6EPA
United States
Environmental Protection
Agency
Office of Pollution EPA 745-K-94-010
Prevention and Toxics '.. May 1994
7408
EPA's 33/50 Program
Company Profile
HADCO Corporation
Printed on Recycled Paper
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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 offsite 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 3 3/50 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: HADCO Corporation
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HADCO Corporation
HADCO achieved a 95% reduction company-
Vide in releases and transfers of 33/50 Program
chemicals from 1988 to 1992. This reduction repre-
sents nearly 2.2 million pounds of toxic chemicals.
In addition, according to company officials, further
reductions have been achieved since the 1992 TRI
filing, and overall reductions for HADCO now stand
at 99.5% as of the end of 1993. The company is
working to completely eliminate all releases and
transfers of 33/50 Program chemicals.
I. CORPORATE BACKGROUND
HADCO Corporation is a manufacturer of
custom printed circuit boards and backplanes for use
in electronic components. Approximately 60% of the
boards produced are used in computers, and an
additional 30% are used in telecommunications
equipment. The remaining 10% find end uses in
various types of instrumentation, principally in
medical devices and the automotive industry.
HADCO is headquartered in Salem, New Hamp-
shire, and operates six facilities. All these facilities
report releases and transfers of TRI chemicals, but
only Derry, NH and Owego, NY reported 33/50
chemical releases.
The company reported using four 33/50 Program
chemicals during the years 1988 to 1992:
dichloromethane, lead, methyl ethyl ketone, and
1,1,1-trichloroethane. Table I at the end of this
profile summarizes the company's TRI releases and
transfers for 1988 through 1992, while Table II
presents these data for selected facilities.
HADCO committed to a 98% reduction
in releases and transfers of 33/50 Pro-
gram chemicals between 1988 and 1995.
Printed circuit boards are manufactured in a
Complex, multi-step process. Circuit board cores,
containing up to 14 layers of "innerlayers," are pro-
duced using a dry film process described below, and
then laminated together. Next, holes are drilled in
the copper-coated plastic substrate board or the
inner layer core. The holes are then lined with
copper using a chemical plating process.
The circuit board pattern is applied to the
surface of each layer of the board by a technique
Releases and Transfers of TRI Chemicals
Reported by HADCO Corporation
(1000 Ibs)
33/50 Chemicals
Dichloromethane
Lead*
Methyl ethyl ketone
1,1,1 -Trichloroethane
33/50 Subtotal
Other TRI Chemicals
Total"
1988 1992
1,977
0
19
283
2,279
545
2,823
60
0
0
51
111
516
627
Lead is used in amounts usually below the reporting
threshold.
Columns do not sum to totals due to rounding.
called "Dry Film Processing." The boards are first
cleaned with a mineral acid solution prior to appli-
cation of the circuit board pattern. The clean
copper surface is then coated with a light-sensitive
polymer. When the circuit pattern is projected onto
the polymer-coated board, the polymer is cured onto
the areas where the copper will remain. The areas
of polymer not subjected to light are washed away
(previously with 1,1,1-trichloroethane). The bare
copper is then etched away, and the circuit pattern
is cleaned of residual polymer (previously using
dichloromethane).
An automated plating line is used to plate addi-
tional copper thickness onto the outer layer circuit
pattern, by reversing the circuit pattern exposure in
the dry film process. The exposed non-circuit film
is then stripped off the borad. On some products,
an electroplating process is used to deposit gold
connectors from a cyanide solution. Finally, tin-lead
solder is applied to component attachment points on
most boards.
II. 33/50 PROGRAM GOALS
HADCO is focusing its reduction efforts at its
two largest facilities - Derry, NH and Owego, NY -
which account for all of the company's total releases
and transfers of 33/50 program chemicals.
33/50 Program Company Profile: HADCO Corporation
-------
In May, 1991, HADCO announced its participa-
tion in the 33/50 Program and reported that the
Derry, NH facility had already achieved reductions in
releases of 33/50 Program chemicals greater than the
national goals for the program.
HADCO has installed a recovery system
to minimize air emissions of 33/50 pro-
gram solvents. This recovery system and
process chemistry substitution has re-
duced air emissions by more than
270,000 pounds over the State of New
Hampshire requirements.
In September of the same year, the company
expanded its participation to include goals for the
Owego, NY facility. The company committed to
reduce releases and transfers of 33/50 Program
chemicals at this facility by 141,400 pounds by 1995,
an 87% percent reduction from the 1988 TRI
baseline.
Incorporating HADCO's reductions at its Derry
facility, as well as the projected reductions at the
Owego facility, the company's 33/50 Program goal is
calculated to be a 98% reduction from 1988 levels by
1995.
III. FACILITY AND PROCESS LEVEL
POLLUTION REDUCTION ACTIVITIES
HADCO's reduction efforts and 33/50 Program
goals were achieved using substitution with less
hazardous or non-hazardous chemicals and, where
necessary, emissions control.
From July, 1989 through August, 1990 the
company implemented a $1.7 million process conver-
sion and emission control project at its Derry
facility. The project's goals were to eliminate use or
minimize air emissions of chemicals used in the
facility's manufacturing operations.
The cornerstone of the project was implemen-
tation of new aqueous-based chemicals in the clean-
ing and dry film processes. The dry film process was
modified to include carbonate based developers
instead of 1,1,1-trichloroethane, and hydroxide solu-
tions instead of dichloromethane. A screen cleaning
use of dichloromethane was also replaced with an
aqueous cleaning solution at the Owego, NH facility.
HADCO's conversion project has resulted in the
following source reduction of 33/50 Program chemi-
cals:
Significant reduction in dichloromethane
through conversion of six of the eight dry film
and cleaning processes to water based chemistry;
Elimination of 1,1,1-trichloroethane through
conversion of the cleaning and dry film pro-
cesses to water based chemistry; and,
Elimination of methyl ethyl ketone as an addi-
tive to dichloromethane in cleaning (its only use
at the facility).
Certain circuit board processes could not be
replaced with this new water-based technology,
however, because of user specifications, and still
required 33/50 Program solvents. To reduce emis-
sions of these chemicals, HADCO also installed a
dual-bed activated carbon adsorption recovery system
at its Derry, NH facility, which reduced remaining
emissions of the three 33/50 Program solvents by
over 99%.
HADCO achieved a 99.5% reduction in
releases and transfers of 33/50 Program
chemicals between 1988 and 1993. The
company is now working toward a 100%
reduction.
As an alternative to a recovery system, HADCO
replaced both 1,1,1-trichloroethane and
dichloromethane with a terpene solvent at its
Owego, NH facility.
The recovery system was installed to further
reduce air emissions. However, HADCO's process
conversion and emission control program achieved
significantly greater reductions than required by New
Hampshire Air Toxics Regulations (adopted April,
1990). HADCO's state permit for dichloromethane
allows emissions of no more than one pound per
hour; however, the company estimates that its emis-
sions level has been reduced to 0.3 pounds per hour.
In addition, the State law did not require control of
methyl ethyl ketone or 1,1,1-trichloroethane at the
33/50 Program Company Profile: HADCO Corporation
-------
Derry site. Thus, HADCO has reduced air emis-
sions by more than 270,000 pounds over the state re-
quirements.
The company has recently implemented similar
conversions and emission control at its Owego
facility. The facility eliminated the use of methyl
ethyl ketone in 1991; 1,1,1-trichloroethane in De-
cember, 1992; and dichloromethane in March, 1994.
IV. PROGRESS TOWARD 33/50
REDUCTION GOALS
HADCO's efforts in pollution prevention and
solvent recovery allowed the company to achieve its
33/50 Program goals two years ahead of schedule.
Company-wide releases and transfers of 33/50
Program chemicals decreased 95% between 1988 and
1992, reflecting a reduction of almost 2.2 million
pounds. In addition, according to company officials,
the company achieved additional reductions in 1993
that have brought its total reductions to 99.5%. The
following achievements have been recorded:
At the Derry, NH facility -
Total releases and transfers of 33/50 Program
chemicals have been reduced by more than 99%
from 1988 to 1992. Since 1990, the facility has
reported no releases and transfers of 1,1,1-trichlo-
roethane to TRI. The largest decrease in releases
and transfers, however, has been for
dichloromethane, a reduction of over 1.8 million
pounds between 1988 and 1992. Moreover, these
reductions were achieved during a period of in-
creasing production at the facility.
The overwhelming majority of the decrease in
dichloromethane was due to source reduction in the
form of substitution with aqueous-based chemicals.
In 1992, the Derry facility recovered over 300,000
pounds of dichloromethane in the adsorption recov-
ery system, of which only 1,800 pounds were sent
off-site for recycling (see Table III). The remainder
of the reductions are attributable to substitution.
At the Owego, NY facility
Total releases and transfers of 33/50 Program
chemicals decreased 40% between 1988 and 1992.
According to company officials however, releases
and transfers of 33/50 Program chemicals were
completely eliminated from the Owego facility in
March, 1994.
HADCO's Progress Toward
Meeting 33/50 Goals
3000
v> 2500
o
o
. 2000
(A
I
| 1500
o
ra
M
1000
8
&
500
D Non-33/50
Chemicals
33/50 Chemicals I
33/50
Goal
1988 1989 1990 1991 1992
33/50 Goal: 98% reduction in releases and
transfers of 33/50 chemicals by 1995
V. SUMMARY OF HADCO's
EXPERIENCE
HADCO's participation in the 33/50 Program
has fit nicely with the company's policy of actively
seeking to reduce the use and release of hazardous
chemicals. Company-wide releases and transfers of
33/50 Program chemicals decreased by 95% between
1988 and 1992, and decreased by 99.5% by the end
of 1993.
The company has replaced the majority of its
33/50 Program solvents with aqueous substitutes, and
plans to continue the process to achieve a complete
elimination of releases and transfers of 33/50 Pro-
gram chemicals. In addition, HADCO has installed
a solvent recovery system which goes beyond New
Hampshire's air toxics regulations, and will continue
to look for substitutes for its other hazardous chemi-
cals.
33/50 Program Company Profile: HADCO Corporation
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Table I
HADCO Corporation
TRI Releases and Transfers, 1988-1992
Chemical Year
Dichloromethane 1988
1989
1990
1991
1992
Lead 1989
Methyl ethyl ketone 1988
1989
1990
1991
1992
'1,1','i-trichioroethane 1988
1989
1990
" 1991
1992
33/50 Program Chemicals 1988
1989
1990
1991
1992
Non 33/50 Program 1988
Chemicals 1989
1990
: 1991
: 1992
All TRI Chemicals 1988
1989
1990
1991
: : 1992
Percent Change. 1988-1992
33/50 Program Chemicals
Non-33/50 Program Chemicals
All TRI Chemicals
Percent Change
Total Air Surface Water Transfers to Other Off-site Total Releases Total Releases
Emissions Discharges POTWs Transfers and Transfers (1) and Transfers
(pounds) (pounds) (pounds) (pounds) (pounds) 1988-1992
1 ,946,750
1,099,000
285,000
71,650
58,950
0
19,000
10,760
0
0
0
282,600
336,000
81,000
35,800
50,500
2,248,350
1,445,760
366,000
107,450
109,450
347,979
312,112
223,878
186,380
198,756
2,596,329
1,757,872
589,878
293,830
308,206
-95%
-43%
-88%
0
0
0
0
0
0
0
0
0
0
0
",
2
0
5
0
0
2
0
5
0
0
18,920
13,002
13,960
11,670
13,640
18,922
13,002
13,965
1 1 ,670
13,640
-100%
-28%
-28%
252
250
250
37
38
250
0
0
0
0
0
0
0
0
0
0
252
500
250
37
38
39,724
98,838
180,479
159,468
171,134
39,976
99,338
180,729
159,505
171,172
-85%
331%
328%
29,805
23,450
7,505
483
1,100
8,350
0
0
0
0
0
0
230
73
96
500
29,805
32,030
7,578
579
1,600
138,222
139,702
137,323
127,895
132,775
168,027
171,732
144,901
128,474
134,375
-95%
-4%
-20%
1,976,807
1,122,700
292,755
72,170
60,088
8,600
19,000
10,760
0
0
0
282,602
336,230
81,078
35,896
51,000
2,278,409
1,478,290
373,833
108,066
111,088
544,845
563,654
555,640
485,413
516,305
2,823,254
2,041,944
929,473
593,479
627,393
-95%
-5%
-78%
-97%
-100%
-100%
-82%
-95%
-5%
-78%
Notes: (1) 1991 and 1992 Total Releases and Transfers do not include on- or off-site recycling or energy recovery.
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Table II
HADCO Corporation
TRI Releases and Transfers at Selected Facilities, 1988-1992
Chemical
Year
Percent Change
Total Air Surface Water Transfers to Other Off-site Total Releases Total Releases
Emissions Discharges POTWs Transfers and Transfers (1) And Transfers
(pounds) (pounds) (pounds) (pounds) (pounds) 1988-1992
Derrv, NH Facility
Dichloromethane 1988
1989
1990
1991
1992
Lead 1989
Methyl ethyl ketone 1988
1989
1,1,1-Trichloroethane 1988
1989
1990
33/50 Program Chemicals 1988
1989
1990
1991
1992
Non-33/50 Program Chemicals 1988
1989
1990
1991
1992
All TRI Chemicals 1988
1989
1990
1991
1992
Owego. NY Facility
Dichloromethane 1988
1989
1990
1991
1992
1,860,000
1,011,000
221,000
18,750
14,750
0
19,000
10,760
231,000
297,000
41,000
2,110,000
1,318,760
262,000
18,750
14,750
208,379
143,762
105,950
72,645
70,584
2,318,379
1,462,522
367,950
91,395
85,334
86,750
88,000
64,000
52,900
44,200
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
250
250
250
37
38
250
0
0
0
0
0
250
500
250
37
38
14,500
36,500
138,770
139,020
147,690
14,750
37,000
139,020
139,057
147,728
2
0
0
0
0
7,805
3,200
0
303
350
8,350
0
0
0
230
55
7,805
11,780
55
303
350
74,250
63,863
73,755
69,624
52,887
82,055
75,643
73,810
69,927
53,237
22,000
20,250
7,505
180
750
1,868,055
1,014,450
221,250
19,090
15,138
8,600
19,000
10,760
23 1 ,000
297,230
41,055
2,118,055
1,331,040
262,305
19,090
15,138
297,129
244,125
318,475
281,289
271,161
2,415,184
1,575,165
580,780
300,379
286,299
108,752
108,250
71,505
53,080
44,950
-99%
-100%
-100%
-100%
-99%
-9%
-88%
-59%
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Table II
HADCO Corporation
TRI Releases and Transfers at Selected Facilities, 1988-1992
Chemical Year
1,1,1-Tricliloroethane 1988
1989
1990
": , ' "1991 -"
1992
33/50 Program Chemicals 1988
1989
1990
1991
1992
Non-33/50 Program Chemicals 1988
1989
1990
1991
1992
All TRI Chemicals 1988
1989
1990
1991
1992
Total Air ,
Emissions
(pounds)
51,600
39,000
40,000
35,800
50,500
138,350
127,000
104,000
88,700
94,700
120,200
'54,310
109,420
102,970
113,150
258,550
281,310
213,420
191,670
308,120
Surface Water
Discharges
(pounds)
"2
0
5
0
0
2
0
5
o
0
18,920
13,000
13,960
1 1 ,670
13,640
18,922
13,000
13,965
1 1 ,670
13,965
Transfers to <
POTWs
(pounds)
0
0
0
0
0
2
0
0
0
0
1,014
758
509
273
274
1,016
758
509
273
509
Other Off-site
Transfers a
(pounds)
0
0
18
96
500
22,000
20,250
7,523
276
1,250
33,792
57,293
47,969
43,264
65,575
55,792
77,543
55,492
43,540
56,742
: :1
Total Releases
nd Transfers (1)
(pounds)
51,602
39,000
40,023
35,896
51,000
160,354
147,250
111,528
88,976
95,950
173,926
225,361
171,858
158,177
192,639
334,280
372,611
283,386
247,153
379,336
Percent Change
Total Releases
And Transfers
1988-1992
:
-\%
40%
11%
13%
Notes: (1) 1991 and 1992 Total Releases and Transfers do not include on- or off-site recycling or energy recovery.
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Table III
HADCO Corporation
Pollution Prevention Act Reporting at Selected Facilities (1)
Chemical Year
Derry, NH Facility
Dichloromethane (only 1991
33/50 Program chemical) 1992
1994
Non-33/50 Program Chemicals 1991
1992
1994
All TRI Chemicals 1991
1992
1994
Recycled
On-site
(pounds) (2)
0
0
0
0
0
0
0
0
0
Recycled
Off-site
(pounds)
31,000
4,800
9,600
590,000
367,400
704,000
621,000
372,200
713,600
Energy
Recovery
Off-site
(pounds)
300
0
0
0
0
0
300
0
0
Treated
On-Sitc
(pounds)
0
0
0
403,000
469,000
470,000
403,000
469,000
470,000
Treated
Off-Site
(pounds)
62
390
350
34,450
22,751
31,900
34,512
23,141
32,250
Quantity
Released
(pounds)
18,000
15,000
8,800
242,950
248,050
246,050
260,950
263,050
254,850
Total
Production
Related
Wastes
(pounds)
49,362
20,190
18,750
1 ,270,400
1,107,201
1,451,950
1,319,762
1,127,391
1,470,700
Notes: (1) Actual data for 1991-1992; projections for 1994.
(2) Does not include recovered vapors reused in the process.
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