
List. If you manufacture several types of products within one product code,
(for example, several different types of pressure sensitive tapes) then fill
out only one sheet and give answers for the sum of these products. If you
produce products from several product codes at your plant, then reproduce the
quest,onnaire sheet and fill out a separate sheet for each product code.
Identify the product code in Part I of each questionnaire sheet.
If your plant does not coat or laminate fabric, paper, plastic ftl« or
metallic foil, even though making a product from the Product Code list or if
you use no organic solvent In coatings, you should check the block In Part II
disregard the remainder of the questionnaire and return the questionnaire to '
tr A«
In Question III - A, give the amount of organic solvent contained in
coatings as the coatings are received fron, the manufacturer or the amount of
organic solvent added to coatings as they are made up in your own plant. In
Question III - B, give the amount of additional organic solvent that is added
as thinner or to adjust coating properties before the coating is used.
In Question IV-A. if no air pollution control device is used, write
"None" in the blank space.
A-4
-------
OMB No. - 2000 - 0'122
Expires - October 1, 1981
I.D. No. -
Web-Coating and Laminating Questionnaire
(Please Type or Print)
Date
Facility Name (Include Parent Company Name):
Facility Address:
' Person to Contact for Information Provided on this Questionnaire:
Phone: ( )
I. Product
A' t
B*
ProduCt Code
« 5> 16' 21' 27' 29« 3L 37. 47,
, 54, 55 or 56 are used, specify the product:
II.
Ill
-S R°? a web coated Ppoduct or ^ manufactured without
™
Solvent Usage
A. Enter the total quantity of solvent received in the coatings
es used for this product during 1979. * pounds
* - _
the total quantity of solvent added to coatings and
adhes^ves 7n this facility for this product in calendar year
C* mpl6Vhe t0tJ7 quant1ty of so]vent us^ for cleaning
ment for manufacture of this product in 1979. _
IV.
Air Pollution Control Devices
u1-! 1E1nera?Sr> C s carbo" adsorption, 0 * other)
Write-None" if control device is not used. —
If other, please define:
B. Enter the total
device in 1979.
C. Enter the total quantity of solvent exhausted to the"
atmosphere from the control device in 1979.
the contro1
_pounds
_pounds
END OF QUESTIQNNATRF
A-5
-------
OMB No. - 2000 - C
Expires - October
Product Code List
Product
Product Code
Coated Fabrics
Polyurethane-coated fabrics
Rubber-coated fabrics «
Nitrocellulose bookcovers - fabric substrate 3
Wallcoverings - fabric substrate A
Other coated fabrics *
Paper Coating and Coverting (also see codes 17, 18. 19 & 21)
Office copier paper
Electrostatic
Heat sensitive 7
I, waxed, and wax-laminated paper a
,-..-.11..i___i i r O
Nitrocellulose bookcovers - paper substrate 9
Laminated or coated rolls and sheets 10
Gift wrap paper, except foil (for foil, see Code 3'5) 11
Wallcoverings - paper substrate 12
Computer paper f
Cigarette paper and packages ,/
Shelf paper g
Other coated or converted paper products !6
Manifold Business Forms
Greeting Cards
18
Carbon Paper and Inked Ribbons
Carbon paper
Coated carbon paper ^o
Carbon film sheets 20
Other carbon paper 7,
Inked Ribbons *
Fabric
Rubber and Plastic Hose and Belts
Rubber and plastic belts 24
Rubber hose, except garden hose 25
Rubber and plastic garden hose 26
Other hose or belts 27
Fabricated Rubber Products
Rubber floor and wall covering 28
Other fabricated rubber products 29
-------
Product Code List (continued)
— — — -— w Wklfc ,
Expires - October 1,
Product
Abrasive Products
Sandpaper
Other abrasive products
Gaskets, Packing, and Sealing Devices
Gaskets and gasketing materials
Packing and sealing devices .
Metal Foil and Leaf
Packages and containers
Gift wrap
Capacitor (condenser) foil
Other foil or leaf
Photographic Equipment and Supplies
Film, silver halide type, except x-ray
Black and white
Color
Paper and cloth, silver halide type
Designed for black and white film
Designed for color film
Film paper and cloth, other than silver halide type
Blueprint type y
Diazo type
Full size
Microfilm
Brownprint type
X-ray film
Other film, paper, cloth
Hard Surface Floor Coverings
Linoleum
Vinyl Floor Coverings
Other floor coverings
B
Magnetic Tape
Video tape
Audio tape
Computer tape
Other magnetic tape
Other Coating
Other Laminating
Product Code
II
35
36
38
39
*
^
43
^
45
4$
47
48
49
50
54
55
56
A-7
-------
Dear Sir:
ll^c5 r a.rem'nder to complete and return, by March 20
'
William L. Johnson
Emission Standards and Engineering Division
U. S. Environmental Protection Agency
REMINDER/THANK-YOU POSTCARD
A-8
-------
APPENDIX B
PRODUCT SUMMARY AND CALCULATION SHEETS
B-l
-------
GUIDE TO CONTROL DEVICE CODES
Code Device
N None
r
Carbon Absorption
Incinerator
0 Other
B-2
-------
wi/~n/*
Remarks:
viduai
Plants that coat or
an
t0tal ™ber <*
* Portions of this industry nay arow at higher rates. One of these portions Is multiweb packaging
-------
Product - Photographic Film, Paper, and Miscellaneous Products
Solvent Usage (pounds)
In
Coatings
Added to
Coatings
For
Cleaning
Total
Type and
Number of
Control
Devices*
Control
Device
Effici-
ency (%)
Solvent
Entering
Control
Device
(Pounds)
Solvent
Exhausted
From
Control
Device
(Pounds)
Average
Control
Device
Effici-
ency (%)
Proportion
of Total
Solvent
Entering
Control
Device(%)
Overall
Indus-
try
Percent
Control
(%)
15,006,115 60,980,405 7,784,493 83,771,013
87.8
52.9
46.4
CD
N-14 0 44,302,822 5,402,847
C-6 90.0-95.6
1-1 96.0
C.I-2 97.2
0-3 50.0-96.0
1,0-5 No data , . . . ....
Estimated percentage of industry included in survey -- 99% •
Estimated yearly growth rate =- 9.9*
Data source — Predicasts, 1977 - Photographic film and sensitized plates (including X-ray) - shipments
Remarks: This category includes black and while and color film; paper and cloth designed for use with film- film
paper and cloth for blueprints, brownprints, and diazo prints (including microfilm); X-ray film; and other
film, paper, and cloth. The other film, paper, and cloth category includes drafting film, transparentized
paper, color proofing film, photographic packaging materials, micrographic imaging paper, color film coin-
po nents, lithoplates, heat sensitive film, electrophotographic film, photocopy paper, X-ray screens
and non-silver films for printed circuits. '
Much of this data was collected by the National Association of Photographic Manufacturers and, thus, was
not collected directly from the individual companies by EPA.
* Other control devices - an inert-gas condensation and recovery system, refrigeration, water scrubber, and
catalytic incineration. Other control devices used with incineration — not specified
Note:
Concern has been expressed by the NAPM over the inclusion of solvent used in cleaning in the total solvent
usage figures that are factored upward to obtain Estimted Yearly Solvent Usage. Since a large portion of
,thlS Jiea2;j2 S°1Vent ^ recovered* NAPM feels that 1* sh°"™ not be included in emissions data-in addi-
tion the NAPM expressed concern over a possible misunderstanding in the solvent in coatings portion of the
' tot" && °f
-------
Product - Magnetic Tape
Solvent Usage (pounds)
In
Coatings
Added to
Coatings
For
Cleaning
Total
Type and
Number of
Control
Devices*
Control
Device
Effici-
ency (%)
Solvent
Entering
Control
Device
(Pounds)
Sol vent
Exhausted
From
Control
Device
(Pounds)
Average
Control
Device
Effici-
ency(%)
Proportion
of Total
Solvent
Entering
Control
Device(%)
Overall
Indus-
try
Percent
Control
(%)
14,717,505 46,412,188 10,992,240 72,121,933
N-10
C-12
1-2
1,0-1
0 36,168,211 2,722,748
49.7-100.0
96.3-100.0
99.3
92.5
50.1
46.4
-( • »
Total number of plants surveyed — 21** ,,
Number of surveyed plants using solvent -- 21 " 7
Number of surveyed plants not using solvents — 0 "''"'' '
Number of plants - estimated from independent list -- 21**
Estimated yearly solvent usage (metric tons)
A. By ratio of estimated number of establishments -- 32,714
B. By factoring solvent usage upward by 3.85 -- Not Applicable
yeaPly 2ro£h rate " J3>3% annual compounded growth in shipments (square feet of tape)
source -- rredicasts, 1977
Remarks:
Car!^nV"ClU!!eS Vldf?' KUCH°' comPuter> and ot^r magnetic tape. The "other" category includes magnetic
cardmedia and magnetic business and banking ribbons. n.aynctn.
** ?ther Control device used with incineration -- pick-up of wash solvent and waste coatings.
Two additional plants were surveyed under this category. However, neither did web coating.
-------
Product - Rubber Coated Fabrics
Solvent Usage (pounds)
In
Coatings
Added to
Coatings
For
Cleaning
Total
Type and
Number of
Control
Devices*
Control
Device
Effici-
ency (%)
Solvent
Entering
Control
Device
(Pounds)
Solvent
Exhausted
From
Control
Device
(Pounds)
Average
Control
Device
Effici-
ency (%)
Proportion
of Total
Solvent
Entering
Control
Device(%)
Overall
Indus-
try
Percent
Control
(%)
7,840,823 9,829,495 190,761 17,861,079
N-14
C-5
1-1
0-1
0
52.5-98.0
85.0
90.0
4,989,020 1,674,359 66.4 27.9
18.6
ro
en
Total number of plants surveyed -- 40
Number of surveyed plants using solvent -- 22
Number of surveyed plants not using solvents — 18
Number of plants listed in Census of Manufacturers -
Estimated yearly solvent usage (metric tons)
A. By ratio of Census of Manufacturers data —
B. By factoring solvent usage upward by 3.85
- 35
Not Applicable
- 31,192
Estimated yearly growth rate — 8.0% growth in pounds of fiber (1979-1984)
Data source - The Industrial Fabrics Market (U.S.) - fiber consumption for industrial fabrics,
Remarks:
* co^sUoT' deVUe " rec1rcu1at1on of * I""-110" °f ^e exhaust to the process heat generation equipment for
-------
CD
I
Product - Vinyl Floor Coverings
Solvent Usage (pounds)
In
Coatings
Added to
Coatings
For
Cleaning
Total
Type and
Number of
Control
Devices*
Control
Device
Effici-
ency (%)
Solvent
Entering
Control
Device
(Pounds)
Solvent
Exhausted
From
Control
Device
(Pounds)
Average
Control
Device
Effici-
ency (%)
Proportion
of Total
Solvent
Entering
Control
Dev1ce(%)
Overall
Indus-
try
Percent
Control
(%)
24,806,319 287,234 353,520 25,447,073 1,0-2 60.0-92.6 8,053,553 3,040,994 62.2
Total number of plants surveyed -- 2
Number of surveyed plants using solvent ~ 2
Number of surveyed plants not using solvents — 0
Number of establishments listed in Census of Manufacturers - 4
Estimated yearly solvent usage (metric tons)
A. By ratio of Census of Manufacturers data — 23,085
B. By factoring solvent usage upward by 3.85 -- 44,439
annually
31.6
wcprtQ7 *M 1n J?rrent dollars
source -- Predtcasts. 1977 - Hard surface floor coverings
19.7
Remarks:
* Other control devices used with the Incinerators - not specified.
-------
Product - Gift Wrap (Paper and Foil)
Solvent Usage (pounds)
In
Coatings
Added to
Coatings
For
Cleaning
Total
Type and
Number of
Control
Devices
Control
Device
Effici-
ency (%)
Solvent
Entering
Control
Device
(Pounds)
Solvent
Exhausted
From
Control
Device
(Pounds)
Average
Control
Device
Effici-
ency(%)
Proportion
of Total
Solvent
Entering
Control
Device(%)
Overall
Indus-
try
Percent
Control
(%)
1,883,237 4,801,332
35,301 6,719,870
N-9
0
0
0
0
CD
i
00
Total number of plants surveyed -- 11
Number of surveyed plants using solvent -- 9
Number of surveyed plants not using solvents -- 2
Number of establishments listed in Census of Manufacturers
— 75
Estimated yearly solvent usage (metric tons)
A. By ratio of Census of Manufacturers data -- 20,783
B. By factoring solvent usage upward by 3.85 — 11,735
Estimated yearly growth rate -- 2.3% real growth compounded annually (1981-1985)
Data source -- 1981 U.S. Industrial Outlook - Converted paper products, n.e.c,
Remarks:
-------
Product - Office Copier Paper
Solvent Usage (pounds)
In
Coatings
Added to
Coatings
For
Cleaning
Total
Type and
Number of
Control
Devices
Control
Device
Effici-
ency (%)
Solvent
Entering
Control
Device
(Pounds)
Solvent
Exhausted
From
Control
Device
(Pounds)
Average
Control
Device
Effici-
ency(X)
Proportion
of Total
Solvent
Entering
Control
Device(%)
Overall
Indus-
try
Percent
Control
(%)
466,496 2,962,076
0
3,428,572
C-l
90.0 3,428,572 342,857 90.0 100.0
90.0
CO
vo
Total number of plants surveyed -- 1
Number of surveyed plants using solvent -- 1
Number of surveyed plants not using solvents -- 0
Number of establishments listed in Census of Manufacturers — 10
Estimated yearly solvent usage (metric tons)
A. By ratio of Census of Manufacturers data -- 15,552
B. By factoring solvent usage upward by 3.85 — 5987
Estimated yearly growth rate - 2.5% annual growth 1979-1985; based on projected shipments in constant dollars
from historical data
Data source — 1977 Census of Manufacturers
Remarks: Additional data received from other establishments as part of the NAPM survey. However, the data are
buried in the "Other Photographic Film, Paper, and Cloth" category.
-------
Product - Inked Ribbons (Fabric and Film Substrates)
Solvent Usage (pounds)
In
Coatings
Added to
Coatings
For
Cleaning
Total
Type and
Number of
Control
Devices
Control
Device
Effici-
ency (%)
Solvent
Entering
Controlg
Device
(Pounds)
Solvent
Exhausted
From
Control
Device
(Pounds)
Average
Control
Device
Effici-
ency(%)
Proportion
of Total
Solvent
Entering
Control
Device(%)
Overall
Indus-
try
Percent
Control
__M.
2,274,901 5,989,668 246,365 8,510,934
N-7 0 5,632,472
C-2 75.5-91.4
1-3 65.5-97.9
780,917 86.1
66.2
57.0
Total number of plants surveyed — 16
m Number of surveyed plants using solvent — 9
,1. Number of surveyed plants not using solvents — 7
0 Number of establishments listed in Census of Manufacturers -
- 31
Estimated yearly solvent usage (metric tons)
A. By ratio of Census of Manufacturers data -
B. By factoring solvent usage upward by 3.85 -
• 7,480
- 14,863
Estimated yearly growth rate — 5.3% growth in current dollars compounded annually
Data source -- Predicasts. 1977
Remarks: Inked ribbons are used for typewriters and other business machines.
-------
Product - Nitrocellulose Coated Products
Solvent Usage (pounds)
In
Coatings
Added to
Coatings
For
Cleaning
Total
Type and
Number of
Control
Devices*
Control
Device
Effici-
ency (%)
Solvent
Entering
Control
Device
(Pounds)
Solvent
Exhausted
From
Control
Device
(Pounds)
Average
Control
Device
Effici-
ency^)
Proportion
of Total
Solvent
Entering
Control
Device (%)
Overall
Indus-
try
Percent
Control
(*)
836,568 3,858,626 531,760 5,226,954
N-5
0-2
0
70.0
3,000,000 900,000 70.0 57.4 40.2
CO
Total number of plants surveyed — 8 (1 fabric, 7 paper)
Number of surveyed plants using solvent -- 7
Number of surveyed plants not using solvents — 1
Number of establishments listed in Census of Manufacturers
— 19 (13 fabric, 6 paper)
Estimated yearly solvent usage (metric tons)
A. By ratio of Census of Manufacturers data --
B. By factoring solvent usage upward by 3.85 -
5631
- 9128
Estimated yearly growth rate — 1.5% real growth for 1981
Data source - 1981 U.S. Industrial Outlook - Paper coating and glazing
Remarks: Products include bookcovers, boxcovers, stencils, and photomounts.
* Other control devices — recirculation of exhaust to burners
-------
Product - Rubber and Plastic Belts
Solvent Usage (pounds)
In
Coatings
Added to
Coatings
For
Cleaning
Total
Type and
Number of
Control
Devices*
3,326,069 898,302 9,620 4,233,991 N-6
1-1
0-2
Total number of plants surveyed -- 16
Number of surveyed plants using solvent -- 9
Number of surveyed plants not using solvents — 7
Number of establishments listed in Census of Manufacturers
Estimated yea
A. By r
B. By f
Estimated yea
Data sou
rly solvent usage (metric tons)
atio of Census of Manufacturers dat
actoring solvent usage upward by 3.
rly growth rate -- 8.6% growth in c
rce — Predlcasts, 1977 - Belts
Control
Device
Effici-
ency (%)
0
90.0
90.0
— 67
Solvent
Entering
Control
Device
(Pounds)
2,061,200
Sol vent
Exhausted
From
Control
Device
(Pounds)
206,120
Average
Control
Device
Effici-
ency(%)
90.0
Proportion Overal 1
of Total Indus-
Solvent try
Entering Percent
Control Control
Device(%) (%)
48.7 43.8
a -- 8,578
85 — 7,394
urrent dollars compounded annually
Remarks:
* Other control devices - electrostatic precipitators and DuPont catalytic abatement system
-------
Product - Wallcoverings - Fabric and Paper Substrates
Solvent Usage (pounds)
In
Coatings
Added to
Coatings
For
Cleaning
Total
Type and
Number of
Control
Devices
Control
Device
Effici-
ency (%)
Solvent
Entering
Control
Device
(Pounds)
Solvent
Exhausted
From
Control
Device
(Pounds)
Average
Control
Device
Effici-
ency(%)
Proportion
of Total
Solvent
Entering
Control
Device(*)
Overall
Indus-
try
Percent
Control
(%)
2,262,858 1,061,276 506,156 3,830,290
N-15 0
C-l ?
1-2 57.1-92.0
296,402 23,885
91.9
7.7
7.1
Total number of plants surveyed -- 28
Number of surveyed plants using solvent -- 18
Number of surveyed plants not using solvents — 10
Number of establishments listed in Census of Manufacturers — 74
Estimated yearly solvent usage (metric tons)
A. By ratio of Census of Manufacturers data -- 4591
B. By factoring solvent usage upward by 3.85 — 6689
Estimated yearly growth rate - >2.3* real growth compounded annually (1981-1985)
Data source - 1981 U.S. Industrial Outlook '
Remarks:
-------
Product - Sandpaper
Solvent Usage (pounds)
In
Coatings
Added to
Coatings
For
Cleaning
Total
Type and
Number of
Control
Devices
Control
Device
Effici-
ency (%)
Solvent
Entering
Control
Device
(Pounds)
Solvent
Exhausted
From
Control
Device
(Pounds)
Average
Control
Device
Effici-
ency(%)
Proportion
of Total
Solvent
Entering
Control
Device(%)
Overall
Indus-
try
Percent
Control
(%)
166,099
769,096 92,547 1,027,742
N-3
0
0
0
0
OO
Total number of plants surveyed — 4
Number of surveyed plants using solvent -- 3
Number of surveyed plants not using solvents — 1
Number of establishments listed in Census of Manufacturers -- 28
Estimated yearly solvent usage (metric tons)
A. By ratio of Census of Manufacturers data -- 3263
B. By factoring solvent usage upward by 3.85 — 1794
Estimated yearly growth rate — 4.5% annual growth 1979-1985, based on projected shipments in constant dollars from
historical data
Data source — 1981 U.S. Industrial Outlook - Abrasive products
Remarks:
-------
Product - Carbon Paper
Solvent Usage (pounds)
In
Coatings
Added to
Coatings
For
Cleaning
Total
Type and
Number of
Control
Devices
Control
Device
Effici-
ency (%)
Solvent
Entering
Control
Device
(Pounds)
Solvent
Exhausted
From
Control
Device
(Pounds)
Average
Control
Device
Effici-
ency^)
Proportion
of Total
Solvent
Entering
Control
Device(%)
Overall
Indus-
try
Percent
Control
(*)
1,451,610 57,986 20,318 1,529,914
N-6
1-2
0
65.5-98.5
151,000 40,525
73.2
9.8
7.2
tn
Total number of plants surveyed -- 31
Number of surveyed plants using solvent -- 8
Number of surveyed plants not using solvents — 23
Number of establishments listed in Census of Manufacturers » 36 (Includes carbon stencils)
Estimated yearly solvent usage (metric tons)
A. By ratio of Census of Manufacturers data -- 836
B. By factoring solvent usage upward by 3.85 -- 2672
Estimated yearly growth rate -- 5.3% growth in current dollars compounded annually
Data source -- Predlcasts. 1977
Remarks: Includes coated carbon paper, carbon film sheets, and other carbon paper.
Other carbon paper not using solvent—tissue carbon paper.
-------
Product - Metal, Foi1 and Leaf
Solvent Usage (pounds)
In
Coatings
Added to
Coatings
For
Cleaning
Total
Type and
Number of
Control
Devices
Control
Device
Effici-
ency (%)
Solvent
Entering
Control
Device
(Pounds)
Solvent
Exhausted
From
Control
Device
(Pounds)
Average
Control
Device
Effici-
ency^)
124,283 1,288,350 50,437 1,463,070 N-4 0 610,385 0 100 0
1-1 100.0
Proportion
of Total
Solvent
Entering
Control
Device (%)
41.7
Overall
Indus-
try
Percent
Control
(%)
41.7
Total number of plants surveyed — 14
Number of surveyed plants using solvent -- 5
Number of surveyed plants not using solvents — 9
Number of establishments listed In Census of Manufacturers — 40
Estimated yearly solvent usage (metric tons)
A. By ratio of Census of Manufacturers data -- 1896
B. By factoring solvent usage upward by 3.85 — 2555
Estimated yearly growth rate - 11.3% growth in current dollars compounded annually
Data source -- Predicasts. 1977
Remarks:
The metal foil and leaf category includes capacitor foil and other foil or leaf.
and
Products using solvent - foil/kraft laminates, hot-die stamping foils, and tin-lead alloy foils.
^"^f °*ited c°PPer ™1 (2), copper foi 1 for printed circuit boards,
-------
Product - Polyurethane Coated Fabrics
Solvent Usage (pounds)
In
Coatings
Added to
Coatings
For
Cleaning
Total
Type and
Number of
Control
Devices
Control
Device
Effici-
ency (%)
Solvent
Entering
Control
Device
(Pounds)
Solvent
Exhausted
From
Control
Device
(Pounds)
Average
Control
Device
Effici-
ency (*)
Proportion
of Total
Solvent
Entering
Control
Device(%)
Overall
Indus-
try
Percent
Control
(%)
1,306,702 2,000
1,000 1,309,702
N-2
0
0
0
Total number surveyed — 4
Number using solvent -- 2
Number not using solvent — 2
Number of plants listed In Census
of Manufacturers — 16
Estimated yearly solvent usage (metric tons)
A. By ratio of Census of Manufacturers data —
B. By factoring solvent usage upward by 3.85 -
2376
- 2287
Estimated yearly
Data source
growth rate -- 8% real growth in poundage (1979-1984)
— The Industrial Fabrics Market (U.S.); fiber consumption, industrial fabrics.
-------
Product - Gaskets, Packing, and Sealing Devices
00
Solvent Usage (pounds)
In
Coatings
611,227
Total number
Added to
Coatings
224,530
For
Cleaning
26,321
of plants surveyed --
Total
862,078
99
Type and
Number of
Control
Devices
N-9
1-2
Control
Device
Effici-
ency (%)
0
Solvent
Entering
Control
Device
(Pounds)
74,642
85.0-95.0
Solvent
Exhausted
From
Control
Device
(Pounds)
8,245
Average
Pnnt rril
l^UIILI U I
Device
Effici-
ency (%)
89.0
Proportion
of Total
Sol vent
Entering
Control
Device^)
8.9
Overall
Indus-
try
Percent
Control
7 9
Number of surveyed plants using solvent -- 11
Number of surveyed plants
Number of establishments
Estimated yearly solvent
not using solvents --
listed in
88
Census of Manufacturers
-- <276
usage (metric tons)
A. By ratio of Census of Manufacturers data -- lOQn
B. By factoring solvent usage
upward by 3.85 -- 1506
Estimated yearly growth rate — 11.0% growth in current dollars compounded annually
Remarks:
-------
Product - Shelf Paper
Solvent Usage (pounds)
In
Coatings
Added to
Coatings
For
Cleaning
Total
Type and
Number of
Control
Devices
Control
Device
Effici-
ency (%)
Solvent
Entering
Control
Device
(Pounds )
Solvent
Exhausted
From
Control
Device
(Pounds)
Average
Control
Device
Effici-
ency^)
Proportion
of Total
Solvent
Entering
Control
Device(%)
Overall
Indus-
try
Percent
Control
(*)
12,200
5,400
9,650 27,250
N-2
0
0
0
Total number of plants surveyed -- 2
Number of surveyed plants using solvent -- 2
Number of surveyed plants not using solvents -- 0
DO Number of establishments listed In Census of Manufacturers — 128 (Includes cigarette packages)
i—«
10 Estimated yearly solvent usage (metric tons)
A. By ratio of Census of Manufacturers data -- 791
B. By factoring solvent usage upward by 3.85 — 47
Estimated yearly growth rate -- 2.3* real growth compounded annually (1981-1985)
Data source -- 1981 U.S. Industrial Outlook - Converted paper products, n.e.c.
Remarks:
-------
Product - Manifold Business Forms
Solvent Usage (pounds)
In
Coatings
Added to
Coatings
For
Cleaning
Total
Type and
Number of
Control
Devices
Control
Device
Effici-
ency (%)
Solvent
Entering
Control
Device
(Pounds)
So 1 vent
Exhausted
From
Control
Device
(Pounds)
Average
Control
Device
Effici-
ency(%)
Proportion
of Total
Solvent
Entering
Control
Device(%)
Overall
Indus-
try
Percent
Control
(%)
10,531
1,500
30,100 42,131
N-5
0
0
0
0
0
Total number of plants surveyed — 101
Number of surveyed plants using solvent — 2
Number of surveyed plants not using solvents -- 99
Number of establishments listed in Dun's Market Identifiers -- 478
Estimated yearly solvent usage (metric tons)
A. By ratio of Dun's Market data -- 91
B. By factoring solvent usage upward by 3.85 — 73
Estimated yearly growth rate — 4% real growth compounded annually (1981-1984)
Data source — Paper. Film and Foil Converter. February 1980
Remarks: The
»l»nt ««« for coating or Iaminatin9. but do not include that used
-------
Product - Oiled, Waxed, and Wax Laminated Paper
Solvent Usage (pounds)
In
Coatings
Added to
Coatings
For
Cleaning
Total
Type and
Number of
Control
Devices
Control
Device
Effici-
ency (%)
Solvent
Entering
Control
Device
(Pounds)
Solvent
Exhausted
From
Control
Device
(Pounds)
Average
Control
Device
Effici-
ency (%)
Proportion
of Total
Solvent
Entering
Control
Dev1ce(%)
Overall
Indus-
try
Percent
Control
(%)
19,199
16,794
6650
42,643
N-2
0
0
0
0
0
CO
f\J
Total number of plants surveyed -- 16
Number of surveyed plants using solvent -- 2
Number of surveyed plants not using solvents — 14
Number of establishments listed in Census of Manufacturers — >70
Estimated yearly solvent usage (metric tons)
A. By ratio of Census of Manufacturers data — 84
B. By factoring solvent usage upward by 3.85 -- 74
Estimated yearly growth rate -- 1.5% real growth for 1981
Data source -- 1981 U.S. Industrial Outlook - Paper coating and glazing
Remarks:
-------
Product - Rubber Hose (Except Garden Hose)
Solvent Usage (pounds)
In
Coatings
Added to
Coatings
For
Cleaning
Total
Type and
Number of
Control
Devices
Control
Device
Effici-
ency (%)
Solvent
Entering
Control
Device
(Pounds )
Solvent
Exhausted
From
Control
Device
(Pounds)
Average
Control
Device
Effici-
ency^)
Proportion
of Total
Solvent
Entering
Control
Device(%)
Overall
Indus-
try
Percent
Control
(%)
0
11,824
0
11,824
N-l
0
0
0
0
0
Total number of plants surveyed -- 23
Number of surveyed plants using solvent -- 1
Number of surveyed plants not using solvents — 22
Number of establishments listed in Census of Manufacturers -- 155
Estimated yearly solvent usage (metric tons)
A. By ratio of Census of Manufacturers data — 38
B. By factoring solvent usage upward by 3.85 -- 21
Estimated yearly growth rate — 7.6% growth in current dollars compounded annually
Data source — Predicasts. 1977 - Hose and Tubing
Remarks:
This solvent usage covers only flat sheet coated webs. It does not include all solvent used In extruded
hose or in constructing three dimensional products, i.e. not flat sheet coating. Hoses are sometimes
made by wrapping cloth and film around a mandrel and using solvent-based adheslves
-------
Product - Other Hose and Belts
Solvent Usage (pounds)
In
Coatings
Added to
Coatings
For
Cleaning
Total
Type and
Number of
Control
Devices
Control
Device
Effici-
ency (%)
Solvent
Entering
Control
Device
(Pounds)
Solvent
Exhausted
From
Control
Device
(Pounds)
Average
Control
Device
Effici-
ency (%)
Proportion
of Total
Solvent
Entering
Control
Device (%)
Overall
Indus-
try
Percent
Control
(*)
5,900
1,000
0
6,900
N-2
0
0
0
0
0
0
oo Total number of plants surveyed — 10
ro Number of surveyed plants using solvent — 2
w Number of surveyed plants not using solvents -- 8
Number of establishments listed in Census of Manufacturers
— 17
Estimated yearly solvent usage (metric tons)
A. By ratio of Census of Manufacturers data -- 5
B. By factoring solvent usage upward by 3.85 -- 12
Estimated yearly growth rate —
Data source --
Remarks:
Products using solvent - silicon Impregnated asbestos "fire sleeve" hose protector and material
handling hose.
Products not using solvent - gaskets, washers, and rubber and polyester lined hose.
-------
Product - Miscellaneous Coated Products
I
-p»
Solvent Usage (pounds)
In
Coatings
Added to
Coatings
For
Cleaning
Total
Type and
Number of
Control
Devices*
Control
Device
Effici-
ency (%)
Solvent
Entering
Control
Device
(Pounds)
Solvent
Exhausted
From
Control
Device
(Pounds)
Average
Control
Device
Effici-
ency (%)
Proport i on
of Total
Solvent
Entering
Control
Device(%)
Overall
Indus-
try
Percent
Control
(*) .
10,324,702
11,074,695 926,028 22,325,425 N-41
C-5
1-2
0-2
0 4,190,775
76.9-98.0
93.0-100.0
33.0-?
566,086 86.5
18.8
16.2
Total number of plants surveyed — 89
Number of surveyed plants using solvent -- 43
OT Number of surveyed plants not using solvents — 46
Number of plants listed in Census of Manufacturers — Not Available
Estimated yearly solvent usage (metric tons)
A. By ratio of Census of Manufacturers data -- Not Available
B. By factoring solvent usage upward by 3.85 — 38,987
Estimated yearly growth rate — Not Available
Data source --
Remarks:
bottle
(Continued)
-------
CO
I
IVJ
en
Product - Miscellaneous Coated Products (Continued)
Products not using solvent - electrolytic recording papers (2), animal glue bonded papers, laminated glass/
asbestos papers and film, folding cartons, paper yarns and cords, folders, index cards, guides, adding
»n* £r^t£ reglstf r°11s« P^er Honeycomb, corrugated paperboard packaging and boxes, paper novelties
and decorations, party favors, cold wave end papers, placemats, calendar roll paper, paperboard, latex
impregnated paper, oiled paper, corrosion inhibiting paper, converted wet wipes, polyethylene coated milk
SSr Ln'nh n°?f°0k ?apeP* envelT.S' Wr1t1"9 tab1fits, ^erlay paper, gift tags, paper bags, creped
paper, and phenolic resin impregnated kraft linerboard. Includes many custom job shops where the product
may vary from day to day.
* Other control devices - recirculation of a portion of the exhaust to a burner and an afterburner.
-------
Product - Laminated or Coated Rolls and Sheets
Solvent Usage (pounds)
In
Coatings
Added to
Coatings
For
Cleaning
Total
Type and
Number of
Control
Devices*
Control
Device
Effici-
ency (%)
Solvent
Entering
Control
Device
(Pounds)
Solvent
Exhausted
From
Control
Device
(Pounds)
Average
Control
Device
Effici-
ency (%)
Proportion
of Total
Solvent
Entering
Control
Device(%)
Overall
Indus-
try
Percent
Control
(%)
7,962,738 562,642 447,425 8,972,805
N-14
1-1
0-1
0
100.0
33.3
319,000 28,000 91.2
3.6
3.2
O3
!
ro
Total number of plants surveyed -- 35
Number of surveyed plants using solvent -- 16
Number of surveyed plants not using solvents — 19
Number of establishments listed in Census of Manufacturers — 134
Estimated yearly solvent usage (metric tons)
A. By ratio of Census of Manufacturers data — 15,582
B. By factoring solvent usage upward by 3.85 — 15,670
Estimated yearly growth rate — 1.5% real growth for 1981
Data source - 1981 U.S. Industrial Outlook - Paper coating and glazing
Remarks:
fs^4b1Jshmfnts usi«9 solvents submitted questionnaires under this product category.
16"'560 Wre fle included'in the flexible packag ng
* Other control device - recirculation of a portion of the exhaust stream back to burner
-------
Product - Other Coated Fabrics
Solvent Usage (pounds)
In
Coatings
Added to
Coatings
For
Cleaning
Total
Type and
Number of
Control
Devices
Control
Device
Effici-
ency (%)
Solvent
Entering
Control
Device
(Pounds)
Solvent
Exhausted
From
Control
Device
(Pounds)
Average
Control
Device
Effici-
ency(%)
Proportion
of Total
Solvent
Entering
Control
Device(%)
Overall
Indus-
try
Percent
Control
(«)
1,604,647 1,298,890 133,139 3,036,676
N-12 0
C-2 No data
1-2 98.0-99.0
359,190
5411
98.5
11.8
11.7
ISi
Total number of plants surveyed -- 23
Number of surveyed plants using solvent — 16
Number of surveyed plants not using solvents — 7
Number of establishments listed in'Census of Manufacturers - 28 (not including vinyl coating)
Estimated yearly solvent usage (metric tons)
A. By ratio of Census of Manufacturers data -- 1676
B. By factoring solvent usage upward by 3.85 — 5303
Estimated yearly growth rate - 4.5* annual growth 1979-1985; based on projected shipments in constant,dollars
from historical data
Data source — 1981 U.S. Industrial Outlook
Remarks:
nn " wi"d°w.shades» Scr1m coat' "ocked fabrics, vinyl organasol coated fabrics, aircraft
. SRM-nonwoven fabric composite, table covers, CAB lacquer on fabric, card cloth foundations
ce ed ?±? *9 ^ ?' "f^K?1^ eU" adhesive <^ed 9lasscioth, friction mater a? ',
c coated fabric, and black or bondable filament.
^
"9 C?at6d "1th 1ead b"e p19ment- an1roa1 8'"e '>»•'*'' ^"ric, various
> l>0ll'eSter/PVC •)lasti"' '-»«« « ^Ic. pipe wrap (waxed cloth),
-------
Product - Miscellaneous Laminated Products
CO
ro
oo
Solvent Usage (pounds)
In
Coatings
358,401
Added to
Coatings
339,922
For
Cleaning
Total
Type and
Number of
Control
Devices*
Control
Device
Effici-
ency (%)
Solvent
Entering
Control
Device
(Pounds 1
Solvent
Exhausted
From
Control
Device
/PnunH<;\
29,410 727,733 N-8 0 113,600 40,600
1-1 100.0
0-1 35.1
Average
Control
Device
Effici-
enrvif.\
c * * ** y \ *> i
35.7
Proportion
of Total
Solvent
Entering
Control
Overall
Indus-
try
Percent
Control
/«/ \
Device (%) u;
15.6 10.0
Total number of plants surveyed — 15
Number of surveyed plants using solvent -- 12
Number of surveyed plants not using solvents — 4
Number of plants listed In Census of Manufacturers
Estimated yearly solvent usage (metric tons)
A. By ratio of Census of Manufacturers data -
B. By factoring solvent usage upward by 3.85
Estimated yearly growth rate --
Data source --
Remarks:
— Nnt
Not Applicable
- 1,271
K foam- ,
^^^^
This category contains many custom job shops whose product may vary from day to day.
* Other control device - recirculation of exhaust to burners
-------
Product - Other Fabricated Rubber Products
Solvent Usage (pounds)
In
Coatings
Added to
Coatings
For
Cleaning
Total
Type and
Number of
Control
Devices
Control
Device
Effici-
ency (%)
Solvent
Entering
Control
Device
(Pounds)
Solvent
Exhausted
From
Control
Device
(Pounds)
Average
Control
Device
Efflci-
jjncy(%]
Proportion
of Total
Solvent
Entering
Control
Device(%)
Overall
Indus-
try
Percent
Control
(%)
112,607
368,283 121,936 602,826
N-17
0
0
0
CO
I
ro
10
Total number of plants surveyed — 93
Number of surveyed plants using solvent — 17
Number of surveyed plants not using solvents -- 76
Number of establishments listed in Census of Manufacturers -
- Data not complete; large number (hundreds)
Estimated yearly solvent usage (metric tons)
A. By ratio of Census of Manufacturers data -•
B. By factoring solvent usage upward by 3.85 -
Not Available
- 1052
Estimated yearly growth rate — 2-3% real growth compounded annually (1981-1985)
Data source — 1981 U.S. Industrial Outlook - Fabricated rubber products
Remarks:
Products using solvents - laminated shoe soles and heels, rollers, custom molded rubber goods, fabricated
latex foam rubber sheets and shades, blood pressure bags, synthetic rubber soling sheets, perimeter sealing
valves materials, molded rubber to metal, and rubber and plastic linings for tanks, pipe, and
Products not using solvents - rubber rollers, tank linings, polyurethane castings, baseball and Softball
cores, sheet and ce lum rubber composites, truck tire flaps, swab cups, elastomeric closures (5), steel
laminated elastomeric bearing pads, rubber stoppers, rubber footwear, polyurethane foam, tubes, 11ferafts
erosion shoes, seals and rollers, rubber bellows, rubber shoe soling sheets, rubber to metal vibration '
tnc,, a rt.s> light sockets, garter buttons, valve disks and liners, prophylactics and diaphragms, toy rubber
A «US 4 r mats' vu1ca"ized cleats on conveyor belts, rubber covered rolls, rubber hose and
and u rings.
Note: This survey tried to concentrate on flat web coating in this industry. Thus much of solvent used for
rubber extrusion 1s not included here.
-------
Product - Other Abrasive Products
1836
Solvent Usage (pounds)
In
Coatings
Added to
Coatings
For
Cleaning
Total
Type and
Number of
Control
Devices
Control
Device
Effici-
ency (%)
Solvent
Entering
Control
Device
(Pounds )
Solvent
Exhausted
From
Control
Device
(Pounds)
Average
Control
Device
Effici-
ency(%)
Proportion
of Total
Solvent
Entering
Control
Device(%)
Overall
Indus-
try
Percent
Control
(*)
0
660
2496
N-l
0
0
0
0
0
CO
I
O)
Total number of plants surveyed -- 29
Number of surveyed plants using solvent — 1
Number of surveyed plants not using solvents -- 28
Number of establishments listed in Census of Manufacturers
-- Data not complete (hundreds)
Estimated yearly solvent usage (metric tons)
A. By ratio of Census of Manufacturers data —
B. By factoring solvent usage upward by 3.85 -
Not Available
- 5
Estimated yearly growth rate - Jj^nnual^grmrth 1979-1985, based on projected shipments in constant dollars from
Data source — 1981 U.S. Industrial Outlook - Abrasive products
Remarks:
-------
Product - Greeting Cards
Solvent Usage (pounds)
In
Coatings
Added to
Coatings
For
Cleaning
Total
Type and
Number of
Control
Devices
Control
Device
Effici-
ency (%)
Solvent
Entering
Control
Device
(Pounds)
Solvent
Exhausted
From
Control
Device
(Pounds)
Average
Control
Device
Effici-
ency (%)
Proportion
of Total
Sol vent
Entering
Control
Device (%)
OverafT
Indus-
try
Percent
Control
(%)
0
350
570
920
N-2
0
0
0
0
Total number of plants surveyed -- 37
Number of surveyed plants using solvent -- 2
Number of surveyed plants not using solvents -- 35
Number of establishments listed In Dun's Market Identifiers -
141
Estimated yearly solvent usage (metric tons)
A. By ratio of Dun's Market data — 2
B. By factoring solvent usage upward by 3.85 -
- 2
Estimated yearly growth rate - 8.0% growth in current dollars compounded annually
Data source — Predicasts. 1977
Remarks:
The solvent usage figures represent solvent used in coating and laminating operations, but do not
represent solvent used for printing of greeting cards.
-------
Product - Shoe Fabric
Solvent Usage (pounds)
In
Coatings
Added to
Coatings
For
Cleaning
Total
Type and
Number of
Control
Devices
Control
Device
Effici-
ency (%)
Solvent
Entering
Control
Device
(Pounds)
Solvent
Exhausted
From
Control
Device
(Pounds)
Average
Control
Device
Effici-
ency(%)
Proportion
of Total
Solvent
Entering
Control
Device(%)
Overall
Indus-
try
Percent
Control
(X)
750,000
0
0
750,000
N-l
0
0
0
0
0
0
CO
<>J
w
Total number of plants surveyed — 1
Number of surveyed plants using solvent — 1
Number of surveyed plants not using solvents -- 0
Number of establishments listed in Census of Manufacturer'
— 68
Estimated yearly solvent usage (metric tons)
A. By ratio of Census of Manufacturers data — 23,133
B. By factoring solvent usage upward by 3.85 -- 1310
Estimated yearly growth rate 11.9% growth in current dollars compounded annually
Data source -- 1981 U.S. Industrial Outlook - Rubber and plastics footwear
Remarks:
-------
1. REPORT NO.
EPA 450/3-81-012
TECHNICAL REPORT DATA
(flease read Instructions on the reverse before completing)
4. TITLE AND SUBTITLE
2.
Organic Solvent Use in Web-Coating Operations
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
George Weant
Robin Segal!
8. PERFORMING ORGANIZATION REPORT NO.
i ORGANIZATION NAME AND ADDRESS
Engineering Science
501 Willard Street
Durham, North Carolina 27701
12. SPONSORING AGENCY NAME AND ADDRESS ~~ "
Director, Office of Air Quality Planning and Standards
Office of Air, Noise and Radiation
U.S. Environmental Protection Agency
Research Triangle Park. North Carolina 27711
15. SUPPLEMENTARY NOTES —— „
3. RECIPIENT'S ACCESSION NO.
5. REPORT DATE
10. PROGRAM ELEMENT NOT
11. CONTRACT/GRANT NO.
68-01-4146
13. TYPE OF REPORT AND PERIOD COVERED
Final
14. SPONSORING AGENCY CODE
EPA/200/04
-\
116. ABSTRACT
A questionnaire concerning organic solvent use was sent to 1402 plants which
perform coating.or laminating of paper, fabric, film or foil (collectively known
as web-coating). Based on the questionnaire results, estimates were made of
national annual solvent use for major web-coating industries. These estimates
are summarized in the report. Types of control devices and amount of control
achieved for these industries is given. The report also lists estimated growth
rates for each industry.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
Air Pollution
Pollution Control
Volatile Organic Compounds
Solvents
Coatings
18. DISTRIBUTION STATEMENT
Release unlimited
EPA Form 2220-1 (R«v. 4-77) PREVIOUS EDITION is OBSOLETE
b.lDENTIFIERS/OPEN ENDED TERMS
Air Pollution Control
19. SECURITY CLASS (TIlis Report)
Unclassified
20. SECURITY CLASS (Thispage)
Unclassified
c. COSATI Field/Group
21. NO. OF PAGES
60
22. PRICE
-------
U.S. Environmental Protection Agency
Region V, Library
230 South Dearborn Street
Chicago, Illinois 60604
------- |