&EPA United States Environmental Protection Agency Office of Pollution EPA 745-K-94-006 Prevention and Toxics May 1994 7408 EPA's 33/50 Program Company Profile Anchor Fence, Inc. Printed on Recycled Paper ------- THE 33/50 PROGRAM This Company Profile is part of a series of reports being developed by EPA to highlight the accomplishments of companies participating in the 33/50 Program. The 33/50 Program is an EPA voluntary pollution reduction initiative that promotes reductions in direct environmental releases and off-site transfers of 17 high-priority toxic chemicals. The program derives its name from its overall goals - an interim goal of a 33% reduction by 1992 and an ultimate goal of a 50% reduction by 1995. The program uses 1988 Toxics Release Inventory (TRI) reporting as a baseline. In February, 1991, EPA began contacting the parent companies of TRI facilities that reported using 33/50 Program chemicals since 1988 to request their participation in the 33/50 Program. As of April, 1994, a total of 1,216 companies had elected to participate in __^ the Program, pledging to reduce emissions of the 17 target chemicals by more than 355 million pounds by 1995. Companies are encouraged to set their own reduction targets, which may vary from the Program's national 33% and 50% - reduction goals. Company commitments and reduction pledges continue to be received by EPA on a daily basis. The 1992 TRI data revealed that releases and transfers of 33/50 Program chemicals de- clined by 40% between 1988 and 1992, surpass- ing the Program's 1992 interim reduction goal by more than 100 million pounds. This accomplish- ment, together with evidence from analysis of facilities' projected releases and transfers of the 17 priority chemicals, reported to TRI under the Pollution Prevention Act, offers strong encourage- ment that the 33/50 Program's ultimate goal of a 50% reduction by 1995 will be achieved. 17 PRIORITY CHEMICALS TARGETED BY THE 33/50 PROGRAM BENZENE CADMIUM & COMPOUNDS CARBON TETRACHLORIDE CHLOROFORM CHROMIUM & COMPOUNDS CYANIDES DICHLOROMETHANE* LEAD & COMPOUNDS MERCURY & COMPOUNDS METHYL ETHYL KETONE METHYL ISOBUTYL KETONE NICKEL & COMPOUNDS TETRACHLOROETHYLENE TOLUENE 1,1,1-TRICHLOROETHANE TRICHLOROETHYLENE XYLENES Also referred to as methylene chloride EPA is committed to recognizing companies for their participation in the 33/50 Program and for the emissions reductions they achieve. The Program issues periodic Progress Reports, in which participating companies are listed and highlighted. In addition, Company Profiles, such as this one, are being prepared to provide more detailed information about companies that have written to EPA describing significant emissions reduction initiatives. Information presented in these profiles is drawn primarily from the company's written 33/50 Program communications and the annual TRI reports submitted by their facilities (including Pollution Prevention Act data reported to TRI in Section 8 of Form R). All company communications to EPA regarding the 33/50 Program are available to the public upon request. EPA does not endorse the performance, worker safety, or environmental acceptability of any of the technical options discussed in this Profile. Mention of any product or procedure in this document is for informational purposes only, and does not constitute a recommendation of any such product or procedure, either express or implied, by EPA. For information on the 33/50 Program, contact the TSCA Hotline at (202) 554-1404 or contact 33/50 Program staff directly by phone at (202) 260-6907 or by mail at Mail Code 7408, Office of Pollution Prevention and Toxics, U.S. EPA, 401 M Street, SW, Washington, D.C 20460. 33/50 Program Company Profile: Anchor Fence, Inc. ------- Anchor Fence, Inc. Anchor Fence, Inc. reduced releases of 33/50 Program chemicals by 87% from 1988 to 1992, and 98% by 1993, for a total reduction of over 120,000 founds. This achievement exceeds the company's goal to the 33/50 Program of 93% by 1995. I. CORPORATE BACKGROUND Anchor Fence, Inc. is a manufacturer of high quality chain link fencing systems, gates, and specialty fencing products. The company has one facility located in Baltimore, MD, employing approximately 85 workers. One of the company's primary products is polyvinyl chloride (PVC) coated components for fences. The company purchases galvanized steel pipe, fittings, and wire, applies the coating, and delivers custom-made components and fencing systems. Prior to coating, the components are typically cleaned and covered with a water-based primer. A PVC powder coating is then bonded to the base material by heating the powder until its melts, and allowing it to cool and harden onto the base material. Anchor Fence reduced releases of all 33/50 and TRJ chemicals 98% from 1988 to 1993. Between 1988 and 1991, the plant used only one 33/50 Program chemical in quantities report- able to TRI: methyl ethyl ketone. The company also uses six other 33/50 Program chemicals at levels below the TRI reporting threshold of 10,000 pounds: dichloromethane, lead and compounds, methyl isobutyl ketone, nickel and compounds, toluene, and xylenes. In addition, the company uses small quantities of zinc and compounds. Methyl ethyl ketone was used as the primary solvent in primers used on pipes and fittings. Dichloromethane was used to strip PVC from off- quality products so that the pipes can be re-used. The other solvents primarily are used in routine cleaning operations and during product color changes. Metals such as lead, nickel, and zinc are used as colorants in the PVC coating process, and are by-products of the galvanized steel cleaning operations. Releases of TRI Chemicals Reported by Anchor Fence, Inc. (1000 pounds) 1988 1992 33/50 Program Chemicals Dichloromethane* Lead & Compounds* Methyl Ethyl Ketone Methyl Isobutyl Ketone* Nickel & Compounds* Toluene* Xylenes* 33/50 Subtotal ** 7 tr 115 <1 tr 123 7 tr *8 <1 tr 16 Other TRI Chemicals < 1 < (Zinc and Zinc Compounds) * Data from company progress reports ** Columns do not sum to totals due to rounding. tr = trace, less than one pound Table I at the end of this profile shows the company's releases and transfers of chemicals reported to TRI between 1988 and 1992. Because most of the chemicals are used below TRI report- ing thresholds, most of the data used in this profile were provided by the company in progress reports to the 33/50 Program. Anchor Fence reported a total of 122,987 pounds of 33/50 Program chemical releases in 1988. All of the releases were air emis- sions. II. 33/50 PROGRAM GOALS AND POLLUTION REDUCTION ACTIVITIES The company joined the 33/50 Program in February of 1992 and committed to achieve a 93% reduction in total releases of all TRI chemicals by 1995 using 1988 TRI data as a baseline. Anchor Fence's 33/50 Program commitment translates to a reduction of 114,378 pounds of air releases from the 1988 baseline. The company has undertaken the following activities to reduce releases of TRI chemicals: • Releases of methyl ethyl ketone have been reduced 93% (113,000 pounds) through substi- 33/50 Program Profile: Anchor Fence, Inc. ------- tution of water based formulations of primers for pipes and fittings. This action accounts for all of the observed decrease in releases of this chemical. In addition, all solvent based paint applications are being strictly monitored to determine which can be converted to water based products in the future. Improvements in the operation of the compa- ny's waste water treatment system have re- sulted in a 50% reduction in releases of lead, nickel, and zinc compounds between 1988 and 1992. These improvements consist primarily of adjusting the pH of the system to increase efficiency of metals removal. Anchor Fence relies primarily on source reduction in its pollution reduction ef- forts. If prevention is not feasible, recy- cling and waste water treatment are also used. • Eliminating the use of dichloromethane at the plant by shifting the PVC stripping process for off-quality products to an off-site cleaning company that uses a hot salt bath PVC remov- al process. This change resulted in cost sav- ings for the company. • Examination of solvent based cleaning process- es using toluene and methyl ethyl ketone to determine where solvent evaporation can be reduced. The company intends to install a water-cooled component cleaning tank to further reduce releases of the solvents. III. PROGRESS TOWARDS 33/50 REDUCTION GOALS By 1992, Anchor Fence had reduced release of 33/50 Program chemicals by 87% from 1988 levels. Virtually all of this reduction was a result of substitution of methyl ethyl ketone-based primers with a water-based formulation. According to company progress reports to the 33/50 Program, Anchor Fence has continued to reduce releases of all 33/50 chemicals. Total releases of TRI chemicals were approximately 2,800 pounds in 1993. This represents a reduction of over 120,000 pounds or 98%, exceeding the Anchor Fence's Progress Towards Meeting 33/50 Goals 140 r 33/50 Goal 1988 1989 1990 1991 1992 1993 33/60 Goal: 93% reduction in releases and transfers of 33/60 chemicals by 1996 company's 33/50 Program goal of 93% by 1995. While most of the reductions were achieved prior to the company's commitment to the 33/50 Pro- gram, they have continued to significantly reduce releases since enrolling in the program, and are planning even further reductions by 1995. TV. SUMMARY OF ANCHOR FENCE'S EXPERIENCE Anchor Fence's participation in the 33/50 Program has been outstanding. The company has reduced its releases of TRI chemicals by 98% by 1993 from 1988 levels through a variety of pollu- tion prevention methods and activities. As a result, a reduction of over 120,000 pounds in TRI chemical releases has been achieved, and the company has exceeded its 1995 33/50 Program goal of a 93% reduction. As use of TRI chemicals has dropped below reporting thresholds, the company no longer reports to TRI. 33/50 Program Profile: Anchor Fence, Inc. ------- Table I Anchor Fence Company TR1 Releases and Transfers, 1988-1992 (All data from TRI unless otherwise noted) Chemical Methyl ethyl ketone (only chemical reported to TRI) Percent Change, 1988-1992 Year 1988 1989 1990 1991 1992(2) 1993(2) Total Air Emissions (pounds) 115,000 36,000 24,000 10,159 8,000 2,000 -93% Transfers Off-site for Treatment/ Disposal/Other (pounds) 6,000 0 2,200 0 NR NR Total Releases and Transfers (1) (pounds) 121,000 36,000 26,200 10,159 8,000 2,000 -93% Notes: (1) 1991 and 1992 Total Releases and Transfers do not include on- or off-site recycling or energy recovery. (2) Data from company progress report to the 33/50 Program. NR = not reported ------- |