Uni«dSt«es EP A-600/R-94-00 7
nmentti Protection
*•*"" January 1994
Research and
Development
IMPROVED EQUIPMENT CLEANING
IN COATED AND LAMINATED
SUBSTRATE MANUFACTURING
FACILITIES (PHASE I)
Prepared for
Office of Pollution Prevention and Toxics
Prepared by
Air and Energy Engineering Research
Laboratory
Research Triangle Park NC 27711
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EPA-600/R-94-007
January 1994
IMPROVED EQUIPMENT CLEANING IN COATED AND LAMINATED
SUBSTRATE MANUFACTURING FACILITIES
(PHASE!)
By:
Beth W. McMinn and Jill B. Vitas
TRC Environmental Corporation
100 Europa Drive, Suite 150
Chapel Hill, North Carolina 27514
EPA Contract No. 68-D9-0173
Work Assignment No. 3/309
EPA Project Officer Michael Kosusko
Air and Energy Engineering Research Laboratory
Research Triangle Park, North Carolina 27711
. Prepared for
U.S. Environmental Protection Agency
Office of Research and Development
Washington, D.C. 20460
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ABSTRACT
The report gives results of a Phase I study to characterize current equipment cleaning
practices in the coated and laminated substrate manufacturing industry, to identify alternative
cleaning technologies, and to identify demonstrable technologies and estimate their emissions
impacts. It presents information from sources including literature searches, industry
questionnaires, plant visits, pollution prevention experts, and industry and trade association
personnel. (NOTE: Phase n activities will be the actual demonstration of selected alternative
technologies, and Phase El will be to transfer related technology by means of conference papers,
journal articles, and newsletters, prepared and presented at industrial workshops, pollution
prevention conferences, and other events where industrial application of pollution prevention
technologies is discussed.) Facilities within this industry tend to operate in one of two segments:
(1) large facilities operating coating lines dedicated to one type of product, such as masking tape
or label stock; or (2) batch processors or plants that manufacture comparatively small quantities
of a wide variety of high value-added products. Both segments of the industry use essentially
the same cleaning methods, even though the segments differ substantially in the range of
substrates, coatings, and application equipment used at the plants.
CH-93-100 U
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TABLE OF CONTENTS
Chapter Page
Abstract ii
List of Figures vii
List of Tables viii
Executive Summary , . ix
Metric Equivalents xi
1 INTRODUCTION AND BACKGROUND 1-1
1.1 PROJECT BACKGROUND 1-1
1.2 PROJECT OBJECTIVES 1-4
1.3 REPORT ORGANIZATION 1-5
1.4 REFERENCES 1-6
2 CURRENT MANUFACTURING AND CLEANING PRACTICES 2-1
2.1 GENERAL 2-1
2.2 INDUSTRY STRUCTURE 2-1
2.2.1 Introduction 2-1
2.22 Industry Market 2-1
2.3 RAW MATERIALS AND PRODUCTS 2-3
2.3.1 Introduction 2-3
2.3.2 Raw Materials 2-3
2.32.1 Substrates 2-3
2.32.2 Coatings 2-7
2.3.3 Finished Products and End-Uses 2-9
2.4 MANUFACTURING PROCESS DESCRIPTION 2-15
2.4.1 Introduction 2-15
2.42 Raw Material Mixing 2-15
2.4.3 Coating Application 2-16
2.4.3.1 Delivery of the Coating Supply 2-16
2.4.3.2 Metering of the Coating Supply 2-18
2.4.3.3 Transfer of the Coating to the Substrate 2-25
2.4.4 Drying/Curing 2-25
2.4.5 Rolling, Printing, Cutting, and Product Shipment 2-29
2.5 SPECIFIC PRODUCTION PROCESSES 2-32
2.5.1 Introduction 2-32
2.5.2 Paper Tape Manufacturing 2-32
2.5.3 Film Tape Manufacturing 2-33
2.5.4 Duct Tape Manufacturing 2-33
2.5.5 Reinforced Tape Manufacturing 2-35
2.5.6 Label Stock Manufacturing 2-35
2.6 CLEANING REQUIREMENTS 2-36
CH-93-100 111
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TABLE OF CONTENTS (Continued)
Chapter Page
2.6.1 Introduction 2-36
2.6.2 Cleaning Frequency and Desired Level of Cleanliness 2-36
2.6.3 Construction of Pan to be Cleaned 2-37
2.6.4 Soil to be Removed 2-38
2.7 CURRENT CLEANING TECHNIQUES 2-38
2.7.1 Specific Equipment Cleaning Requirements 2-39
2.7.1.1 Ovens 2-39
2.7.1.2 Reservoirs 2-39
2.7.1.3 Troughs 2-39
2.7.1.4 Pumps, Lines, and Hoses 2-39
2.7.1.5 Dams 2-40
2.7.1.6 Miscellaneous 2-40
2.7.2 Cleaning Techniques 2-40
2.7.2.1 Run Dry 2-40
2.7.2.2 Mechanical Scraping 2-40
2.72.3 Solvent Wiping 2-41
2.72.4 Immersion 2-41
2.72.5 Other 2-41
2.8 PROPERTIES OF CURRENT CLEANING SOLVENTS 2-42
2.8.1 Introduction 2-42
2.82 Toluene 2-42
2.8.3 Mineral Spirits 2-43
2.8.4 Methyl Chloroform 2-44
2.8.5 Methyl Ethyl Ketone (MEK) 2-45
2.8.6 Xylene 2-46
2.8.7 Other 2-47
2.9 CHARACTERIZATION OF POLLUTION RESULTING FROM
CURRENT PRACTICES 2-49
2.9.1 Air Emissions 2-49
2.92 Liquid Waste Streams 2-50
2.9.3 Solid Wastes 2-51
3 QUESTIONNAIRE RESULTS 3-1
3.1 GENERAL 3-1
32 DESCRIPTION OF ORIGINAL QUESTIONNAIRE 3-1
3.3 DESCRIPTION OF REVISED QUESTIONNAIRE 3-2
3.4 FINAL QUESTIONNAIRE SUMMARY AND CONCLUSIONS 3-3
3.4.1 Saturation Processes 3-17
CH-93-100 IV
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TABLE OF CONTENTS (Continued)
Chapter Page
3.4.2 Release Backing Processes 3-17
3.4.3 Adhesive Coating Processes 3-18
3.4.4 Other Processes 3-18
3.4.5 General Pollution Prevention Industry Trends 3-19
3.4.6 Conclusions 3-20
3.5 REFERENCES 3-20
4 POLLUTION PREVENTION ALTERNATIVES 4-1
4.1 GENERAL 4-1
4.2 CLEANUP AVOIDANCE 4-1
4.2.1 Job Scheduling/Production Campaigning 4-1
4.2.2 Run Dry 4-2
4.3 BEST PRACTICES 4-2
4.3.1 Storage of Cleaning Solvents 4-2
4.3.2 Use and Accessibility of Cleaning Materials 4-2
4.3.3 Mechanical Pre-Cleaning 4-3
4.3.4 Disposal of Spent Cleaning Materials 4-3
4.3.5 Centralization of Major Cleanup 4-4
4.4 RECYCLING OF SOLVENTS AND CLEANING MATERIALS 4-4
4.4.1 Solvent Recovery 4-4
4.4.2 Extension of Solvent Ufe/Countercurrcnt Rinsing 4-5
4.4.3 Cleaning Rags 4-5
4.5 ALTERNATIVE CLEANING MATERIALS 4-6
4.5.1 Mineral Spirits 4-6
4.5.2 Citrus Based Cleaners and Terpenes 4-6
4.5.3 Di-Basic Esters (DBEs) 4-6
4.6 EQUIPMENT MODIFICATIONS 4-7
4.6.1 Improved Shielding 4-7
4.6.2 Surface Coating 4-7
4.6.3 Surface Wrapping 4-8
4.6.4 Substrate Edge Guides 4-8
4.7 ULTRASONIC CLEANING 4-8
4.8 WATERBASED ADHESIVES 4-11
4.9 REFERENCES 4-11
5 SUMMARY AND EVALUATION OF DEMONSTRATION OPPORTUNITIES . . 5-1
5.1 GENERAL 5-1
52 TECHNOLOGY SELECTION CRITERIA 5-1
5.2.1 Potential Environmental Impact 5-1
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TABLE OF CONTENTS (Continued)
Chapter Page
5.22 Technology Cost 5-4
5.2.3 Applicability and Longevity 5-5
5.2.4 Availability 5-5
5.3 SITE SELECTION CRITERIA 5-5
5.3.1 Industry Segmentation 5-6
5.3.2 Resource Availability 5-7
5.3.3 Tuning 5-7
5.4 REFERENCES 5-8
APPENDIX A COATED AND LAMINATED SUBSTRATE INDUSTRIES WITH
ANNUAL SALES GREATER THAN $1 MILLION A-l
APPENDIX B COATED AND LAMINATED SUBSTRATE FACILITIES
AND ASSOCIATED TRIS EMISSIONS B-l
APPENDIX C TRIP REPORTS C-l
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LIST OF FIGURES
Number Page
1-1 EPA's Pollution Prevention Research Plan 1-3
2-1 Adhesive Mixing Process 2-17
2-2 Metering Roll Control of Coating Thickness 2-19
2-3 Blade-over-roll Coater 2-21
2-4 Coating Knives 2-21
2-5 Metering Rod Coater 2-22
2-6 Metering Rod 2-22
2-7 Dip and Squeeze Coater 2-23
2-8 Air Knife Coater 2-24
2-9 Direct Gravure Coater, Coating Reservoir Between the Roll and the Blade 2-24
2-10 A Schematic Diagram of a Direct Roll Coater 2-26
2-11 Offset Application Roll 2-26
2-12 Direct Application Roll 2-27
2-13 A Schematic Diagram of a Reverse Roll Coater 2-27
2-14 Floating Knife Coater 2-28
2-15 Two-Zoned Drying Oven 2-30
2-16 Coating Line with Exhaust Recirculation 2-31
2-17 Paper Tape Manufacturing Process Flow Diagram 2-34
4-1 Ultrasonic Cleaning System 4-10
CH-93-100 VU
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LIST OF TABLES
Number Page
2-1 1987 Distribution of 2641 Facilities Among 2671 and 2672 Facilities 2-2
2-2 Raw Materials Consumed in 1987 2-4
2-3 End-Uses of Adhesive Coated and laminated Films 2-6
2-4a SIC 2671 Product End-uses 2-10
2-4b SIC 2672 Product End-uses 2-12
2-5 Physical and Chemical Properties of Toluene 2-43
2-6 Physical Properties of Varsol 2-44
2-7 Physical and Chemical Properties of Methyl Chloroform 2-45
2-8 Physical and Chemical Properties of Methyl Ethyl Ketone 2-46
2-9 Physical and Chemical Properties of Mixed Xylenes 2-47
2-10 Physical Properties of Perchloroethylene 2-48
2-11 Physical Properties of Heptane 2-48
2-12 Physical Properties of Isopropyl Alcohol 2-49
3-1 Questionnaire Respondent Profiles 3-4
3-2 Process Profile 3-5
3-3a Saturation Process Equipment Cleaning 3-9
3-3b Release Process Equipment Cleaning 3-10
3-3c Adhesive Process Equipment Cleaning 3-12
3-3d Other Process Equipment Cleaning 3-14
3-4 General Pollution Prevention Research 3-15
5-1 Technology Selection Criteria 5-2
A-l Coated Paper, Packaging Facilities (SIC 2671) With 1992
Annual Sales Greater Than $1 Million A-2
A-2 Coated and Laminated Paper, NEC Facilities (SIC 2672) With
1992 Annual Sales Greater Than $1 Million A-4
B-l SIC 2671 - Coated Paper, Packaging B-2
B-2 SIC 2672 - Coated and Laminated Paper, NEC B-4
B-3 Miscellaneous Coated and Laminated Substrate
Manufacturing Facilities B-7
CH-9J-100 Vlll
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EXECUTIVE SUMMARY
As a result of the Pollution Prevention Act of 1990, the Environmental Protection Agency
(EPA) established the 33/50 Program which calls for voluntary industry emissions reductions of
17 high-priority toxic chemicals. The goal of this program is to reduce the total amount of these
chemicals released into the environment and transferred off-site by 33 percent by the end of 1992
and by 50 percent by the end of 1995.
In support of the 33/50 Program, EPA's Air and Energy Engineering Research Laboratory
(AEERL) is investigating ways to reduce air emissions of these 17 chemicals through pollution
prevention in selected industry segments. Two criteria were used to select industrial categories
for study: annual toxics emissions and the potential for pollution prevention opportunities. First,
the Toxic Release Inventory System (TRIS) was reviewed to identify categories with the greatest
mass emissions of the 33/50 chemicals. Categories with the greatest emissions were then Tanked
according to the potential for successful pollution prevention projects.
One of the key industries identified through this process was the coated and laminated
substrate manufacturing industry. This industry is the number one source of methyl ethyl ketone
(MEK) and the number three source of the toluene releases in TRIS. Both toluene and MEK are
33/50 chemicals. With the assistance of the Pressure Sensitive Tape Council (PSTQ, the Tag
and Label Manufacturers Institute (TLMI), industry personnel, and TRC Environmental
Corporation (TRC), AEERL is conducting a three-phased effort to investigate in detail the
pollution prevention options for process equipment cleaning associated with the coated and
laminated substrate industry.
Through the use of an industrial questionnaire and the results of an extensive literature
search, this industry was characterized, and alternative cleaning technologies were identified. In
addition, seven site visits were conducted to better understand the manufacturing process, current
cleaning technologies, and to identify possible demonstrable technologies that will be the basis
for the demonstration phase (Phase IT) of this project The results of these Phase I activities are
discussed in this document
CH-93-100 IX
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Facilities within the coated and laminated substrate manufacturing industry tend to operate
in one of two segments. One segment consists of large facilities operating coating lines dedicated
to one type of product such as masking tape or label stock. The other segment consists of batch
processors or plants that manufacture comparatively small batches of a wide variety of high
value-added products.
Both segments of the coated and laminated substrate manufacturing industry use
essentially the same cleaning methods, even though the segments differ substantially in the range
of substrates, coatings, and application equipment used at the plants. The solvents required to
clean equipment in a coated and laminated substrate manufacturing facility are, in large part,
determined by the resin in the coating formulation.
AEERL plans to conduct demonstrations in facilities that represent the two industry
segments. The first demonstration facility will be a facility operating lines dedicated to one
product type. The focuses at this facility would be the implementation and evaluation of a
cleaning solvent substitute, improved operating practices, and process modifications such as
Teflon coated rollers. AEERL has discovered through their contacts with industry personnel that
some "dedicated line" facilities are pursuing these options while others are not The focus at the
second type of facility, the batch processor, would be geared toward improving the efficiency of
cleaning operations. AEERL has found that the nature of the batch processing business requires
a high degree of cleaning between jobs and mat this cleaning often takes place much more
frequently than does cleaning at dedicated line facilities. The objective at the batch processing
would be to calculate the optimum amount of cleaning solution necessary to achieve the required
degree of cleanliness. A second objective at this facility would be to identify the optimum
method of administering the cleaning solution. The details and the results of both of the facility
studies would be documented in a final report It is intended that the case studies described in
the final report will assist not only the dedicated line facilities and the batch processors, but also
those facilities that have characteristics of each. In a subsequent report, AEERL will describe
demonstration activities and results.
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METRIC EQUIVALENTS
Certain non-metric units are used in this document for the reader's convenience. Readers
more familiar with metric units may use the following equivalents to convert to that system.
Non-metric Multiplied bv Yields Metric
atm 101 kPa
gal. 0.00379 m3
Ib 0.454 kg
ton 907 kg
yd2 0.836 m2
CH-93-100 XI
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CHAPTER 1
INTRODUCTION AND BACKGROUND
1.1 PROJECT BACKGROUND
As a result of the Pollution Prevention Act of 1990, the Environmental Protection Agency
(EPA) established the 33/50 Program which calls for voluntary industry reductions in releases
of the following 17 high-priority toxic chemicals which are listed by mass of emissions.
Toluene Trichloroethylene
Xylenes Methyl Isobutyl Ketone
1,1,1-Trichloroethane Tetrachloroethylene
Dichloromethane Benzene
Methyl Ethyl Ketone Chloroform
Chromium and Compounds Nickel and Compounds
Lead and Compounds Cyanide and Compounds
Cadmium and Compounds Mercury and Compounds
Carbon Tetrachloride
The goal of the 33/50 program is to reduce the total amount of these chemicals released into the
environment and transferred off-site by 33 percent by the end of 1992 and by 50 percent by the
end of 1995. These reductions will be based upon the Toxic Release Inventory System (TRIS),
with 1988 as the base year.1
In support of the 33/50 Program and the Agency's pollution prevention goals, EPA's Air
and Energy Engineering Research Laboratory (AEERL) is investigating ways to reduce air
emissions of these 17 chemicals through pollution prevention. The Pollution Prevention Act of
1990 defines pollution prevention as "any practice which reduces the amount of any hazardous
substance, pollutant, or contaminant entering the waste stream or otherwise released to the
environment (including fugitive emissions) prior to recycling, treatment, or disposal; and reduces
the hazards to public health and the environment associated with the release of such substances,
pollutants, or contaminants."2 Pollution prevention efforts offer economic and reduced health and
ecological risk benefits to many sectors of society that are not available through traditional
pollution control methods.
CH-9MOO 1-1
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In 1991, AEERL representatives met with industry, academia, and State environmental
agency representatives to identify several source categories deserving of pollution prevention
research. Two criteria were used to select the industrial categories for study: annual toxics
emissions and the potential for pollution prevention opportunities. First, the TRIS was reviewed
to identify categories with the greatest mass emissions of the 33/50 chemicals. Categories with
the greatest emissions were then ranked according to the potential for successful pollution
prevention projects resulting in significant reductions of 33/50 chemical releases. One of the
industries identified during the 1991 meeting was the adhesives-coated and laminated paper
manufacturing industry [Standard Industrial Classification (SIC) 2672]. This industry was chosen
because of significant air emissions of 33/50 Program chemicals methyl ethyl ketone (MEK) and
toluene as reported through the TRIS.
In October of 1991, a Focus Group Meeting was held between AEERL, pollution
prevention experts, and representatives of the adhesives-coated and laminated paper
manufacturing industry to discuss specific pollution prevention projects that would support the
33/50 Program. Meeting participants indicated that emissions of toluene and MEK from
equipment cleaning operations are second only to emissions from the coatings and coating
application steps, and, therefore, would present a good opportunity for the implementation of
pollution prevention techniques. As a result of this meeting and preliminary industry inquiries,
the scope of the industry investigation was later expanded to include other coating and substrate
varieties (such as those included in SIC 2671 -Coated and Laminated Packaging Paper and Plastics
Film) because the manufacturing methods and cleaning processes are similar, therefore,
technology transfer is possible over a wider range of industries. Figure 1-1 illustrates how the
equipment cleaning research project fulfills pan of EPA's goal to stimulate the development and
use of products and processes that result in reduced pollution.3
CH-95-100 1-2
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9
*
8
INFORMATION NEEDS
EPA
ssessment methods
;ts.
,._„_.—jstrtutes
Trends in product-use patterns
Voduct i
Jew.prpduc
'roducfsuf
INDUSTRY
Product substitutes
New products
Product applicability
OTHER AGENCIES
New products
Product assessment methods
CONSUMERS
New products
Product substitutes
±
RESEARCH GOALS
1) Stimulate the development and
use of products that result In
reduced pollution
2) Stimulate development and
Implementation of technologies
and processes...
3) Expand reusability. recydablllty, and demand...
4) Identify and promote non-technological
approaches...
5) Conduct technology transfer and technical
assistance...
6} Identify and address future
environmental problems...
OBJECTIVES
PRODUCT RESEARCH PROGRAM
Establish standard methods
Evaluate products
Facilitate product development
Demonstrate production and use
PROCESS RESEARCH PROGRAM
Establish standard methods
Conduct pollution prevention opportunity assessments
Identify, demonstrate, and
evaluate process techniques
Identify opportunities for
technology transfer
RESEARCH
TOPIC
AREA
Identify improved equipment
cleaning methods
SPECIFIC RESEARCH PROJECT
Improved Equipment Cleaning In Coated and
Laminated Substrate Manufacturing Facilities (Phase I)
1) Characterize Industry
2) Identify current cleaning technologies
3) Identify alternative cleaning technologies
4) Compile technical guidance on use of water-based coating systems
Figure 1-1. EPA's Pollution Prevention Research Plan.
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1.2 PROJECT OBJECTIVES
This report presents the results of a Phase I study to characterize current equipment
cleaning practices in the coated and laminated substrate manufacturing industry, to identify
alternative cleaning technologies, and to identify demonstrable technologies and estimate their
emissions impacts. In order to successfully accomplish these objectives, information was
collected from several sources including literature searches, industry questionnaires, plant visits,
pollution prevention experts, and industry and trade association personnel
Literature searches of the EPA on-line databases, local university library databases, and
Dialog* were conducted. The Pollution Prevention Information Clearinghouse (PPIQ and the
Pollution Prevention Information Exchange System (PIES) were accessed on a biweekly basis.
The E-Mail capabilities of PEES were also used to communicate with other PIES users with
knowledge of the coated and laminated substrate manufacturing industry.
The second source of project background information was data retrieved through industry
questionnaires. Two separate questionnaires were distributed, under a previous EPA contract, to
14 adhesive-coated and laminated paper manufacturers, primarily pressure sensitive tape
manufacturers and tag and label manufacturers. A separate questionnaire was prepared for
manufacturers operating under either SIC 2672 or SIC 2641 (Paper Coating and Glazing)
depending on their SIC. Neither questionnaire was sent to more than 8 manufacturers. The
results of the questionnaires were clarified through follow-up contacts with the recipients and
through revised questionnaires. Over 30 additional facilities (i.e., not recipients of the original
questionnaires) were contacted for further information on equipment cleaning practices. The
second group of facilities contacted were representative of the expanded scope of the research
project, and consisted of facilities involved in the coating and laminating of flexible substrates
(SIC 2671) as well as those included in SIC 2672.
In addition to conducting literature searches and distributing two industry questionnaires,
contacts were made with industry and pollution prevention experts with the Massachusetts Office
of Technology Assistance (OTA), the North Carolina Office of Waste Reduction (OWR), the
Pressure Sensitive Tape Council (PSTQ, the Tag and Label Manufacturers Institute (TLMI), and
equipment manufacturing firms.
CH-93-100 1-4
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The final source of project and industry information was compiled during a total of seven
site visits. Two of these site visits were conducted under a previous EPA effort The trip reports
and associated data for these facilities were combined with the information resulting from the
additional five trips. Together, these information gathering efforts provided the background
needed to accurately describe the coated and laminated substrate manufacturing industry, to
evaluate the range of equipment cleaning methods used in the industry, to identify demonstrable
technologies, and to form the foundation for future Phase n and lit efforts of this project
Phase n activities will begin upon the completion of Phase I. Phase n of the project will
be the actual demonstration of selected alternative technologies. This phase will quantify air
emissions and other media wastes, record production parameters, and make other observations
and measurements necessary to assess the impacts of the alternative technology. The
demonstration project will include a training component focused on the production personnel at
the demonstration site to teach any skills or modified techniques that are required to properly
implement the alternative technology. Phase n will also involve summarizing the results of the
demonstration.
The final phase of the project (Phase HI) is to conduct technology transfer. Focused
documents such as conference papers, journal articles, and newsletters will be prepared and
presented at industrial workshops, pollution prevention conferences, and other events where
industrial application of pollution prevention technologies is discussed. Trade associations and
contacts made during Phases I and n will be targeted audiences and vehicles used for technology
transfer. PPIC, the National Roundtable of State Pollution Prevention Programs, and other groups
focused on pollution prevention will also be used
13 REPORT ORGANIZATION
This report is divided into five chapters and three appendices. Chapter 2 identifies and
describes current manufacturing and cleaning practices. It includes an overview of the industry's
use of raw materials, coating application equipment, current cleaning techniques, current cleaning
solvents, and resulting waste streams.
Chapter 3 describes the evolution of the industry questionnaires and the methodology by
which the recipients were selected. Chapter 3 also presents a summary of efforts to compile and
CB-W-100 1-5
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tabulate the questionnaires' results. This chapter identifies current industry trends in coating
formulations, current trends in equipment cleaning methodologies and technologies, and
opportunities for pollution prevention research as indicated by the questionnaire respondents.
Chapter 4 discusses some of the pollution prevention alternatives to currently used
equipment cleaning techniques and materials. This chapter also briefly identifies some of the
opportunities for retrofitting current processing equipment to allow for the use of waterbased
coatings.
The last chapter (Chapter 5) presents a summary and evaluation of pollution prevention
demonstration opportunities. Appendix A lists coated and laminated substrate facilities with
annual sales greater than one million dollars. Appendix B lists SIC 2671 and 2672 facilities and
their associated emissions as they appear in the TRIS. Appendix C contains copies of the seven
trip reports conducted under this and the previous EPA-led effort to investigate and identify the
improved equipment cleaning methods for the coated and laminated substrate manufacturing
industry.
1.4 REFERENCES
1. U.S. Environmental Protection Agency. Pollution Prevention Fact Sheet: EPA's 33150
Program. Office of Pollution Prevention, Washington, DC. August 1991.
2. Pollution Prevention Act of 1990, 42 U.S.C. §13101, et seq.
3. U.S. Environmental Protection Agency. Pollution Prevention Research Plan: Report to
Congress, EPA-600/9-90-015. Office of Research and Development, Washington, DC.
March 1990.
CH-93-100 1-6
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CHAPTER 2
CURRENT MANUFACTURING AND CLEANING PRACTICES
2.1 GENERAL
This chapter provides an overview of the coated and laminated substrate manufacturing
industries. The chapter is divided into eight sections: (1) Industry Structure, (2) Raw Materials
and Products, (3) Manufacturing Process Description, (4) Specific Production Processes, (5)
Cleaning Requirements, (6) Current Cleaning Techniques, (7) Properties of Current Cleaning
Solvents, and (8) Pollution Characterization. The industry structure section addresses the current
market, materials used in the manufacturing process, products manufactured, and product end-
uses. The manufacturing process section describes the various elements of the manufacturing
process with emphasis on equipment and procedure. Current cleaning techniques and cleaning
materials are discussed in relation to the manufacturing processes. The last section characterizes
the air emissions and liquid and solid waste streams that result from current industry
manufacturing practices.
2.2 INDUSTRY STRUCTURE
2.2.1 Introduction
This section gives an overview of the coated and laminated substrate manufacturing
industry, including geographic distributions, production trends, industry issues, and the major
subdivisions within the industry. Much data are based on SICs 2671 and 2672.
122 Industry Market
The coated and laminated substrate industry, as defined by SIC 2671 and 2672, consists
of firms that manufacture coated or flexible materials made of combinations of paper, plastic
films, metal foils, and similar materials for packaging (SIC 2671) and other purposes, including
pressure sensitive tapes (SIC 2672). Some facilities continue to report SIC 2641, Paper Coating
CH-93-100
2-1
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and Glazing, as their primary SIC even though SIC 2641 was discontinued in 1972. (During the
information gathering phases of this project, several of these facilities were identified and
contacted through a questionnaire.) In 1972, SIC 2641 was split into 2671 and 2672.1-2
(Facilities operating under these SICs were contacted through separate questionnaires.) Because
the current SICs are 2671 and 2672, this discussion will focus on these two classifications.
However, Table 2-1 summarizes the effect of the SIC revisions on the industry and the
corresponding employment data.
According to the 1987 Census of Manufactures, SIC 2671 employed 15,000 people in 21
states, and SIC 2672 employed nearly 31,000 people in 23 states. The leading states in
employment of 2671 personnel, accounting for 42 percent of the industry's employment, were
Wisconsin, Indiana, Pennsylvania, and Illinois. Similarly, Massachusetts, Ohio, Illinois, and
Pennsylvania accounted for 38 percent of SIC 2672's employment. Over 93 percent of SIC 2671
and 55 percent of SIC 2672 plants are small facilities employing less than 20 people.2 These
smaller facilities often provide a highly customized product line marketed within a small
geographic region. Some of the larger companies, however, own multiple manufacturing
facilities and distribute products nationwide.
TABLE 2-1. 1987 DISTRIBUTION OF SIC 2641
FACILITIES AMONG SIC 2671 AND SIC
2672 FACILITIES
Industry
No. of Cost of
No. of No. of Employees Materials
Facilities Companies (thousands) (million $)
Value of New
Shipments Expenditures
(million $) (million $)
Old Industry SIC 2641, 532 439
Paper Coating and
Glazing
New Industry SIC 2671, 120 89
Paper Coated and
Laminated, Packaging
New Industry SIC 2672, 412 362
Paper Coated and
Laminated, NJE.C.
455 4,476.5 8307.7 329.6
15.0 1,442.0 2,416.0 1283
30.9 3,034.5 5,891.7 2013
Source: Reference 2
NEC - Not Elsewhere Classified
CH-9MOO
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2.3 RAW MATERIALS AND PRODUCTS
2 J.I Introduction
The products manufactured by the coated and laminated substrate industry are used in a
variety of applications. Generally, these produces can be categorized as being either tapes, labels,
or miscellaneous products. Each of these product types is composed of some combination of
backings and coatings which can be described in terms of its construction or function. The
product backings often designate construction. In the case of pressure-sensitive adhesive (PSA)
products, which constitute a large portion of the industry, the adhesive may be the defining
component The other method of subdivision is functional use. End-use product categories
include hospital and first aid products, office and graphic arts products, packaging and surface
protection products, building industry materials, electrical products, and automotive industry
products. This section includes information relating to raw materials, finished products, and
product end-uses.
232 Raw Materials
The raw materials used in the coated and laminated substrate manufacturing process consist
of substrates, adhesives and other coatings, and cleaning materials. Commonly used raw
materials in both SIC 2671 and SIC 2672 facilities are listed in Table 2-2.
232.1 Substrates
A substrate (backing) is the material to which an adhesive is applied to make the desired
product Substrates are supplied to the manufacturer in large, continuous rolls called webs.
Substrates provide strength, protection, and/or a colored surface for the adhesive. Substrate
categories include paper, film, fabric, foil, and foam. Paper and film are the two most frequently
used backing materials.2*3
Paper is the most common and one of the least expensive web materials available, however,
at least one facility considers raw paper its most expensive production raw material, ranging in
cost from $0.50 to $0.75 per pound, depending on the paper grade and specification.3'4 Paper
CH-93-100 2-3
-------
TABLE 2-2. RAW MATERIALS CONSUMED IN 1987
Material
Quantity
INDUSTRY 2671, PAPER COATED AND LAMINATED, PACKAGING
Primary Materials, parts, containers, and supplies
Paper
Glues and adhesives
Plastics resins consumed in the form of granules, pellets,
powders, liquids, etc.
Plastics, products consumed in the form of sheets, rods, tubes,
and other shapes
Printing ink (complete formulations)
Petroleum wax
Paperboard containers, boxes, and corrugated paperboard
Aluminum foil:
Plain
Converted
INDUSTRY 2672, PAPER COATED AND LAMINATED, NJE.C.
Primary Materials, parts, containers, and supplies
Paper
Glues and adhesives
Plastics resins consumed in the form of granules, pellets,
powders, liquids, etc.
Plastics, products consumed in the form of sheets, rods, tubes, and other shapes
Printing ink (complete formulations)
Petroleum wax
Paperboard containers, boxes, and corrugated paperboard
Aluminum foil:
Plain
Converted
926 million Ib
NA
520.9 million Ib
NA
NA
30.1 million Ib
NA
25.9 million Ib
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
Source: Reference 2
NA = Not Available
NJLC. = Not Elsewhere Classified
CH-93-100
2-4
-------
substrates may be either coated with a saturant (i.e., saturated) or uncoated (i.e., unsaturated).
Saturated paper backings include flatback paper (which is smooth) and creped paper (which has
small "folds" giving it high stretching properties). Unsaturated kraft papers'have also been
developed within the last twenty years. This substrate variety is common in the United States,
and is used extensively in Japan. Additional paper substrates are classified as specialty papers
and include rope fiber paper which has a high tensile strength and nylon paper tape which has
increased temperature resistance in electrical applications.3
One common use of paper substrates is the manufacture of masking tapes. Masking tapes
were first used in the automotive industry for painting applications in which the tape, or maskant,
had to be resistant to elevated temperatures for long periods of time. New applications for
masking tapes quickly developed, to include general-purpose masking tapes which serve a variety
of household needs.3
Polymeric film substrates include cellophane, acetates, polyester, vinyl, polypropylene, and
polyethylene. These polymeric films have many properties (e.g., impermeability, thinness,
smooth surface, good dielectric properties, and chemical inertness) which make them desirable
in a variety of applications including packaging, and electrical and pipe wrapping. The cost of
film substrates is currently declining, consequently films are competing more in traditional paper
markets.3
Cellophane tape, the oldest transparent film tape, is used widely in office and general-
purpose household applications. Because cellophane is hygroscopic and becomes brittle when
dry and soft when humid, it is being replaced by other films (such as acetates) in certain
applications despite the higher cost of the replacement films.3
End-uses of some of the common film tapes are presented in Table 2-3. Polyester films
are used in electrical applications requiring high tensile strength and high tear resistance.
Polyethylene films are often used in high volume applications, because of the film's low cost
Tetrafluoroethylene (TFE) film, one of the most expensive of the film substrates, imparts high
dimensional stability, resistance to elevated temperatures (482°F/250°C), chemical inertness, and
a low coefficient of friction.3
A third substrate category used in coating and laminating applications is foil. Foils are
typically aluminum, lead, or copper, with aluminum used most frequently. Aluminum backings
create a moisture seal and are often used in electrical applications, in heating and air conditioning
CH-9MOO 2-5
-------
TABLE 2-3. END-USES OF ADHESIVE COATED AND LAMINATED FILMS
Tape Type
End-Use
Plasticized vinyl film
Rigid vinyl film
Polyester film
Polypropylene film
Colored vinyl film
Polyethylene film
Tetrafluoroethylene (TFE) film
Polyimide film
Electrical insulation applications
Protection of electroplating racks
Maskant of metal surfaces to be plated
Can sealer
Protection of metal window frames
Corrosion resistance for underground pipes
Printable label tapes
Packaging
General purpose
Packaging
Electrical applications
Packaging
Identification
Floor markings
Medical tapes
Electrical insulating
Duct insulating
Carpeting
Corrosion protection for underground gas and oil lines
Coil winding
Transformers
Cables
Relays
Condensers
Resisters
Dry film lubricants
Electrical applications
Flat cable construction
Masking in soldering operations
Source: Reference 3, 5
CH-93-100
2-6
-------
insulation ducts as a reflective heat shield, in high temperature masking operations (e.g., printed
circuit board manufacture), in repairing sheet metal, and in blocking radiation on X-ray plates.
Aluminum laminated to cloth or foam provides vibrational and acoustical damping. Lead foils
are used for their resistance to the chemicals in plating operations, in acoustical damping
applications, and in radiation shielding.
Foam substrates include polyethylene, vinyl, urethane, and polychloroprene. The structure
of a foam backing imparts many unique characteristics including the ability to conform to uneven
surfaces and to distribute force loads to prevent stress concentration and ultimate product failure.
Law density foam substrates are used for sealing and gasketing, while foam/foil and foam/film
laminates are used for thermal and acoustical insulations. Two-sided adhesive-coated foam
products are used to mount a wide variety of objects including vehicle reflectors and balancing
weights, bathroom fixtures to walls, medallions to wine and liquor bottles, and electrocardiogram
terminals to patients.3 Fabric tapes offer a backing with both high tensile strength and high
flexibility. Low tear strength may also be incorporated with no loss of tensile strength. Medical
tapes and duct tapes are made with fabric backings.
2 JJ J Coatings
The various coatings applied, along with the type of substrate, define the end-use of a
coated and laminated product Coatings typically consist of solvents, resins, and additives, with
the composition varying depending on the desired characteristics. The fluid portion of the
coating is referred to as the vehicle. Vehicles maintain a coating in liquid form for easy
application. Once a coating is deposited on a substrate, the vehicle solvents should evaporate
completely. Vehicles transfer the solid portion of the coating to the substrate surface in a
uniform layer and typically play no role in film formation. Some commonly used coatings
include saturants, release coats, tie coats, and adhesives. Not all coated and laminated products
incorporate all of these coatings. For example, saturants are used primarily with paper substrates,
while tie coats are used mainly with film products. A brief discussion of each type of coating
follows.
Saturants are mixtures applied to raw paper to improve the paper's internal strength and
resistance to various environments. The backing of paper tape, for example, may contain as
much as 50 percent saturant by weight6 The two types of saturants used are solvent-based and
CH-93-100 2-7
-------
waterbased. Saturants are used to reduce the amount of loose fibers extending from the surface
of a paper web. They also impart strength to the web once dried. Solvent-based saturants orient
all the fibers uniformly and provide better water resistance than the waterbased coating; however,
they do not strengthen the web as much as waterbased saturants. Natural rubber and styrene-
butadiene rubber (SBR) are the preferred polymers for solvent-based saturants. Other saturant
raw materials include polyurethanes, toluene, polyether blends, and hydrocarbon resins. Although
pollution problems and high costs of solvents make waterbased saturants more attractive, solvents
arc necessary for the manufacture of electrical paper tapes because of the high performance
characteristics currently offered only by solvent-based saturants.3
Waterbased saturants or latexes are used more often than solvent-based saturants for tape
backing. Waterbased latexes are easier to use than solvent-based saturants, which must be broken
down and compounded to dissolve the rubber. Several synthetic latexes used in the waterbased
saturants are SBR, acrylics, and carboxylated SBR. Acrylics provide excellent saturation, have
a light color, and are heat and light stable. Other waterbased coatings are available but not used
as frequently as the ones previously mentioned.
Release coatings are applied to the substrate backing on the side opposite of the adhesive.
The release coat allows rolled adhesive products to be unwound, prevents tearing, and provides
resistance to fluids.6 A release coat or "backsizing" contains release material, liquid resins, and
solvents such as silicone solution, isopropyl alcohol, and toluene.3'7 The release coat should
provide an adequate and consistent release, the release agent should not transfer to the adhesive
surface, and aging should not effect the ability to unwind the tape. Polymer coatings, waxes,
silicones, and chained polymers are used in release coatings. Polymers are used to prevent the
adhesive from penetrating into the backing. Waxes are added to polymer coatings to improve
the slip, blocking resistance, and release of the coating.
Tie coats or primers are coatings applied between natural rubber adhesives and film
substrates to improve the bond between the adhesive and the film. Primers may be a mixture
of creep rubber, diphenylmethane diisocyanate, and toluene or blends of SBR, with and without
resins.3'5
Adhesive is applied to the saturated/backsized substrate. The adhesive product may contain
petroleum resins, solvents, natural and synthetic rubber, antioxidant, and filler.6 Adhesives are
required to have three main properties: peel adhesion, cohesive holding power, and surface tack.
Cfl-95-100 2-8
-------
Natural rubber has a low tack and adhesion to surfaces. Therefore, tackifying resins must be
added to natural rubber-based adhesives. Wood rosin and its derivatives, terpene resins, and
petroleum-based resins arc the main resins used with natural rubber. Other adhesive products
include block copolymers; thermoplastic rubbers including polyethylene or polybutylene; butyl
rubber, a copolymer of isobutylene with a minor amount of isoprcne; polyisobutylene, a
homopolymer, acrylic polymers; vinyl ether polymers; and, silicon adhesive which is both a gum
and a resin. Facilities have a wide variety of choices for raw material inputs for adhesive
mixing.
2.33 Finished Products and End-Uses
A summary of coated and laminated substrate product end-uses is included in Tables 2-4a
and 2~4b. In 1987, the value of all product shipments for SIC 2671 was $2.4 billion and the
value of all product shipments for SIC 2672 was $5.9 billion.2 Wartf s Business Directory lists
43 SIC 2671 facilities and 81 SIC 2672 facilities with 1992 sales greater than one million dollars.
These lists are provided in Appendix A, Table A-l (SIC 2671) and Table A-2 (SIC 2672).8
There are several types of products manufactured by coated and laminated substrate
manufacturers. Two of the largest product categories are tapes and labels. Classes of tape,
identified by construction, include woven and nonwoven fabric tape, paper tape, film tape, foil
tape, and foam tapes. Some of the web materials mentioned previously are used in combination
with glass, rayon, nylon, polyester, or acetate fibers to produce reinforced substrates. Films such
as polyethylene, polyester, or polypropylene are often combined with these fibers to produce
tapes used in heavy-duty packing and bundling applications. The type and number of reinforcing
strands per area, the thickness of the coating applied, and the type of film used differentiate the
grades and types of film tape.3*5 Two-faced tapes are substrates with an adhesive coating applied
on both sides of the substrate (usually foam or film). Two-faced tapes have both heavy-duty uses
(e.g., carpet tapes and securing plates to a printing cylinder) and light-duty uses (e.g., business
forms and nametags).
CH-93-100 2-9
-------
TABLE 2-4a. SIC 2671 PRODUCT END-USES
1987 Product Shipments
1987
Product
Code
2671- -
26711-
26711 11
26711 15
2671100
26712-
26712 11
26712 12
2671200
26713-
26713 13
26713 14
26713 18
26713 21
2671300
26714-
26714 11
Product
No. of
Companies
with Ship-
ments of
$100,000 or
More
Quantity
Value
(millions)
PAPER COATING AND LAMINATING,
PACKAGING
Total
Single-web paper (coated rolls and
waxed) for packaging uses
Plastics-coated
Other
sheets, including
. . . 1,000's tons
do
Single-web paper, coated rolls and sheets, including
waxed, for packaging uses, n.sJc.
Single-web film (coated rolls and sheets, including
coextruded) for packaging uses
Single-web film, coated ' nno's tm*
Coextruded film
do
Single-web film, coated rolls and sheets, including
coextruded, for packaging uses, n.sJc.
Paper/paper mnltiweb laminations for packaging
uses
Polyethylene laminations:
Coated , , , , . , ..,..,,,,
Uncoated
Other laminations:
Coated
Uncoated
Paper/paper multiweb laminations, for
o&k.
. . . 1,000's tons
do
. . . 1,000's tons
do
packaging uses,
Multiweb laminated rolls and sheets, except
paper/paper and foil, for packaging uses
Film/paper multiweb laminations ... l -OOO's tons
(NA)
(NA)
26
34
(NA)
(NA)
54
20
(NA)
(NA)
12
6
9
10
(NA)
(NA)
15
(X)
(X)
912
156.1
(X)
(X)
197.4
110.7
(X)
(X)
(S)
44.8
7.5
62.4
(X)
(X)
31.0
2,460.1
474.4
168.5
285.1
20.7
879.1
483.4
343.1
52^
249.1
105.8
46.4
10.8
51.6
34.6
857.6
953
(Continued)
CH-93-100
2-10
-------
TABLE 2-4a. SIC 2671 PRODUCT END-USES (continued)
1987 Product Shipments
1987
Product
Code
26714 12
26714 13
26714 14
26714 15
26714 16
2671400
26710-
2671000
2671002
No. of
Companies
with Ship-
ments of
$100,000 or
Product More
Him/film multiweb laminations:
Polypropylene/polypropylene 1,000's ions
Cellophane/polypropylene do
Cellophane/polyethylene do
Metalized film/film laminations do
Other film/film laminations do
Multiweb laminated rolls and sheets except paper/paper
and foil, for packaging uses, ius.k.
Paper coating and laminating, packaging, n^k.
Paper coating and laminating, packaging, n.sJc.
typically for establishments with IS employees or more
(see note)
Paper coating and laminating^ packaging, n.sJc~,
typically for establishments with less than IS
employees (see note)
20
7
9
19
27
(NA)
(NA)
(NA)
(NA)
Quantity
42.4
(S)
5.5
14.6
99.9
(X)
(X)
(X)
(X)
Value
(million $)
205.9
9.6
14.9
723
364.1
95.4
(NA)
(NA)
(NA)
Source: Reference 2
do-Ditto
nsJc. - not specified by kind
NA - Not Available
X - Not Applicable
S - Withheld because estimate did not meet publication standards
CH-93-100
2-11
-------
TABLE 2-4b. SIC 2672 PRODUCT END-USES
1987
Product
Code
2672--
26721-
26721 13
26721 53
2672100
26722-
2672200
26723-
2672300
26724-
2672445
2672451
2672453
2672455
2672456
2672459
2672400
26720-
2672000
i
1
Product
PAPER COATING AND LAMINATING,
N.E.C.
Total
Printing paper coated at establishments other
than where paper was produced
Coated, one side
(for labels and similar uses) .... 1,000's tons
Coated, two sides (for printing of magazines.
directories, catalogs, and similar uses) .... do
Printing paper coated at establishments other
than where paper was produced, ius.k.
Gummed products:
Gummed products
Pressure-sensitive products:
Pressure-sensitive products
Other coated and processed papers, except
for packaging uses
Processed paper
(embossed, leatherette, etc.) 1,000's tons
Oiled and similarly treated paper do
Waxed and wax-laminated paper for
nonpackaging uses, including household . . do
Carbonless paper do
Plastics-coated paper do
Other coated and processed paper, including
soap-impregnated paper but excluding
sensitized paper do
Other coated and processed papers, except for
packaging uses, n-sJc.
Paper coating and laminating, n.e.c, nsJL
Paper coating and laminating, n.e.c., n.s.k.,
typically for establishments with 15 employees
or more
(Continued)
NO. or
Companies
with Ship-
ments of
(100,000 or
More
(NA)
(NA)
38
19
(NA)
25
123
(NA)
7
5
11
4
7
34
(NA)
(NA)
(NA)
1987 Product
Quantity
(X)
(X)
(S)
(S)
(X)
(X)
(X)
(X)
532
10.0
(S)
(S)
Wx
(X)
(X)
(X)
: Shipments
Value
(million $)
5,497.7
464.5
301.7
156.8
5.9
218.4
3,100.0
1,200.0
64.2
10.4
104.0
953.5
68.0
514.7
339.5
CH-93-IOO
2-12
-------
TABLE 2-4b. SIC 2672 PRODUCT END-USES (continued)
1987
Product
Code
2672002
\
Product
Paper coating and laminating, n.e.c., n.sJc,
typically for establishments with less than 15
employees
No. of
Companies
with Ship-
ments of
$100,000 or
More
(NA)
1987 Product
Quantity
(X)
Shipments
Value
(million $)
1752
Source: Reference 2
do- Ditto
n.s Jc. • not specified by kind
n.e.c. - not elsewhere classified
NA - Not Available
X - Not Applicable
S - Withheld because estimate did not meet publication standards
CH-93-100
2-13
-------
Tape end-use categories include the following.-3"5-7'9"11
Medical and first aid tapes were the first application of pressure-sensitive products. These
products are used by doctor's offices, and at home for first aid purposes, foot care, and
athletic protection wraps.
Office and graphic an tapes were first produced as clear cellophane film tapes, but now
include many other substrate varieties.
Packing and surface protection film tapes are the most frequently used tapes for packaging.
Saturated paper tape is still dominant in surface protection tape applications and sheet
products.
Building industry products include tapes used for paint masking, temporary attachment of
wood products, weather sealing a building, bridging narrow cracks to overpaint, electrical
wrapping, coverings for doors and walls, floor tile installation, and glass treatments.
Electrical tapes include two classes: tapes intended for original equipment manufacturers
(OEM) and tape for electrical insulation during installation. Current OEM tape may have
cloth, film, paper, aluminum foil, nonwoven fabrics, or laminated substrates depending
upon the desired qualities in the backing. Electrical installation tapes often have either a
plasticized vinyl or polyethylene film backing.
Automotive industry products are used in the electrical system of automobiles. These
products are similar to the OEM tapes discussed above. Other automotive tape products
include tape strips used to mount interior moldings and trim.
Shoe industry tapes are used to cover the backseam to reduce pressure spots. Fabric, paper,
and film tapes may be used in this application. Tapes are also used in binding and
reinforcing areas in the construction of shoes.
Appliance industry products include decorative strips, nameplates, foam gasketing, and
foam pads for sound insulation for attachment to appliances.
Splicing tapes are used to splice various webs during manufacturing operations. Paper
tapes, two-faced tapes, and film tapes are used for this purpose.
Corrosion protective tapes help to prevent the breakdown of materials covered by the tape.
Consumption of polyethylene film tapes for corrosion protection is very large.
Label manufacturing is similar to pressure sensitive tape manufacturing, with priority
properties being backing, printability, flatness, ease of die cutting, and release paper components.
A label manufacturer may sell his product either in rolls or sheets as a final product, or as a raw
product for a printing and die cutting operation.3'4
CH-93-100 2-14
-------
Other adhesive coated and laminated product lines include adhesive-coated floor tiles, wall
coverings, automotive and furniture woodgrain films, and decorative sheets.
2.4 MANUFACTURING PROCESS DESCRIPTION
2.4.1 Introduction
Coated and laminated substrate facilities use numerous methods to process the wide variety
of products that they manufacture. Manufacturing variables include the design and capabilities
of the coating equipment, the type of substrate, the type and viscosity of the coatings being
applied, and the drying or curing method. The manufacturing process generally consists of the
following four steps:
• raw material mixing
• coating application
• drying/curing
rolling, printing, cutting, and product shipment
2.42 Raw Material Mixing4*7"9*10
Many coating and laminating facilities formulate their coatings on-site in a central mix
room. The complexity of the mixing process depends on the size of the facility and the number
of products manufactured. Generally speaking, large facilities operating dedicated lines formulate
all of their own coatings from raw materials. Smaller coating and laminating facilities may
purchase premixed coatings which they either use as-shipped or modify to satisfy customer needs.
Modification typically consists of adding small amounts of performance enhancing chemicals.
Saturants, release coatings, tie coatings, and some adhesives are typically manufactured in
mix tanks using high- or variable-speed dispersers. Facilities that purchase pre-mixed coatings
and add performance enhancing chemicals often blend these chemicals directly into the coating
drum. Facilities equipped with stainless steel mixing tanks and dispersers are capable of
preparing coatings of any chemical composition [i.e., 100 percent solids, waterbased, solvent-
based, ultra-violet (UV) curable].
CH-93-100 2-15
-------
Adhesive preparation often follows a slightly different process. The thicker adhesive stock
is prepared by blending natural and synthetic rubbers, hydrocarbon resins, oils, and fillers in a
banbury, a specialized disperser similar to a bread mixer. The banbury output is then directed
to mills where a sheet of adhesive stock is extruded, cut, and palletized for further processing.
The palletized sheets are sent to a mixing area, where they are loaded into large (e.g., 10,000
gallons) mix tanks. Solvent (often toluene) which dissolves the stock, additional resins, rubber
(self polymerizing), and oils are pumped into the mix tank to complete the adhesive formulation.
Figure 2-1 illustrates the adhesive mixing process.
Once the coatings are formulated, they are either pumped to storage tanks or transferred
via tote vessels or dedicated piping to specific process lines for immediate use.
2.43 Coating Application
The application of a coating to a flexible web involves four major functions: (1) transport
of the web, (2) delivery of the coating supply, (3) metering of the coating, and (4) transfer of the
coating from the supply vessel to the substrate. For purposes of this report it is not important
to understand web transport, other than to note that the mechanisms used to tension and advance
the web can become contaminated with coatings and require cleaning. These mechanisms include
items such as rollers, gear boxes, belts, and equipment housings. The mechanisms used to
supply, meter, and apply coating are also subject to contamination, and thus require cleaning; but
more importantly, their design influences the degree to which coatings are spilled during
application. The following sections describe the other three coating application functions, along
with some common coating equipment configurations.
2.43.1 Delivery of the Coating Supply
After mixing, coatings are stored in permanently installed tanks, movable tote vessels, or
drums, depending on the size and production methods of the coating operation. In order to coat
a substrate web, the coating must be transferred from such storage locations to a reservoir, from
which it can be made available to the coating apparatus. Depending on the size of the operation
and production methods, this is accomplished through permanently installed piping and manifold
systems, or portable lines that are attached to mobile storage vessels. Various types of pumps
CH-93-100 2-16
-------
STOCK PREPARATION
* Banbury mix rubber/fillers
* Mil! banbury stock
* Palletize stock, send to mixing
MIXING
* Solvent
* Rubber stock
* Resins
* Oiis
T
BULK STORAGE
* To coating lines
T
TOTE TANKS/DRUMS
* Small volume coatina
Figure 2-1. Adhesive Mixing Process.
CH-93-100
2-17
-------
are used to maintain a flow of coating materials through these distribution networks. Most
coating operations periodically flush these pumps and transport lines with solvent to prevent a
buildup of coating material on the interior surfaces. Some facilities pack their lines with solvent
during production shut-down periods to avoid the curing of coatings in the line.
The delivery system brings coating material into close proximity with the web and coating
head, depositing the liquid at a steady rate into a reservoir. In some cases, this flow is subjected
to continuous monitoring and adjustment, particularly on short runs. But in longer production
runs, once the flow is adjusted to the proper rate, the coating supply is left alone, and process
control is exercised with the metering mechanism.
The reservoir, the dams around it, and the spill pans beneath it are all regularly subjected
to contamination, and require cleaning on a regular basis. The reservoir itself must be cleaned
prior to the start of any new job, and the other surfaces are cleaned frequently to avoid
contamination of the incoming coating.
2.432 Metering of the Coating Supply
The coating that is applied to the web must be sufficient to completely wet its surface, but
not exceed the design thickness for the application. To some degree, applied coating thickness
is controlled through adjustment of the supply system and the coating's viscosity. Fine
adjustments are accomplished by a metering device. Metering can occur before or after the
coating is applied to the web. The most common metering mechanisms are (1) a metering roller,
(2) a doctor blade, (3) a metering rod, and (4) nip rollers.
A metering roller controls the amount of coating that reaches the web in roll coating
applications. Metering rollers are very smooth and spin counter to the direction of the application
roller. They are set at a predetermined distance from the application roller, so that as the coating
laden roller rotates towards the surface of the web, the metering roller restricts the amount of
coating that can pass through the preset gap. Coating typically collects at the outer edges of this
gap, so many coating heads incorporate a solvent drip that solubilizes mis buildup, allowing it
to wash away. A coating apparatus employing a metering roll to control coating thickness is
depicted in Figure 2-2.
Doctor blades or floating knives are used to remove excess coating either from the surface
of the transfer mechanism, or after the coating has been transferred to the web. Doctor blades
CH-93-100 2-18
-------
METERING ROLL
DAMS
APPLICATOR ROLL
BACKING ROLL
CH-93-100
Figure 2-2. Metering Roll Control of Coating Thickness.
2-19
-------
have very clean, straight edges, and are finely adjustable to provide a level scraping effect over
the surface of the coating. Doctor blades are most effective in providing metering of an already
well controlled coating layer. If a doctor blade is set to remove too much coating, either from
an application roller or from the surface of a web, it will begin to foul and actually pull too much
coating away, resulting in adhesive voids on the web. Figure 2-3 shows a doctor blade-over-roll
coater. Figure 2-4 shows various types of knives used to achieve different coating effects.
Metering rods, like doctor blades, can control coating thickness before or after transfer to
the web. A metering rod is a thin rod wrapped in wire. It is brought into tangential contact with
the coating laden surface and coating passes through the grooves in the wire wraps. The
diameter of the wire wrapping determines the amount of coating that is allowed to pass. The
viscosity of the coating must be controlled to allow the coating to level after it has passed the
metering rod. Figure 2-5 shows a typical metering rod set up to control the thickness of a
coating applied by a direct roll coater. Figure 2-6 depicts the flow of coating through the
grooves in a metering rod's wire wrapping.
Nip rollers are used to squeeze a saturated web to remove excess coating. Nip rollers are
adjacent rollers that rotate counter to one another, allowing the web to travel between them.
They are usually covered with a flexible surface material, primarily rubber, so that they may be
set in contact with one another, but flex enough to accommodate passage of the web. Figure 2-7
shows a dip and squeeze coater using chilled iron rollers as nip rollers.
Additional metering mechanisms include air knives, which are high speed curtains of air
that literally blow excess coating back as an application roller rotates towards the web, and
mechanisms uniquely associated with a single coating application, such as the engravings in a
gravure cylinder. Gravure coaters are similar to roll coaters in that they transfer coating to the
surface of a web through the rotational motion of a cylinder. The major difference is that
gravure cylinders are engraved while the surface of standard coating rollers is mirror smooth.
Gravure coating is a common way of selectively coating the surface of a web. Figure 2-8 shows
a typical air knife coater. The arrows indicate that the applicator roll can be either a reverse or
direct rolL Figure 2-9 depicts a simple gravure coating system. Regardless of the mechanism
used, the metering device must be kept as clean as possible to allow it to effectively perform its
task.
CH-93-100 2-20
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Figure 2-3. Blade-over-roll Coaler.
A B C D E
1
DIP
J
E(
:TION
c
)F V
2
/EE
(?
1
f
Figure 2-4. Coating Knives (A = beveled; B,C = rounded edge;
D = hook; E = bull nose; F = spanishing knife)
Oi-93-100
2-21
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APPLICATOR ROLL
WIRE WOUND ROD
Figure 2-5. Metering Rod Coater.
COATING
WIRE
ROD
Figure 2-6. Metering Rod.
CH-93-100
2-22
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OVEN
CHILLED IRON
ROLLS
Figure 2-7. Dip and Squeeze Coater."
CH-93-100
2-23
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NOZZLE
BACKING
ROLL
DIRECT OR
REVERSE ROLL
APPLICATOR
BLOW OFF
HOOD
COATING
PAN
Figure 2-8. Air Knife Coater."
GRAVURE ROLL
Figure 2-9. Direct Gravure Coater, Coating Reservoir Between the Roll and the Blade.
CH-W-100
2-24
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2.43.3 Transfer of the Coating to the Substrate
Transfer of a coating from a reservoir to a web is most commonly accomplished with a roll
coating mechanism. Roll coaters are a series of one or more cylinders that remove coating from
the reservoir and then contact the web transferring a portion of the coating to the web surface.
If the same cylinder that contacts the coating in the reservoir also contacts the web, such as the
coater shown in Figure 2-10, the roll coater is known as a direct roll coater. If the supply roller
transfers the coating to a counter-rotating cylinder before it reaches the web, the device is called
an offset roll coater. Offset roll coaters are capable of greater control of the coating deposit, but
require more exacting process control and have more surfaces that require cleaning. Figure 2-11
shows an offset roll coater.
In addition to describing the transfer of coating from the reservoir to the web (i.e., with a
single roller), the term direct roll coater is also used to indicate that the web and the coating
cylinder surface are moving in the same direction at their tangential point of contact. Figure 2-12
shows the relative direction of motion of the web and application roller in a direct roll coater.
If these two surfaces are moving counter to one another at this point, then the system is described
as a reverse roll coater, shown in Figure 2-13. Reverse roll coaters are capable of effecting a
smoother and more uniform coated surface.
In some coating applications, there is less need for precision and coatings can be poured
directly onto the web and metered using a metering roller, doctor blade, or metering rod. These
applications generally incorporate a less viscous coating, and are intended for low performance
environments, such as disposable labeling or general purpose masking tape. In such cases, the
transfer mechanism is the pouring device, such as an aperture in the reservoir, or a weir (dam)
that the coating pours over as the reservoir is fed. In such applications it is essential to control
the flow of coating to the reservoir to ensure that the pouring mechanism does not deliver too
much coating to the surface of the web. Figure 2-14 shows a floating knife coater, which meters
the coating from a reservoir directly on the web.
2.4.4 Drying/Curing
Ovens serve two primary functions: to dry the coating by evaporating the solvent or to cure
a polymer coating. Important characteristics of an oven are the source of heat, the operating
2-25
-------
RUBBER ROLL
APPUCATION
ROLL
Figure 2-10. A Schematic Diagram of a Direct Roll Coater.
APPLICATION
ROLL
SUBSTRATE
RUBBER TRANSFER ROLL
Figure 2-11. Offset Application Roll.
CH-9MOO
2-26
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SUBSTRATE
RUBBER ROLL
FOUNTAIN ROLL
Figure 2-12. Direct Application Roll.
SUBSTRATE
RUBBER ROLL
APPLICATION
ROLL
Figure 2-13. A Schematic Diagram of a Reverse Roll Coater.
CH-93-100
2-27
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Figure 2-14. Floating Knife Coater.
temperature, the residence time (a function of web speed), the allowable hydrocarbon
concentration, and the oven circulation (a function of air velocity).
Ovens are of two types: direct and indirect An indirect-fired oven involves heat exchange.
An incoming air stream exchanges heat with steam or combustion products, but does not mix
with them. This heat transfer is often accomplished using shell-and-tube or plate type heat
exchangers.3'11 Direct heating routes the hot products of combustion (blended with ambient air
to achieve the desired temperature) directly into the drying zone. The fuels for a direct-fired
oven are usually either natural gas or liquefied petroleum gas (e.g., propane). Direct-fired ovens
are used most frequently because of their higher thermal efficiency. Indirect-heated ovens lose
efficiency in the production of steam and in the heat transfer process.3'11
Oven drying involves raising a coating's temperature above the boiling point of the vehicle
solvent and keeping the temperature elevated long enough for entrapped solvents to migrate to
the surface and evaporate. The time required to drive off vehicle solvents at the boiling
temperature is known as the drying residence time. During the drying process, heat is transferred
to the coating and backing. Approximately 80 to 95 percent of the vehicle solvent evaporates
CH-93-100
2-28
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and is removed with the oven exhaust in most coating processes.11 The remaining trapped
solvents generally migrate to the edge of the adhesive once it is used in its functional application.
(This process is known as out-gassing, and is frequently a cause of adhesive failures.) Another
important factor to consider with temperature is the temperature profile. If the initial drying
proceeds too quickly, voids may develop in the coating. Conversely, if drying occurs slowly at
low temperatures, longer ovens may be necessary to achieve sufficient residence time.
Multi-zone ovens almost always overcome these difficulties. A typical two-zoned oven is
illustrated in Figure 2-15. Zoned ovens are physically divided into several sections, each with
its own exhaust and supply of hot air. The temperature in the first zone is typically low, but
gradually increases in later zones. This structure allows for uniform drying. Large drying/curing
ovens may have as many as six zones ranging in temperature from 110°F (43°C) to 400°F
(204°C). Facilities may also employ recirculating ovens to provide better drying efficiency.
Recirculation of the exhaust gas is an energy saving practice, but care must be taken to ensure
that sufficient makeup air is circulated to prevent solvent saturation inside the oven. Figure 2-16
illustrates oven exhaust recirculation.4'5'7'9"11
2.4.5 Rolling, Printing, Cutting, and Product Shipment
Many coating operations also offer value-added converting services to their customers.
Such services include custom slitting and roll winding, printing, die-cutting, and sheeting. A roll
of coated product may weigh up to 5,000 Ibs and be 30 inches wide when it comes off the
production line. Such products are generally slit to a customer specified width, and automatically
rolled onto standard cores for customer use in automatic dispensers. Many facilities have the
ability to slit and wind product on-site, however, some facilities send finished rolls to contract
converters to be sized.
In addition to slitting and winding of stock products, coaters often customize label and
packaging products by printing a logo and die-cutting to size. Printing is typically done using
flexographic or screen printing. The industry trend is towards the use of waterborne and
radiation curable inks for these processes. Die cutting is typically done with hydraulic-ram
presses and steel-rule dies. The product is generally cut to the liner with the waste removed and
the web rolled and packaged for shipping.
CH-93-100 2-29
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8
HEATED AIR
HEATED AIR
FROM BURNER
4-ROLL
REVERSE
ROLL
COATER
BURNER"""" l 1
ZONE 1
EXHAUST
I
n
**•
— II II
TJ U
ZONE 2
EXHAUST
1
n
II 11
U <_r
HOT AIR NOZZLES
TENSION
ROLLS
UNWIND
WIND
Figure 2-15. Two-Zoned Drying Oven."
-------
Q
*
§
EXHAUST
RECIRCULAT10N
COATING KNIFE —7
FUEL
(NAT. GAS, FUEL
OIL. PROPANE)
FRESH AIR
Figure 2-16. Coating Line with Exhaust Recirculation."
-------
When coating and all custom conversion is finished, the product rolls are ready for
shipment Finished products are wound on cardboard cores with plastic caps inserted into the
ends of the roll to prevent damage to the edges of the product The rolls are then placed in
containers (e.g., cardboard boxes) for shipment Large rolls which have not been cut and sized
are shipped in open rolls with wood-end caps, and metal straps around the rolls for support
2.5 SPECIFIC PRODUCTION PROCESSES
2.5.1 Introduction
The following section provides process descriptions specific to certain manufactured
products. The actual process descriptions include some of the fundamental processes described
in Section 2.4. The production processes described in this section will deal specifically with
paper tape, film tape, duct tape, reinforced tape, and labels.
Paper Tape Manufacturing
The manufacture of paper tape involves three basic coating steps: saturation, release
coating, and adhesive coating. Coloring and priming may be used in specific applications. In
some cases, facilities may purchase saturated paper webs, thus eliminating the saturation step.
Facilities choosing to saturate their own webs most frequently use the dip and squeeze method.
The paper web is placed on an unwinder and is threaded through the coating line. The web
passes through the saturant trough, is squeezed to remove any excess saturam, and is then sent
to a drying oven.
Once the paper is saturated, and colored and/or primed, the release coat is applied to the
non-bonding surface of the substrate (i.e., the side mat will not receive the adhesive coating).
Application rollers (direct or gravure) are normally used to apply the release coat to the top side
of the substrate. Additional rollers maintain the tension of the paper to ensure an even coating.
A doctor blade or knife may be used to remove any excess coating which is fed back to the
coating bath for reuse. The release coating bath is often fed from a small line tank which, in
turn, is fed from a larger tank in a mixing area. Once release-coated, the tape will pass through
CH-9MOO 2-32
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a drying oven. The saturated and release-coated paper is then either wound and physically
moved to the next coating step (i.e., adhesive coating) or it continues processing on the same
coating line.
The adhesive coating is applied to the bottom or non-release coated side of the paper. A
doctor blade may also be used to remove excess adhesive and return it to the adhesive bath. The
adhesive is fed by a line tank or directly from a large mixing tank. The adhesive coated paper
passes through another set of dryers. The product is then wound, followed by slitting, packaging,
and shipping. Figure 2-17 is a paper tape manufacturing process flow diagram.
2.53 Film Tape Manufacturing
The coating of film substrates is nearly identical to paper coating, with a primer, or tie-coat,
replacing the saturant coating step prior to the adhesive coating. The film web, which may be
polypropylene, vinyl, polyvinyl chloride (PVQ, polyester, acetate, or cellophane, is coated with
the primer, which is a thin layer of a high tack polymer material, to improve the bond between
the adhesive and the film.
2.5.4 Duct Tape Manufacturing
Duct tape is manufactured in a two stage process. First, a laminated web of cloth and film
is prepared Duct tape adhesive, in solid form, is calendared to the cloth side of this laminated
web. In the calendaring process, the web and adhesive are laminated together by a nip roller
which contacts the adhesive leaving a very smooth surface. The difference between calendaring
and roll coating is that the calendared adhesive is removed cleanly from the roll, while liquid
adhesive applied by roll coating actually splits, with some adhesive remaining on the roller. The
three layer product is then given a release coating on the film side, slit to width, and wound in
rolls of varying length.
CH-93-100 2-33
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INTERMEDIATE
COATING
* Tie coat
* Color coat
PAPER FROM VENDOR
' Latex saturate
* Poiyurethane
saturate
COATING
* Apply release coat
* Apply adhesive
COATINGS
* Adhesive from
mixing/bulk storage
* Release coat
SLITTING
* Tube (core) making
* Slitting (automatic & duplex)
* Bulk pack at slitter or load on
peg carts for packing
PACKING
* Bulk pack in boxes
* Individual roll wrap (film wrap)
"Box
SHIPPING
Figure 2-17. Paper Tape Manufacturing Process Flow Diagram.
CH-93-100
2-34
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2.5.5 Reinforced Tape Manufacturing
Reinforced tapes arc manufactured in the same manner as film tapes except with an
additional step of joining reinforcing fibers to the film backing. The reinforced tape
manufacturing process consists of tie, release, and adhesive coatings, and possibly a laminating
step. Reinforced tapes consist of a film backing substrate (e.g., polyester, acetate) that has been
joined with reinforcing fibers, such as fiberglass. The fiber reinforcers provide superior strength
compared to paper or film tape.
The film and reinforcing fibers are threaded through the coating line. The fibers are tie-
coated/laminated to the film. The film substrate has the release coat applied on the opposite side
of the tie-coat Several rollers are used to maintain the tension of the substrate during this
process. A doctor blade may be used to return any excess release coating to the coating bath.
The substrate is then passed through a set of dryers and rewound. The release-coated substrate
is then threaded through the adhesive coating system. The adhesive coat is applied over the
reinforcing threads. Any excess adhesive may be returned to the coating bath by a doctor blade.
The product is then passed through another set of dryers. The finished product is then wound,
followed by slitting, packaging, and shipping.
2.5.6 Label Stock Manufacturing
Label stock manufacturing is also similar to paper tape manufacturing. The two rolls of
paper that are typically used in the label making process include a release liner (the label
backing) and the face stock (the label itself). A release liner is formed by applying a release
coating to the saturated paper. This release coating is often a mixture of silicone and solvents.
The substrate coated with the release coating is men dried in an oven and rewound. The release-
lined substrate is placed on a coater-laminator machine. The silicone-coated surface is coated
with an adhesive then dried in a oven. As the coated paper comes from the oven, it is laminated
by pressure rollers with the label face stock creating a three-layer lamination (face stock,
adhesive, and release liner). Once laminated, the coated paper is slit Slitting machines cut the
paper into particular sizes as a finished product or for further processing. If the slit laminate is
CH-93-100 2-35
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to be printed, it is sent to a printing press where it may be die-cut, perforated, and/or printed.
The labels are then rolled or fan-folded into sheets and boxed for storage and shipping.
2.6 CLEANING REQUIREMENTS
2.6.1 Introduction
The equipment used in the manufacture of adhesive paper products is cleaned to prevent
coating contamination, ensure product performance, maintain equipment operations, and reduce
waste buildup. Cleaning materials attack and break the bond between the adhesive and the metal
(or other surface) being cleaned. The total quantity of cleaning material used depends on several
variables including cleaning frequency; desired level of cleanliness; size, shape, and composition
of part to be cleaned; and soil to be removed.
2.6.2 Cleaning Frequency and Desired Level of Cleanliness
Facilities typically clean on an "as-needed" basis, rather than on a set schedule. As-needed
often means upon product changeover or during equipment shutdowns. However, as-needed
cleaning is also performed when substrate webs break, spilling wet coating material on equipment
surfaces, when coatings splash from troughs, and when excess coating seeps from behind dams
and splash guards.
The frequency of cleaning during product changeovers varies depending on the type of
facility. As discussed previously, the industry may be divided into two groups: "dedicated line"
facilities and "batch processing" operations. Dedicated line facilities operate lines dedicated to
one type of product (e.g., grades of masking tape or label stock), while batch processors
manufacture a wide range of products using a number of different substrates and coatings. Batch
processors include facilities that manufacture and market a line of products, and those which
provide contract coating services. The latter are known as toll coaters. Dedicated line facilities
may run their lines up to 24 hours per day, 7 days per week, and 52 weeks per year. Production
runs are typically scheduled with compatible batches in sequence. When a product change is
about to occur, the production operator will add only enough coating to the application troughs
CH-93-100 2-36
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to coat the length of substrate remaining on the substrate web. This allows the substrate web and
the coating to be exhausted at approximately the same time. As the first web finishes, the second
web is threaded and the new coating formulation is added to the application trough. A similar
technique is used just prior to a shutdown, with the equipment allowed to "run dry."
If such "on-the-fly" changeovers are not possible, excess coating is drained from the
application pans and coating lines back into storage drums and is retained for future use, and the
equipment is cleaned prior to start-up of the next job. Although some product contamination
occurs with either process changeover scenario, the substrate coated with the mixed coatings is
the last portion of the first roll or the first part of the succeeding web. In either case, this portion
of the web, the "makeready" substrate, can be discarded if it is not suitable for use. Makeready
is generated regardless of substrate and coating. Product changeovers in a dedicated line facility
generally occur no more often than one time per day. In many cases, major product changeovers
occur once per week (following a designated shutdown period during which coating line
equipment undergoes thorough cleaning and preventive maintenance.)
In contrast, batch processors generally do not clean equipment on any specific schedule.
Due to the relatively short production runs and the custom nature of the specialty products that
these facilities manufacture the desired level of cleanliness between jobs is critical. Therefore,
at the end of each job, all application equipment is thoroughly cleaned in the manner described
for dedicated lines. Batch processors are likely to use the solvents toluene and MEK because a
high level of cleaning is required. Alternative cleaners, such as mineral spirits (which may be
used by dedicated line facilities for some cleaning applications), are often described by batch
processors as achieving "inadequate" cleaning results. Product changeovers in batch facilities
may occur as frequently as every one to two hours. Seldom do batch processors run a job longer
than one eight-hour shift
2.6.3 Construction of Part to be Cleaned
The effort required to achieve the desired level of cleanliness is often dependent on the
construction of the part to be cleaned. While many small parts (e.g., portions of pipe, or valves)
can be removed from the equipment line for thorough cleaning, other pieces of equipment (e.g.,
ovens and coating application rollers, coating application pans) must be cleaned in place. When
CH-93-100 ' 2-37
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components of these larger pieces of equipment arc removed from the coating line, they are
typically cleaned in centralized cleaning areas in parts washers specifically designed to handle
them. Another cleaning apparatus used in some centralized cleaning rooms is an ultrasonic
cleaner.
Another illustration of the effect that equipment design can have on cleaning is the material
used to construct the application cylinder. Some application rollers are made of rubber rather
than carbon steel. Cleaning rubber rollers with a solvent such as toluene or MEK accelerates
deterioration of the roller. Therefore, equipment of this nature is often cleaned with a caustic-
based cleaning solution.
2.6.4 Soil to be Removed
The soil to be removed from the equipment or part also influences the cleaning method.
The solvents required to clean equipment in coating and laminating facilities are, in large part,
determined by the resin in the coating formulations. For example, adhesives often stick to
application rollers, equipment housings, or transfer pipes. Typically, facilities using solvent-based
coatings use the primary vehicle solvent in the coating formulation for cleaning purposes. For
instance, if an adhesive is formulated with butyl acetate, butyl acetate would be used to clean the
adhesive coating line. If the formulation solvent is not used for cleaning, then another solvent
with strong cutting power is used. Toluene and MEK are solvents frequently used because of
their strong cutting power.
Waterbased coatings are often easier to clean, as the incorporated resin will dissolve in
water. Cleanup of waterbased materials often involves an equipment wipe with a wet rag.
Sometimes the cleanup solution will consist of water mixed with an alcohol, like isopropyl
alcohol (IPA). The addition of an alcohol results in added "cutting" power for waterbased
coatings.
2.7 CURRENT CLEANING TECHNIQUES
This section discusses some of the common cleaning needs and methods of specific pieces
of equipment such as ovens, reservoirs, troughs, hoses and dams.
CH-93-100 2-38
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2.7.1 Specific Equipment Cleaning Requirements
2.7.1.1 Ovens
Because ovens are enclosed systems, full cleaning is done during equipment shutdowns,
although exterior surfaces may be cleaned during or between production runs. Oven cleaning is
necessary because the ovens are used to volatilize the coating solvent and dry the substrate to a
specific weight Consequently, some of the solvent and coating mix and become trapped either
as gel or cured adhesive in the oven screens and hoods. If the ovens are not routinely cleaned,
the oven screens will become clogged, thereby decreasing the efficiency of drying or curing.
2.7JJ2 Reservoirs
Reservoirs are bins located under the application rollers, that are used to supply the coatings
for application purposes. Slashes and breaks in the substrate web result in contamination of the
reservoirs and the area around the reservoir. Because these bins act as a catch basin for excess
coating, they often become encrusted and require cleaning.
2.7JJ Troughs
Troughs are bins which catch any overflow from the reservoirs. Some facilities use the
troughs as a holding basin for cleaning solvents. These facilities like the easy access to solvents
which encourages workers to clean the immediate area more thoroughly when splashes occur.
Moreover, when a coating overflow from the reservoir occurs, the solvent in the trough aided in
cleanup.
2.7 J.4 Pumps, Lines, and Hoses
Pumps, lines, and hoses transfer coatings from mixing tanks, holding tanks, and other
temporary storage areas to process lines. Coatings that stick to the exterior surfaces of these
pieces of equipment are removed with mechanical scraping and solvent-soaked rags. One facility
using waterbased adhesives uses plastic vinyl chloride (PVC) pipes to transfer the coating from
the mixing tanks to the production lines. When these pipes become clogged, they are replaced
rather man cleaned. The facility has not replaced their pipes in approximately three years.
CH-93-100 2-39
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2.7.1.5 Dams
Both overflow containers around reservoirs and flat metal sheets on the end of rollers are
considered dams, which prevent coatings from splashing over the side of the machinery. Hie
dams are cleaned during shutdown with rags soaked with the cleaning solvent
2.7.1.6 Miscellaneous
Miscellaneous cleaning includes the cleaning of product and raw material storage tanks,
process lines, and floors. Generally, storage tanks and process lines in dedicated line facilities
are limited to one type of material and, therefore, do not require cleaning. When the lines are
not in use, some facilities fill (pack) them with solvent to prevent coating in the lines and tanks
from solidifying. Floors are often mopped using equipment cleaning solvent Other facilities use
scrap cardboard or off-specification substrate sheets to protect the floor and reduce the amount
of mopping. As the floor coverings are torn and become unprotective, they are disposed of as
either solid or hazardous waste and are replaced.
2.7.2 Cleaning Techniques
2.72.1 Run Dry
Running a line dry is an operating technique, occurring at the end of a production run, that
involves adding only enough coating to the application troughs to coat the length of substrate
remaining on the web.7 This process technique reduces coating waste and thus, coating cleanup.
Running dry reduces the requirement to remove gross amounts of coating from reservoirs prior
to cleaning, results in less adhesive remaining on the coating apparatus, and reduces the amount
of cleaning solvent required.
2.73.3. Mechanical Scraping
Mechanical scraping involves the use of a putty knife or other straight-edged instruments
to physically remove the coating by scraping it from the part surface. Mechanical scraping is
of greatest benefit when performed before the coating has time to settle and harden. Many
facilities follow mechanical scraping with a solvent wipe. Care must be taken when scraping
equipment to avoid damaging surfaces that meter or apply coatings.
CH-93-100 2-40
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2.7.2 J Solvent Wiping
Solvent wiping is the most commonly used cleaning technique within the coated and
laminated substrate industry. It is primarily used in conjunction with mechanical scraping to
remove coating residue. A rag is moistened with a cleaning solvent and used to wipe the coating
from the part Facilities often maintain safety cans of solvent with both rags and a scraper next
to the machinery for immediate access by the operators to wipe away the coating when a splash
occurs. Solvent wiping is a major source of fugitive emissions.
2.73.4 Immersion
Immersion involves the "bathing" of products in a solution to remove coating residue.
Immersion techniques are most commonly used in centralized parts cleaning areas. A number
of different cleaning materials are used in immersion parts washers including toluene, MEK,
mineral spirits, aqueous cleaners, and custom blends. Some facilities scrape parts prior to
immersion in the baths. This technique removes as much coating as possible before bathing in
the solvent bath, helping to increase the useful life of the solvent in the bath by reducing the
amount of coating contamination. Some facilities use the spent solvent from the immersion bath
as makeup solvent for their coating process. This practice is especially prevalent when the
primary vehicle solvent is used as the immersion bath.
2.725 Other
Other cleaning techniques identified were the use of high pressure water sprayers and
coating machinery surfaces with disposable wraps or impregnated metal powders. One facility
uses high pressure water washes for yearly cleaning of the floors, storage tanks, and equipment
parts. A solution of high pressure water (12,000 psi), heptane, isopropyl alcohol, and salts is
used to clean dry adhesives from these areas. This process results in a hazardous waste stream
with a low Btu value, and consequently a high disposal cost Due to the high cost of this service
($800 a day) and the costly disposal of the water as hazardous waste, this process is due to be
discontinued. One facility coated the machinery with non-useable paper or aluminum foil which
reduced the need for chemicals for cleanup and cleanup time, but increased the cost of solid
hazardous waste disposal.7 Other facilities use porous, flame-coated metal powders, which are
CH-93-100 2-41
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then impregnated with release chemicals, to prevent adhesive from adhering to machine surfaces.
This technique is discussed in Chapter 4.
2.8 PROPERTIES OF CURRENT CLEANING SOLVENTS
2.8.1 Introduction
Some cleaning materials are used more frequently than others. This section describes the
properties of some of the currently used cleaning solvents. The materials discussed include
toluene, mineral spirits, methyl chloroform, MEK, and xylene.
2.82 Toluene
Toluene is a man-made aromatic hydrocarbon produced from petroleum. Toluene is used
as a raw material in several types of coatings including paints, inks, Pharmaceuticals, and
adhesives. The chemical formula for toluene is C^tl5CR3. Toluene is not corrosive and will not
react with either bases or dilute acids. It has been estimated that 86 percent of all toluene used
is released to the biosphere where its life span ranges from 4 days, at high-altitudes during the
summer, to several months, in low-altitudes during winter months.12 Table 2-5 lists the physical
and chemical properties of toluene. Toluene is a chemical included in EPA's 33/50 Program.
CH-93-100 2-42
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TABLE 2-5. PHYSICAL AND CHEMICAL PROPERTIES OF TOLUENE
Property Value
Chemical name Toluene
Synonyms Methylbenzene; toluol; phenylmethane; methacide;
methylbenzol
Molecular formula CgHjCH^
CAS Registry 108-88-3
Molecular weight 92.14
Melting point -95 to -94.5°C (-139 to -138.1*F)
Boiling point (760 mm Hg) 110.63'C (231.13°F)
Density, g/cnr
at25eC(77°F) 0.8623
at20°C(68<'F) 0.8667
Physical state (ambient conditions) Liquid
Color Clear
Odor Benzene-like
Solubility:
Water at 20" C (68*F) Very slightly soluble (0.05 g/100 mL)
Vapor pressure at 20*C (68"F) 219 mm Hg (2.92 kPa)
Source: Reference 12
2.83 Mineral Spirits
Most coated and laminated substrate manufacturers that use mineral spirits for cleaning use
Varsol. Varsol is a branded petroleum solvent blend manufactured by Exxon Company, USA.
It is a clear liquid with a mild mineral spirits odor. Varsol 18, one of the varieties of Varsol,
contains approximately 92 percent saturated hydrocarbons («.#., hexane and heptane), and toluene,
xylene, ethylbenzene, and an aromatic mixture for a combined concentration of 7.1 percent
Table 2-6 summarizes the physical properties of Varsol.13
CH-93-100 2-43
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TABLE 2-6. PHYSICAL PROPERTIES OF VARSOL
Property
Value
Chemical name
Molecular Weight
PH
Melting Point
Boiling Range (760 mm Hg)
Specific Gravity (15.6eC/15.6"C)
Physical State
Color
Odor
Solubility:
Water at 25° C (77° F)
Vapor Pressure at 25° C (77°F)
Percent Volatile by Volume at 1 atm
and25"C(77°F)
Evaporation Rate @ 1 atm. and 25° C (77° F)
(n-butyl Acetate = 1)
Petroleum solvent blend
145
Essentially neutral
<-18«C (0*F)
153-202° C (308-396° F)
0.78
Liquid
Clear
Mineral Spirits
Negligible: less than 0.1%
<10 mm Hg (< 1.3 IcPa)
100
0.1
Source: Reference 13
2.8.4 Methyl Chloroform
Methyl chloroform or 1,1,1-trichloroethane (TCA) is a man-made chlorinated solvent which
is predominantly used in cold cleaning operations and vapor degreasing. Methyl chloroform's
use in adhesives accounts for 10 percent of its total use.14 Methyl chloroform in the atmosphere
has a half-life of approximately 6 months to 25 years.14 Though not all methyl chloroform
travels to the stratosphere, that which does contributes to the depletion of the stratospheric ozone
layer. It is responsible for approximately 16 percent of the ozone-destroying chlorine in the
stratosphere from anthropogenic sources. Table 2-7 provides physical and chemical properties
of methyl chloroform.14 Methyl chloroform is a 33/50 Program chemical.
Consumption and production of methyl chloroform will decline as a result of the
implementation of the 1987 Montreal Protocol on Substances that Deplete the Ozone Layer and
Title VI of the 1990 Clean Air Act Amendments (CAAA).15 Under both of these provisions,
CH-93-100
2-44
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Property
TABLE 2-7. PHYSICAL AND CHEMICAL PROPERTIES OF
METHYL CHLOROFORM
Value
Chemical name
Synonyms
Methyl Chloroform
1,1,1-trichloroethane; ethylidine chloride;
methyltrichloromethane; trielene; algylen;
trichloromethylmethane; chloroethane; inhibisol; trichloran;
gemalgene; TCA; TCEA; aerothene; a- Trichloroethane;
1,1,1-TCE; 1,1,1-Tri; trichloroethane
Molecular formula
CAS Registry
Molecular weight
Melting point
Boiling point (760 mm Hg)
Density, g/cm3
at250C(?rF)
at20°C(68*F)
Physical state (ambient conditions)
Color
Solubility-
Water at 20° C(68*F)
Vapor pressure at 20* C (68°F)
71-55-6
133.42
-30.4" C (-12.TF)
74.1eC (165.4°F)
1.136
1.324
Liquid
Gear
Insoluble (0.095 g in 100 g water)
0.034 g (water in 100 g methyl chloroform
99.8 mm Hg (133 kPa)
Source: Reference 14
methyl chloroform is classified as a controlled substance scheduled for phase-out within the next
ten years (i.e., 2005 under the 1990 Revision of the Montreal Protocol and 2002 under the 1990
CAAA).16*17 However, the U.S. has pledged to stop methyl chloroform production by
December 31,1995. In addition, in November 1992,87 nations agreed to accelerate the Montreal
Protocol schedule and phase out methyl chloroform by the beginning of 1996.18
2.8.5 Methyl Ethyl Ketone (MEK)
MEK or 2-butanone is a colorless organic liquid with an acetone-like odor and a low
boiling point MEK, which is highly reactive, has exceptional solvency and a short atmospheric
lifetime (approximately eleven hours.)19 Table 2-8 provides physical and chemical properties of
•MEK. MEK is another 33/50 Program chemical.
CH-9MOO
2-45
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Property
TABLE 2-8. PHYSICAL AND CHEMICAL PROPERTIES OF
METHYL ETHYL KETONE
Value
Chemical name
Synonyms
Molecular formula
CAS registry number
Molecular weight
Melting point
Boiling point
Density at 20° C, g/cm3
Physical State (ambient conditions)
Color
Odor
Solubility:
Water at 90" C (1948F)
Vapor pressure at 20°C (68°F)
Methyl Ethyl Ketone
2-butanone, ethyl methyl ketone, MEK, methyl acetone
C4H,O
78-93-3
72.1
-86.3'C (123.3'F)
79.6°C (175.3eF)
0.8045
Liquid
Clear
Sweet
190 g/L
77.5 mm Hg (10.3 kPa)
Source: Reference 19
2.8.6 Xylene
Xylene is an aromatic hydrocarbon that occurs naturally in petroleum and coal tar. Xylene
is a colorless liquid with a sweet odor and is volatile, flammable, and explosive in air. Xylene
is not soluble in water, but is soluble in alcohol and many organic liquids. There are three
xylene isomers ortho-xylene (o-xylene), meta-xylene (m-xylene), and para-xylene (p-xylene).
Mixed isomers are a mixture of two or more xylene isomers and a small amount of ethylbenzene.
Xylenes can be transformed by photo-oxidation in the troposphere, and can participate in the
formation of ground-level ozone.20 Table 2-9 lists some physical and chemical properties for
mixed xylene. Xylene is also a 33/50 Program chemical.
CH-93-100
2-46
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TABLE 2-9. PHYSICAL AND CHEMICAL PROPERTIES OF MIXED XYLENES
Property Value
Chemical name Xylene isomers
Synonyms dimethylbenzene
xylol
methyl toluene
Molecular formula C6H4(CR3)2
CAS Registry 1330-20-7
Molecular weight 106.16
Melting point No data
Boiling point (760 mm Hg) 137° to 144° C
Density, g/cm3 0.860
at 20°C (68°F)
Physical state Liquid
Color Clear
Odor Benzene-like
Solubility: 0.013 g/100 1
Water at 25° C (77°F)
Miscible with absolute alcohol, ether, and
other organic liquids
Vapor pressure at 20°C (68°F) 6.15 mm Hg (0.82 kPa)
Source: Referenced
2.8.7 Other
Three other products currently used in equipment cleaning operations at coated and
laminated substrate facilities are perchloroethylene, heptane, and isopropyl alcohol. In some
facilities perchloroethylene and heptane are used in adhesive cleaning and isopropyl alcohol (IPA)
is used to clean the press plates. Approximately seven percent of total perchloroethylene output
is dedicated to metal cleaning and degreasing.21*22 Table 2-10 lists several physical and chemical
properties of perchloroethylene.
CH-93-100 2-47
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TABLE 2-10. PHYSICAL PROPERTIES OF PERCHLOROETHYLENE
Property Value
Chemical name Perchloroethylene
Molecular formula ^C^
Molecular weight 165.83
Melting point -22.4° C (8.32°F)
Boiling point 121.2° C (250.2°F)
Physical state (ambient conditions) Liquid
Color Clear
Vapor pressure at 20°C (68°F) 14 mm Hg (1.87 kPa)
Specific gravity at 20° C (68°F) 1.623
Source: Reference 21
Heptane is a hydrocarbon solvent made from petroleum products. Table 2-11 provides
several physical and chemical properties of research grade heptane.
^ TABLE 2-11. PHYSICAL PROPERTIES OF HEPTANE
Property Value
Freezing point -131.10°F
Boiling point 209.17°F
Specific gravity 0.6882 @ 60°F
Vapor Pressure 1.62 psia @ 100°F
Source: Reference 22
Isopropyl alcohol may be used to clean small amounts of adhesive from application,
metering, and tensioning rollers. Isopropyl alcohol is a colorless, flammable, mobile liquid.
Table 2-12 list several physical and chemical properties of isopropyl alcohol.
CH-93-100 2-48
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TABLE 2-12. PHYSICAL PROPERTIES OF ISOPROPYL ALCOHOL
Property Value
Chemical name Isopropyl alcohol
Molecular weight 60.09
Melting point -89.5° C (129.1°F)
Boiling point (760 mm Hg) 82.5°C (180.5°F)
Specific gravity at 20° C (68°F) 0.7855
Physical state Liquid
Color Clear
Source: Reference 21,23
2.9 CHARACTERIZATION OF POLLUTION RESULTING FROM CURRENT
PRACTICES
2.9.1 Air Emissions
In 1990, the total of all MEK releases to the air by facilities operating under SIC 2671 was
1.1 million pounds.24 Toluene air releases totalled 8 million pounds.24 SIC 2672 facilities
emitted nearly 15 million pounds of MEK and 18 million pounds of toluene.24 Facilities
contributing to these releases are listed in Appendix B, Table B-l and Table B-2. Most coated
and laminated substrate manufacturing facilities calculate these emissions based on raw material
consumption. Therefore, total emissions reflect solvent losses occurring during raw material
mixing, coating processing (including fugitive releases), equipment cleaning, and material storage.
Some industry representatives estimate that ten percent of total solvent releases are due to
equipment cleaning. This percentage represents the greatest source of fugitive emissions from
coated and laminated substrate manufacturing. These emissions are difficult to control with add-
on devices, so some facilities are attempting to find alternative cleaning products and methods.
Depending upon the cleaning chemicals used (e.g., toluene, methyl chloroform, mineral spirits),
VOCs or toxic pollutants may be emitted.
The primary impacts of VOC reductions are dependent on the facility location. In heavily
industrialized areas, the reduction of VOC emissions may produce a corresponding reduction in
CH-93-100 2-49
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ambient hydrocarbon levels, and thus a reduction in ozone formation. In rural areas, lower VOC
emissions will result in lower overall ambient hydrocarbon levels, helping to reduce the transport
of ozone precursors to urban areas. Many air toxics are also VOCs. Therefore, the reduction
of the toxics will result in benefits similar to those achieved with VOC reduction. In addition,
the reduction of air toxics will lead to reduced environmental impacts on other media. For
example, improperly handled chlorinated materials (e.g., methyl chloroform) often result in
contaminated soil and groundwater. Reducing the quantities of these materials used for cleaning
will reduce contaminated aquifers, drinking water wells, and soils.
Emissions from the application of solvent-based coatings are often directed to a control
device (e.g. carbon absorption, catalytic or thermal incinerators). While such control devices
reduce VOC emissions, the use of incineration will actually increase ambient levels of carbon
monoxides (CO) and nitrogen oxides (NOX) in the area.
2.92 Liquid Waste Streams
Spent cleaning solvents are the largest liquid waste produced by coated and laminated
substrate manufacturers. Many of these solvents are recoverable through distillation and can be
incorporated in a coating, however they may also be sent off-site for disposal A second liquid
waste stream consists of excess or off-specification coating.
Another source of liquid wastes may be the control equipment Facilities using carbon
adsorption systems (usually associated with controls on dryers or ovens) have the potential to
discharge contaminated water from the steam used to desorb the carbon beds. Facilities typically
have three options for disposing of this waste: (1) use the water for boiler feed; (2) use the water
for cooling tower purposes; or (3) discharge the water into a wastewater treatment facility or
local sewer for further treatment.
Facilities are responsible for the environmental impacts their water may have on a sewer
or water system. A facility must always consider the effects of a new liquid waste stream on
plant wastewater treatment (WWT) operations or on the Publicly Owned Treatment Works
(POTW). Some cleaners may reduce toxicity, hazardous waste, and air emissions, but create
excursions in effluent limitations.
CH-93-100 2-50
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2.93 Solid Wastes
Solid wastes from the manufacturing operations may be classified into three areas: cleaning
waste, waste substrate, and solidified coating waste. Solid waste from cleaning includes items
such as rags, floor coverings, machinery coverings, and coating filters. The disposal of waste
substrate (from the edge of paper rolls, at the beginning and ending of a run, and from cutting
and packaging operations) is dependent on local/state regulations. The characteristics of the
solvent on the paper affect its classification as solid waste.
In addition, solid waste may be created by emissions control equipment. Activated carbon
from carbon adsorption systems must be replaced periodically, presenting a solid waste disposal
problem. The remains from incineration or catalytic oxidation must be disposed of as solid
waste. The carbon may be able to be re-used for fuel or recycling for other uses. Waste from
incineration or oxidation may also have alternative uses.
2.10 REFERENCES
1. Standard Industrial Classification Manual, Office of Management and Budget 1987.
2. U.S. Department of Commerce. 1987 Census of Manufactures, Industry Series: Convened
Paper and Paperboard Products, Except Containers and Boxes, MC87-1-26C. Bureau of
the Census. Washington, D.C 1990.
3. Satas, Donatas, ed, Handbook of Pressure-Sensitive Adhesive Technology. Van Nostrand
Reinhold Company. New York, NY. 1982.
4. Nashua trip report; see Appendix C
5. 3M trip report; see Appendix C.
6. "Shurtape®, What is pressure-sensitive tape?" Shuford Mills, Inc., Hickory, NC. Provided
in Memorandum from WJL Little, Jr. to Radian Corporation, Research Triangle Park, NC.
June 12, 1992.
7. Anchor trip report; see Appendix C
8. Gale Research, Inc. Warfs Business Directory of US. Private and Public Companies,
Volumes. Detroit, MI. 1992.
CH-93-100
2-51
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9. Rexham trip report; see Appendix C.
10. Tesa Tuck trip report; see Appendix C
11. Goodwin, D.R. Pressure Sensitive Tape and Label Surface Coating Industry - Background
Information for Proposed Standards: Draft EIS. EPA-450/3-80-003a. (NTIS PB81-
105942). Office of Air Quality Planning and Standards. Research Triangle Park, NC.
September 1980.
12. U.S. Environmental Protection Agency. Locating and Estimating Air Emissions from
Sources of Toluene. EPA-454/R-93-047. Office of Air Quality Planning and Standards.
Research Triangle Park, NC. September 1993.
13. Varsol 18. Material Safety Data Sheet (MSDS). Exxon Company, USA.
14. U.S. Environmental Protection Agency. Locating and Estimating Air Emissions from
Sources of Methyl Chloroform. EPA-454/R-93-045. Office of Air Quality Planning and
Standards. Research Triangle Park, NC. September 1993.
15. U.S. Environmental Protection Agency. 40 CFR 82, "Protection of Stratospheric Ozone,"
Federal Register, December 30,1991.
16. United Nations Environment Programme. Handbook for the Montreal Protocol on
Substances that Deplete the Ozone Layer. Ozone Secretariat Narobi, Kenya. May 1991.
17. Public Law 101-549. The Clean Air Act Amendments of 1990, Title VI - Stratospheric
Ozone Protection. November 15,1990.
18. "Cross Media: Ozone Talks," Environmental Policy Alert. December 9, 1992.
19. U.S. Environmental Protection Agency. Locating and Estimating Air Emissions from
Sources of Methyl Ethyl Ketone. EPA-454/R-93-046. Office of Air Quality Planning and
Standards. Research Triangle Park, NC September 1993.
20. U.S. Environmental Protection Agency. Locating and Estimating Air Emissions from
Sources ofXylene. EPA-454/R-93-048. Office of Air Quality Planning and Standards.
Research Triangle Park, NC September 1993.
21. Most, CC Locating and Estimating Air Emissions from Sources ofPerchloroethylene and
Trichloroethylene. EPA-450/2-89-013 (NTIS PB89-235501). Office of Air Quality
Planning and Standards. Research Triangle Park, NC August 1989.
22. Mellan, Ibert. Industrial Solvents Handbook: Second Edition. Noyes Data Corporation.
Park Ridge, NJ. 1977.
CH-9MOO 2-52
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22. Mellan, Ibeit Industrial Solvents Handbook: Second Edition. Noyes Data Corporation.
Park Ridge, NJ. 1977.
23. Lowenheim, Frederick A., and Moran, Marguerite K. Industrial Chemicals; 4th edition.
John Wiley & Sons. New Yoric, NY. 1975.
24. Toxic Chemical Release Inventory Database. U.S. Department of Health and Human
Services, National Institutes of Health, National Library of Medicine. Bethesda, MD.
Toxicology Information Program Online Services TOXNET* Files. 1990.
CH-93-100 2-53
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CHAPTERS
QUESTIONNAIRE RESULTS
3.1 GENERAL
A questionnaire is frequently used to obtain industrial process information that cannot be
gathered through literature searches. With the exception of actual facility visits, questionnaire
distribution is often the best method for gathering specific facility data. Questionnaire
distribution may either be via paper or disk mail-outs. Limited information gathering may also
be conducted by telephone contacts. It is important to conduct a preliminary phone or mail
questionnaire prior to facility site visits to help identify willing participants, to obtain general
knowledge of facility products and processes, and to inform industrial personnel of EPA's project
objectives. As discussed in Chapter 1, the responses to several targeted questionnaires provided
much of the background for the Improved Equipment Cleaning for Coated and Laminated
Substrate Manufacturing Facilities research project Preliminary questionnaire development
began under a previous EPA effort. Initially, the questionnaire was to be conducted by phone.
However, because of the quantity of information required, two separate mail-out questionnaires
were developed. The poor response rate led to the development of revised questionnaires which
were mailed and then followed by phone contacts. This chapter summarizes questionnaire
development and industry responses. The last section in this chapter identifies pollution
prevention trends within the industry, as identified through responses to questionnaire efforts.
33, DESCRIPTION OF ORIGINAL QUESTIONNAIRE
The initial project plan, under a previous EPA effort, included the development of a brief
telephone questionnaire to be used to prepare a cursory industry characterization and to select
potential demonstration sites for Phase n activities. Because of the number of industry
unknowns, including the variety of industrial processes, products, cleaning technologies, and
associated emissions, a more thorough written questionnaire was developed. This questionnaire
requested information on product type and manufacturing capacity, processes and coatings,
equipment cleaning techniques, solvent consumption and recycling, and pollution prevention
CH-93-100 3-1
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research efforts. Prior to the distribution of this questionnaire, it was reviewed by several
industry and trade association personnel including representatives of Anchor Continental and
Shuford Mills.
The original 14 recipients of the two written questionnaires, were identified through a
search of the TRIS database and through leads obtained from members of the October 1991
Industry Focus Group.1 Separate questionnaires were prepared for manufacturers operating under
SIC 2672 and SIC 2641. Prior to distribution of the questionnaire by mail, each anticipated
recipient was contacted by phone to assess willingness to cooperate in the questionnaire effort
Of the approximately fourteen questionnaires mailed, only four industries responded. Many of
the non-respondents indicated that confidentiality was a concern. They believed that answering
the questions would lead to the disclosure of confidential business information (CBI).
Facilities not responding to the initial questionnaire received follow-up phone calls.
Although some of these calls were met with persistent industry reluctance to participate, some
calls did result in the retrieval of valuable information. Several facilities did agree to host site
visits and to consider continued participation as a demonstration site.
3 J DESCRIPTION OF REVISED QUESTIONNAIRE
In an effort to receive input from a wider and more representative industry cross-section,
a revised questionnaire was developed. The revised questionnaire tables were adapted from the
initial questionnaire to include clarification of processes, products, and associated cleaning
methods. The final questionnaire consisted of ten tables addressing the cleaning issues for each
of four primary coating operations. Two tables (i.e., one for process characteristics and a second
for equipment cleaning techniques) were developed for each of the four coating processes (i.e.,
adhesive, saturant, release, and other). Two additional tables summarized facility location,
product line, and general pollution prevention research activity information.
An extensive list of facilities and potential questionnaire respondents operating within the
SICs 2641, 2671, and 2672 was compiled. Facility names, addresses, phone numbers, and
contacts were extracted from Ward's Business Directory, Dun &. Bradstreet Million Dollar
Directory, Air Tones & VOCs, and North Carolina Manufacturing Firms Directory.2'3'4'5
Facilities that agreed to review the questionnaire were sent a copy either by mail or by fax to
CH-93-100 3-2
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ensure that the contact would have sufficient time to become acquainted with the questions asked
and gather any specific data. A phone appointment to review and complete the tables was
established with the facility contact Several additional questions not amenable to the table
format were also asked during the phone interview.
Approximately 51 facilities were contacted by phone to assess their interest in participating
in the questionnaire effort or in hosting a site visit These contacts included the 14 facilities that
had already received the initial questionnaire. Over half of the facilities contacted were small,
label printing operations claiming a variety of SICs. None of these small facilities were willing
to complete the questionnaire or host a site visit Within the timeframe allowed for this task,
nine companies completed the questionnaire for ten facilities. (One company responded for two
of its facilities.)
3.4 FINAL QUESTIONNAIRE SUMMARY AND CONCLUSIONS
The final questionnaire was developed to show the relationship between products,
manufacturing processes, waste generation, and cleaning technologies. Responses are
summarized according to the four primary coating application processes: saturation, release
coating, adhesive application, and other processes. The results are discussed in the remainder
of this chapter and summarized in Tables 3-1 through 3-4. These tables use the same format as
those used to collect the data.
Table 3-1 provides an overview of the nine companies (and ten plants) that responded to
the questionnaire. Facility size is represented by either number of employees or by square yards
of product manufactured. A uniform parameter to characterize size was not possible as many
of the facilities considered either number of employees or production volume confidential.
Table 3-2 identifies the manufacturing processes of each of the questionnaire respondents.
Table 3-2 is organized by process (i.e., saturation, release coating, adhesive application, and other
processes) and by facility. Line numbers are indicated under the company name. A facility
operating three lines using exactly the same process and equipment will have the number three.
If the facility operates three lines with slightly different parameters, the line numbers will be
listed individually (i.e., 1, 2, 3). The Table 3-2 headings include coating technology, coating
method, resin type, percent resin, carrier type, solvent percent solvent, solvent quantity, and
CH-9MOO 3-3
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TABLE 3-1. QUESTIONNAIRE RESPONDENT PROFILES
Company
Plant A
PlantB
Plant C
Plant D
Plant E
Plant F
Plant G
Plant H
Plant I
Plant J
Product
Consumer and Painting Tapes
Printing and Drafting Films
Drafting and Reproduction Films
Pressure Sensitive Labels
Pressure Sensitive Labels, Paper,
and Film
Pressure, Sensitive Tape;
Industrial Duct and Masking Tapes
Pressure Sensitive Tape for
Industrial Applications
Pressure Sensitive Films and
Screen Inks
Pressure Sensitive Tape
Pressure Sensitive Labels
SIC
2672
2672
2671
2671,
3080, 3081
2672
2672
2672
2672
2672
Size
12-100 million yd2
10 million yd2
10 million yd2
380 Employees
900 Employees
100 Employees
75 Employees
50 Employees
$10 million in sales
500 Employees
200 to 300 million yd2
percent solvent recycled The coating technology category refers to the general coating
formulation (e.g., waterbased, solvent-based, two-part reactive, hot melt, or other). Coating
method refers to either the method of coating application or the type of application roller. Resin
type refers to the type of resin used in the coating formulation, while percent resin indicates the
percent solids in the coating formulation. The carrier is the liquid portion of the coating that
transfers the solid resin to the substrate. The quantity of solvent present in the coating
formulation is represented by the percent solvent category, while the solvent quantity category
indicates the volume of solvent used in the formulation during a specified time frame. The last
category indicates the quantity of formulation solvent that is recycled on-site. Table 3-3 shows
cleaning operations subdivided by the four process categories. Each sub-table describes the
cleaning method, frequency, solvent, and waste streams generated/employed by the individual
companies. This table is further subdivided according to equipment component Table 3-4
summarizes the pollution prevention efforts undertaken by each of the questionnaire respondents.
It was difficult to obtain every category of data from every respondent because of varying
policies.
CH-93-100
3-4
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TABLE 3-2. PROCESS PROFILE
Process/
Company
Capacity
Coating
Technology
Coating
Method
Resin Type
Percent
Resin
Saturation
Plant A
Plant C
Plant I
1
2
Solvent
Water
2 part
corrosion
inhibitor
Solvent
Water
Water
Metering bar
Dip/squeeze
Knife/blade
Dip/squeeze
Protein latex
Methyl-
styrene and
oil
Styrene-
butadiene
Styrene-
butadiene
5-20
20-100
Carrier
Type
Solvent
or
Water
Solvent
Water
Water
Solvent
IPA
MEK
Heptane
None
None
Percent
Solvent
3-5
Solvent
Quantity
Percent
Solvent
Recycled
0
100
100
Release
Plant A
1
2
3
4
70 million yd2
Water
Solvent,
2-part
Solvent,
2-part
Solvent,
2-part,
water
Metering bar
Metering bar
Metering bar
Metering bar
Vinyl
corrosion
inhibitor
Vinyl
corrosion
inhibitor
Vinyl
corrosion
inhibitor
Toluene,
Heptane
MEK,
IPA
0-97
600 gal/wk
0
(Continued)
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TABLE 3-2. PROCESS PROFILE (Continued)
Process/
Company
Plant D
2
1
Plant F
3 lines
Plant I
1
2
3
Plant!
Adhesive
Plant A
2 lines
Plant B
Plant D
2 lines
(1 can
convert
toH2O
2 lines
1 line
1 line
Capacity
200 to 300
million yd2
Coating
Technology
Silicone
Water
Solvent or
water
Water
Water
Water
Solvent,
2-part
Coating
Method
Knife/blade
Knife/blade
Applicator roll
Knife
Gravure
Resin Type
Nitrile
butadiene and
silicone
Vinyl acetate
Latex
Latex
Silicone
12 million yd2
Water
Solvent
Solvent
Water
Water
Hot melt
Metering bar
Extrusion die
Metering bar
Reverse roll
Reverse roll
Metering bar
Latex
Acrylics
Starch base
Acrylics
Starch base
Plastic resin
Percent
Resin
2-100
Carrier
Type
Water
Water
Water
Solvent
30-60
25-30
100
100
100
Water
Solvent
Solvent
None
None
None
Toluene,
Xylene,
Heptane
Percent
Solvent
50-98
Toluene
MEK
Toluene
Water
Water
50-75
Solvent
Quantity
4200gal/yr
Percent
Solvent
Recycled
90-96
N/A
N/A
N/A
0-90
15,000
gal/yr
2-3 thous
gal/yr
0
50
(Continued)
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TABLE 3-2. PROCESS PROFILE (Continued)
Process/
Company
Plant D (con't)
1 line
1 line
Plant E
8 lines
1 line
4 lines
Plant G
1
2
3
4
Capacity
136 million
yd2
49.8 million
yd2
Coating
Technology
Wax coaler
Hot melt
Solvent
Water
Solvent or
water
Solvent or
water
Solvent or
water
Hot melt
Solvent or
water
Coating
Method
Knife, rev. roll,
gravure
3 reverse roll
Knife, rev. roll,
gravure
Knife/blade
Reverse roll
Hot melt
Knife/blade
Resin Type
Wax
petroleum
Acrylic
rubber,
styrene-
butadiene,
nitrile-
butadiene
Acrylic,
methane and
others
Acrylic,
methane and
others
Nitrile-
butadiene
Acrylic,
methane and
others
Percent
Resin
35-60
avg. »
40
15-65
15-65
100
15-65
Carrier
Type
Solvent
Water
Solvent
or water
Solvent,
water or
mixed
Solvent,
water or
mixed
Solvent,
water or
mixed
Solvent
Toluene,
elhylacetate,
hepane,
hexane, IPA,
xylene
Toluene,
MEK
Acetone,
ethylacetate,
Heptane,
hexane
N/A
Ethanol
Percent
Solvent
40-65
avg. = 60
35-85
35-85
35-85
Solvent
Quantity
5,417
gal/mo
825 gal/mo
Percent
Solvent
Recycled
20 reuse
or recycle
0
0
0
(Continued)
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TABLE 3-2. PROCESS PROFILE (Continued)
Process/
Company
Plant H
Plant I
4 lines
Plant J
2 lines
Capacity
5001bs/hr
200 to 300
million yd2
Coating
Technology
Solvent
Solvent or
water
Surface Web Coating
Plant B
Plant C
Solvent
Solvent
Coating
Method
Knife
Reverse roll
Reverse roll,
gravure,
metering bar
Metering bar
Metering bar
Resin Type
Acrylic
Nat synthetic
rubber
Styrene-
butadiene
Nitrile-
butadiene
acrylic
Acrylics,
cellulose,
esters
Acrylics,
cellulose,
esters
Percent
Resin
25-45
30-60
15-30
20-35
Carrier
Type
Solvent
Solvent
or water
Solvent
Solvent
Solvent
Ethylacelate
toluene
Toluene
Toluene,
Heptane
Percent
Solvent
55-75
40, 55-57
40-70
Solvent
Quantity
1320 gal/yr
Percent
Solvent
Recycled
0
0-90
Toluene,
MEK,
Alcohol
Toluene,
MEK,
Alcohol
0
90
X>
-------
TABLE 3-3a. SATURATION PROCESS EQUIPMENT CLEANING
Company/Product
Rollers
Troughs
Dams
Floors
Mixing
Vessels
Method
Rant A
Plant C
Plant I
Scrub brush,
wipe, spray
Wipe
Wipe
Scrub brush,
wipe, spray
Dip
Wipe
Frequency
Plant A
Plant C
Plant I
Product
change
Daily and
product
change
I/week
Product
change
Daily and
product
change
I/week
Scrub brush,
wipe, spray
Wipe
Scrub brush,
wipe, spray
Wipe
Scrub brush,
wipe, spray
Bath
Wipe
Product
change
Daily and
product
change
I/week
Product
change
Daily and
product
change
I/week
Product
change
Daily and
product
change
I/week
Solvent
Plant A
Plant C
Plant I
Water
Heptane,
5 gal/event
Toluene
Water
Heptane,
5 gal/event
Toluene
Water
Heptane,
5 gal/event
Toluene
Water
Heptane,
S gal/event
Toluene
Water
Heptane,
5 gal/event
Toluene
Waste Type
Plant A
Plant I
Water
SOgal/wk
water
Rags
Water
SOgal/wk
water
Rags
Water
SOgal/wk
water
Rags
Water
SOgal/wk
water
Rags
Water
SOgal/wk
water
Rags
CH-93-100
3-9
-------
TABLE 3-3b. RELEASE PROCESS EQUIPMENT CLEANING
I
Company/
Product
Rollers
Troughs
Dams
Floors
Mixing
Vessels
Method
Plant A
Plant D
Silicone
Waterbased
emulsion
Plant F
Plant J
Plant I
Putty knife,
scrub brush,
wipe, spray
Solvent run
through
process
Wipe
Wipe, scrub
brush, putty
knife
Wq>e,dip,
bath, scrub
brush
Wipe
Putty knife,
scrub brush,
wipe, spray
Solvent run
through
process
Wipe
Wq«, scrub
brush, putty
knife
Wipe, dip,
bam, scrub
brush
Wipe
Putty knife,
scrub brush,
wipe, spray
Solvent run
through
process
Wipe
Wipe, scrub
brush, putty
knife
Wipe, dip,
bath, scrub
brush
Wipe
Putty knife,
scrub brush,
wipe, spray
Solvent run
through
process
Wipe
Wipe
Wipe, dip,
bath, scrub
brush
Wipe
Putty knife,
scrub brush,
wipe, spray
Solvent run
through
process
Wipe
Run Dry
Wipe, dip,
bath, scrub
brush
Wipe
Frequency
Plant A
Plant D
Silicone and
Waterbased
emulsion
Plant F
Plant I
Plant J
Product
change
Product
change and
weekly
Product Change
Product
change
Product
change and
upset
conditions
Product
change
Product
change and
weekly
Product Change
Product
change
Product
change and
upset
conditions
Product
change
Product
change and
weekly
Product Change
Product
change
Product
change and
upset
conditions
Product
change
Weekly
Daily
Product
change
Product
change and
upset
conditions
Product
change
Product
change and
weekly
When empty
or product
change
Product
change
Product
change and
upset
conditions
(Continued)
CH-93-100
3-10
-------
TABLE 3-3b. RELEASE PROCESS EQUIPMENT CLEANING (Continued)
Company/
Product
Rollers
Troughs
Dams
Floors
Mixing
Vessek
Solvent
Plant A
Plant D
Silicone and
Waterbased
Emulsion
Plant F
Plant I
Plant J
Toluene
Citrus based
mineral spirits
(Previously
TCA)
MEK
Toluene
Toluene and
TCA
Toluene
Citrus based
mineral spirits
(Previously
TCA)
MEK
Toluene
Toluene and
TCA
Toluene
Citrus based
mineral spirits
(Previously
TCA)
MEK
Toluene
Toluene and
TCA
Toluene
Citrus based
mineral spirits
(Previously
TCA)
MEK
Toluene
Toluene and
TCA
Toluene
Citrus based
mineral spirits
(Previously
TCA)
MEK
Toluene
Toluene and
TCA
Waste Type
Plant A
Plant D
Silicone
Waterbased
emulsion
Plant F
Plant I
Solvent,
600/gaVwk
Water.
3SOgal/wk
Spent cleaner
Rags
Rags
Rags
Spent cleaner
Rags
Rags
Spent cleaner
Rags
Rags
Spent cleaner
Rags
Rags
Spent cleaner
Rags
Rags
CH-93-100
3-11
-------
TABLE 3-3c. ADHESIVE PROCESS EQUIPMENT CLEANING
1
Company/Product
Rollers
Troughs
Dams
Floors
Miring Vessels
Method
Plant A
PlantB
Plant D
Plant E
Plant G
Plant H
Plant I
Plant J
Putty knife
Wipe
WqK/scrape
Wipe
Wipe, dip, and
bath
Wipe
Run dry/putty
knife/wipe
Wipe, dip,
bath, scrub brush,
spray
Putty knife
Dip
Wipe/scrape
Wipe
Dip, bath, and
putty knife
Run dry/putty
knife/wipe
Wipe, dip,
bath, scrub
brush, spray
Wipe/scrape
Soak
Wipe, bath, and
putty knife
Wipe
Run dry/putty
knife/wipe
Wipe, dip,
bath, scrub brush,
spray
Scraper
Wipe/scrape
Blades are
soaked
Wipe
Run dry/putty
knife/wipe
Wq», dip,
bath, scrub
brush, spray
Putty knife
Dip
Wipe/scrape
Spray
Run dry/putty
knife/wipe
Wipe, dip, bath,
scrub brush,
spray
Frequency
Plant A
PlantB
Plant E
Plant G
Plant H
;
3
Plant I
| Plant J
Product change
Daily
1-2/day
Product change
1/mo
I/day
1/wk
Product change
Product change,
upset conditions,
continual
Product change
and every 1-2
weeks
Daily
1-2/day
Product change
Product change
Product change,
upset
conditions,
continual
1-2/day
Product change
I/day
3/day
9/day
Product change
Product change,
upset conditions,
continual
Daily
2/yr
2/yr
2/yr
Product change
Daily
1/yr
1/wk
I/day
Solvent
Plant A
Plant B
Water
Toluene,
15,000 gal/yr
Water
Toluene,
15,000 gal/yr
Water
Toluene,
15,000 gal/yr
Water
Toluene,
15,000 gal/yr
Water
Toluene,
15.000 gal/yr
(Continued)
CH-93-100
3-12
-------
TABLE 3-3c. ADHESIVE PROCESS EQUIPMENT CLEANING (Continued)
Company/Product
Plant C
Acrylics,
plastic resin
Starch
Solvent
Hot melt
Plant E
Plant G
Plant H
Plant I
Plant!
Rollers
Mono
methyl butyl
ether
Hot water
Toluene
Citrus based
cleaner
(90%VOC
content)
Toluene,
MEK,
Ethylacetate
MEK,
xykne
PM Acetate™
(25%),
Cvclohexane
(25%),
API 100
Aromatic™
(50%)
Toluene
Toluene,
TCA
Troughs
Mono
methyl butyl
ether
Hot water
Toluene
Citrus based
cleaner
(90% VOC
content)
Toluene,
MEK,
Ethylacetate
MEK,
xylene
PM Acetate™
(25%),
Cyclohexane
(25%),
API 100
Aromatic™
(50%)
Toluene
Toluene,
TCA
Dams
Mono
methyl butyl
ether
Hot water
Toluene
Citrus based
cleaner
(90% VOC
content)
Toluene,
MEK,
Ethylacetate
MEK,
xykne
PM Acetate™
(25%),
Cyclohexane
(25%),
API 100
Aromatic™
(50%)
Toluene
Toluene,
TCA
Floors
Mono
methyl butyl
ether
Hot water
Toluene
Citrus based
cleaner
(90% VOC
content)
Toluene,
MEK.
Ethylacetate
MEK,
xylene
PM Acetate™
(25%),
Cyclohexane
(25%),
API 100
Aromatic™
(50%)
Toluene
Toluene,
TCA
Mixing Vessels
Mono
methyl butyl
ether
Hot water
Toluene
Citrus based
cleaner
(90% VOC
content)
Toluene,
MEK,
Ethylacetate
MEK,
xylene
PM Acetate™
(25%).
Cyclohexane
(25%).
APIIOO^
Aromatic™
(50%)
Toluene
Toluene.
TCA
Waste Type
Plant A
Plant B
Plant D
Plant E
Plant G
350 gal
water/wk
Rags
Rags
Rags
Fugitives,
rags.
cardboard tray
liners
350 gal
water/wk
Rags
Rags
Rags
Fugitives,
rags,
cardboard tray
liners
350 gal
water/wk
Rags
Rags
Rags
Fugitives,
rags,
cardboard tray
liners
350 gal
water/wk
Rags
Rags
Rags
Fugitives,
rags.
cardboard tray
liners
350 gal
water/wk
Rags
Rags
Rags
Fugitives,
rags.
cardboard tray
liners
(Continued)
CH-9MOO
3-13
-------
TABLE 3-3c. ADHESIVE PROCESS EQUIPMENT CLEANING (Continued)
Company/Product
Plant H
1 &2
3
Plant I
Plant J
Rollers
lOOgal/yr
1540 gal/yr
Wastepaper
and salvage
ends
toluene wash,
150 gal/mo
TCA,
200 gal/mo
Troughs
lOOgal/yr
1540 gal/yr
Wastepaper
and salvage
ends
toluene wash,
150 gal/mo
TCA,
200 gal/mo
Dams
100 gal/yr
1540gal/yr
Wastepaper
and salvage
ends
toluene wash,
150 gal/mo
TCA,
200 gal/mo
Floors
lOOgal/yr
1540 gal/yr
Wastepaper
and salvage
ends
toluene wash,
ISOgalAno
TCA,
200 gal/mo
Mixing Vessels
lOOgal/yr
1540 gal/yr
Wastepaper
and salvage
ends
toluene wash,
150 gal/mo
TCA,
200 gal/mo
TABLE 3-3
-------
TABLE 3-4. GENERAL POLLUTION PREVENTION RESEARCH
Company
Plant A
PlantB
Plant C
Plant D
Plant E
Plant F
Plant G
WB'
Y/N
Y
N
N
Y
Y
Y
Y
Years WB§
in Use
27yrs
58yrs
15-20 yrs
5yrs
10 yrs
Level of
Research
Minimal
Minimal
Moderate
Extensive
Extensive
Moderate
to
Extensive
Minimal
Limitations
High cost
Poor curing lusters
Product specifications
Product specifications
High cost,
Waterbased coatings unable to
provide required tack
Tack
Waterbased coatings unable to
provide required tack
Waterbased cleaners do not
remove adhesives adequately
from rollers
Waterbased coatings unable to
provide required tack
Low
Solvent
Research
Moderate
Minimal
None
Moderate
Moderate
to
Extensive
Minimal
General Pollution Prevention Efforts
Description
Higher solids adhesives; Investigated
distillation
Scheduling product runs
Reuse cleaning solvent
Trying mineral spirit/
terpene mix
Run jobs together;
Dilute toluene drip bottle with nontoxic
solvent;
Distillation of waste solvent
Scans technical literature
Designing process line to accept UV
curing equipment in the future;
Operator training;
Run similar adhesive jobs together
Plant H
Waterbascd
PSAs
UV-Curable
Coatings
Y
N
lyr
High
Moderate
Poor physical properties
High cost.
Poor physical properties
Research Impacts
on Cleaning
•
On-silc water
treatment
Non VOC products
are not effective
(Continued)
-------
TABLE 3-4. GENERAL POLLUTION PREVENTION RESEARCH (continued)
Company
Plant I
Plant J
WB«
Y/N
Y
Y
Yean WB*
in Use
20f yrs
10f yra
Level of
Research
Extensive
Extensive
Limitations
High cost
Slower line speeds
Stow line speeds
Slow drying time
Low
Solvent
Research
Minimal
None
General Pollution Prevention Efforts
Description
Backsizing line(s) use cellophane-like
plastic as roller covers
Replacement of all solvent-based
products by 1994
Research Impacts
on Cleaning
Mineral spirits don't
clean effectively;
Solvent recycling.
Investigating non-
VOC cleaning
products
*WB - Waterbased coatings (saturants, release coats, and/or adhesives)
O\
-------
3.4.1 Saturation Processes
Only three companies manufacture products requiring saturation process lines. Plant A
process lines may operate with solvent, water, or two-component reactives. Plant C operates with
solvent-based materials. Plant I uses waterbased saturants exclusively. Coating methods used
on the saturation process lines include blade, dip and squeeze, and metering rod. Latex and
styrene-based resins are formulated with isopropyl alcohol (IPA), MEK, and heptane solvent
carriers.
Cleaning of saturation process lines is primarily accomplished by wiping the equipment
components with solvent-soaked rags, as indicated in Table 3-3a. While Plant A uses waterbased
cleaners, Plant C and Plant I use heptane and toluene, respectively. The three companies clean
on a variety of schedules including after product changes, daily, or weekly. Rags and spent
cleaning solutions are the primary waste generated from equipment cleaning.
3.4.2 Release Backing Processes
Due to confidentiality concerns of some respondents, the information presented in Tables
3-2 and 3-3b is not complete. Five of the nine responding companies operate 13 release backing
process lines. As the tables indicate, waterbased formulations are used extensively in release
backings. Plant F's process lines may be run either with water- or solvent-based release coatings.
Plant I uses waterbased emulsions exclusively. Plant A and Plant J use a mixture of solvent and
two-part reactive coatings. Vinyl- and silicone-based resins are common in release backing
formulations. Plant F and Plant J recycle at least 90 percent of the solvent
As indicated in Table 3-3b, equipment cleaning methods employed for release backing
process lines include preliminary residue scraping followed by wiping the equipment components
with solvent-soaked rags. Almost exclusively, the respondents clean only after product changes
or on a weekly basis. Toluene is by far the most common cleaning solvent, followed by MEK
and 1,1,1-trichloroethane (TCA). One company uses citrus based materials to clean silicone
release backing lines. Rags and spent solvent are the primary wastes generated from the cleaning
of equipment
CH-93-100 3-17
-------
3.4.3 Adhesive Coating Processes
As indicated in Table 3-2, 33 adhesive coating lines are operated by the companies
receiving questionnaires. Only one facility does not contain an adhesive application station.
Facility adhesive-coating capacities range from 12 million to 300 million square yards per year.
A diverse mixture of coating application methods and equipment was represented, including
reverse roll, gravure, knife-over-roll, metering rod, hot melt, and extrusion die. While most of
the facilities operate lines dedicated to the coating of either solvent-based or waterbased
adhesives, two companies (i.e., Plant G and Plant J) are able to use either solvent- or waterbased
adhesives on the same coating line.
A variety of coating formulation resins (e.g., acrylic, natural and synthetic rubber, nitrile,
styrene butadiene, urethane, and starch) were identified by industry respondents. Although
several resin types were reported, this variety does not appear to impact the coating method or
technology employed for the process.
Commonly used solvents include toluene, ethyl acetate, MEK, heptane, and hexane, with
toluene being the most commonly used vehicle solvent in adhesive formulations among
questionnaire respondents. Cleaning with water is possible on water- and starch-based adhesive
lines. Solvent vehicles used did not depend on the types of resins in the formulations. The
solvent content in the adhesives formulations ranged from 35 to 85 percent
Although the questionnaire recipients employ a variety of processes, the reported cleaning
of all adhesive-coating process equipment is similar, as indicated in Table 3-3c. Again, the
preferred cleaning method is wiping the equipment with solvent-soaked rags. A putty knife or
scraper is often used on difficult-to-clean areas to loosen dried coating materials. No trends in
cleaning frequency were identified among the companies or equipment components. Daily
cleaning or cleaning after a product change are common. The primary wastes generated during
cleaning are solvent soaked rags and waste solvent
3.4.4 Other Processes
As shown in Tables 3-2 and 3-3d, the only other coating process identified by the
questionnaire respondents is surface web coating (Le., printing and drafting and reproduction
CH-93-100 3-18
-------
films) at Plant B and Plant C. Acrylic, cellulose- or ester-based resin formulations formulated
with toluene, MEK, and alcohol are applied by metering rods. Plant C recycles approximately
90 percent of their solvent Equipment cleaning techniques used by Plant B and Plant C on then-
web coating lines do not differ from those described earlier.
3.4.5 General Pollution Prevention Industry Trends
Some of the equipment cleaning pollution prevention techniques identified by the
questionnaire recipients include job scheduling, operator awareness training, and equipment
retrofits to accommodate both water or UV-curable coatings as indicated in Table 3-4. Several
companies have taken steps to reduce the amount of solvent used to clean equipment by
consecutively scheduling production runs using adhesives or coatings with similar formulations.
While many companies dedicate equipment lines to specific products, the majority of companies
do not dedicate products to certain process lines. Water- and solvent-based formulations are
frequently dedicated to particular process lines. Very few companies coat both water and solvent
formulations on the same process lines. Product specifications generally mandate whether
waterbased formulations are applicable to a particular job. Certain coating properties are possible
with waterbased coatings, while others are not
Other solvent reduction techniques include dilution of solvents with non-toxic cleaning
compounds, and use of roller covers, such as cellophane-like materials or teflon coatings which
prevent the coating from adhering to the roller.
Although there is much emphasis on reducing cleaning solvent consumption and waste
generation, most facilities still give then- operators free access to cleaning solvents. Safety cans,
filled with solvent, are often located near the application equipment Large solvent storage drums
(i.e., 55 gallons) are located in a central storage area with no monitoring or access restrictions.
Additionally, few companies take advantage of waste solvent recycling.
Two waste reduction methods identified through industry questionnaires, that do not directly
involve equipment cleaning involve equipment retrofit opportunities. One company is
investigating reducing solvent consumption by designing new process lines and retrofitting
current lines to accept UV curing equipment retrofits. Another potential retrofit of equipment
involves waterbased materials. The general level of waterbased coatings research conducted by
CH-9J-100 3-19
-------
facilities in the questionnaire is "moderate." Many of the companies conduct research or
adhesive formulation in on-site research and development laboratories. Other facilities have
reported that they would consider using waterbased formulations if a coating supplier would
produce a "reliable" material. Plants A, E, I, and J have all used waterbased coatings in some
coating applications (e.g., saturants and release coats) for at least twenty years. These companies
cite the reduced ability to meet customer product specifications, lack of adhesiveness and luster,
and high cost as the primary drawbacks of waterbased coatings. Some of the same complaints
were noted for waterbased cleaners. According to questionnaire respondents, low-VOC or non-
VOC cleaning products do not effectively clean the equipment
3.4.6 Conclusions
In conclusion, equipment cleaning techniques for solvent-based coating formulations do not
seem to be dependent upon the type of process or product. Rather, the same cleaning materials
and methods appear to be used across the wide range of products and processes reported by the
questionnaire recipients. One universal waste reduction method would be limiting operator access
to solvent storage areas, however, increased recycling and recovery efforts will also provide
reduced solvent waste generation benefits. Non-stick roller covers, protective wrappings on other
equipment components, and regulated solvent spray or drip systems may also offer effective
alternatives to current cleaning techniques.
3.5 REFERENCES
1. U.S. Environmental Protection Agency, Office of Toxic Substances, Toxic Release
Inventory System, July 1992.
2. Gale Research, Inc. Ward's Business Directory of US. Private and Public Companies,
Volume5. Detroit, MI. 1992.
3. Dun & BradstreeL Million Dollar Directory: America's Leading Public & Private
Companies. Parsippany, NJ. 1992.
CH-9J-100 3-20
-------
4. "Pressure Sensitive Tape and Label Industry," Air Toxics & VOCs, Chapter IV. McDvaine
Co. 1991.
5. North Carolina Manufacturing Firms: 1989-90 Directory. Prepared by North Carolina
Department of Commerce. Raleigh, NC 1989.
CH-93-100 3-21
-------
CHAPTER 4
POLLUTION PREVENTION ALTERNATIVES
4.1 GENERAL
This chapter provides an overview of the pollution prevention alternatives for the coated
and laminated substrate manufacturing industry. The chapter is divided into eight sections: (1)
General, (2) Cleanup Avoidance, (3) Best Practices, (4) Recycling of Solvents and Cleaning
Materials, (5) Alternative Cleaning Materials, (6) Equipment Modifications, (7) Alternative
Cleaning Technologies, and (8) Waterbased Adhesives. The cleanup avoidance section addresses
job scheduling, and running the equipment dry. The best practices section discusses the impacts
of best operating practices on the reduction of emissions associated with equipment cleaning.
The recycling section focuses on the benefits associated with recycling. The alternative cleaning
materials section addresses the use of mineral spirits, citrus based cleaners, and di-basic esters
in equipment cleaning. The equipment modifications section discusses changes that can be made
to existing equipment to reduce waste generation. Alterative cleaning technologies focuses on
the use of ultrasonic cleaning and its impact on equipment cleaning. The final section discusses
the impact of converting from solvent-based adhesives to waterbased adhesives on equipment
cleaning.
CLEANUP AVOIDANCE
42.1 Job Scheduling/Production Campaigning
Efficient production scheduling can be a very effective way to reduce the need for
equipment cleaning in any industry. In job scheduling, similar products are run together. For
the coated and laminated substrate industry, products with similar coatings would be run in
sequence. Proper scheduling will reduce the need to clean reservoirs, application rollers, and
other pieces of equipment that require large amounts of cleaning solvent. Job scheduling requires
prior planning with production needs balanced against reduced cleaning.1
CH-93-100 4-1
-------
Job scheduling can cause some cross-contamination between batches of adhesives.
However, this problem is often solved with the use of makeready substrate. Makercady substrate
involves the disposal of the cross-contaminated end of one run and the beginning of the
subsequent run of substrate.
4.22 Run Dry
Running the coating line dry is an operating technique, occurring at the end of a
production run, that involves adding only enough coating to the application trough to coat the
length of the remaining web. This allows the substrate web and the coating to end at
approximately the same time. In some facilities, the excess coating, following a run dry step,
is drained from the troughs and coating lines and put back into storage drums for future use.
Both of these methods require considerable operator planning and attention.2
4.3 BEST PRACTICES
4 J.I Storage of Cleaning Solvents
Many facilities store cleaning solvents close to the production areas to provide easy
worker access. Most facilities have small containers (e.g., 3 to 5 gallon safety cans) at or near
the production machinery, larger containers in the production area for exchange of solvents, and
a storage area for delivery and pickup of the solvent barrels or tanks. Occupational Safety and
Health Act (OSHA) regulations provide guidance on storage and movement of drums and
containers within a facility. Restricting operator access to these solvents is discussed in the next
section.
Use and Accessibility of Cleaning Materials
Coated and laminated substrate facilities typically do not restrict operator access to
cleaning solvents. Consequently, in many cases, operators dispense more cleaning material than
actually needed to achieve the desired level of cleaning.
CH-93-100 4-2
-------
Additionally, if an operator has a choice of cleaning materials, the material with the
greatest solvency and cutting power (and consequently the highest VOC content) is often
selected. Although the management may provide and encourage the use of alternative cleaners,
this use may not be enforced.
4.3.3 Mechanical Pre-Cleaning
Dry cleaning techniques can be used to remove coating material that has adhered to the
sides of mix tanks, coating application heads, application rollers, troughs, dams, and equipment
housings. These techniques typically consist of using fiber or metal brushes, squeegees, or putty
knife-type scrapers to mechanically remove excess coating prior to wet cleaning processes.
An alternative to full solvent wiping may consist of an initial dry scraping, followed by
a solvent wipe, followed by a second mechanical scraping step. In this case, most of the coating
is removed prior to any wet cleaning. The solvent-wipe step serves only to loosen and break the
bond between the coating and the equipment, not to completely dissolve and remove the coating.
Actual coating removal is achieved by the second dry step.
43.4 Disposal of Spent Cleaning Materials
Waste cleaning materials include spent rags, cleaning solvents, and wash water. Solvent-
soaked rags are typically considered solid hazardous waste and must be shipped off-site for
disposal. One facility reported being able to incinerate rags and filters used with Varsol in their
boiler. Depending upon State regulations, this may be an option available to many facilities.
One facility distilled TCA for use in the mixing area for solvent-based adhesives. Spent mineral
spirits were recycled by another facility to be used as a paint thinner for facility painting
applications. Additionally, washwater and the high pressure water used to clean large pieces of
equipment were determined to be hazardous waste at facilities using solvents to clean spills.
CH-93-100
4-3
-------
4.3.5 Centralization of Major Cleanup
Several facilities have centralized cleaning areas for parts which can be removed from the
machinery and cleaned. The creation of a centralized area may allow a facility to control air
emissions from the cleaning process by using a ventilation system to collect the solvent-saturated
air. The centralized cleaning area also reduces the possibility of a large spill of solvent occurring
on the process line.
Exterior sections of large vats may be cleaned by hand while the interior may have a mop
bath cleaning. Roller and other similar sized pans may be scrapped, bathed, and hung to dry.
Smaller parts may simply be bathed or dipped. Facilities may also have stages of cleaning. The
parts may be dipped in a less concentrated bath or dirty cleaner as an initial first step. Then, the
part may move to a intermediate bath where it is bathed and wiped by hand. The third bath area
may apply a clean solvent for a final cleaning and then drying.
4.4 RECYCLING OF SOLVENTS AND CLEANING MATERIALS
4.4.1 Solvent Recovery
Some facilities recover solvent using a batch distillation unit A batch distillation system
consists of four components: a spent solvent collection tank, a heated boiling chamber, a
condenser, and a clean solvent collection tank. Once an operator has cleaned a piece of
equipment, the spent solvent is stored in a small container which is later sent to the solvent
distillation system to be reclaimed.
As the spent solvent is added to the collection tank, a filter removes the large particles.
When the tank is full, the solvent is transferred by a pumping system to the heat chamber. As
the solvent is heated to a specific vaporization temperature, the low boiling point constituents are
vaporized and collected in a condenser. The unusable residue that collects at the bottom of the
heat chamber is referred to as still bottoms. These still bottoms are considered hazardous waste
and are disposed of off-site.
CH-93-100 4-4
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The vapors in the condenser are quickly cooled to promote optimum condensation. The
condensate is now nearly 100 percent solvent that is drained off and collected in containers to
be reused.3
4.4.2 Extension of Solvent Life/Countercurrent Rinsing
One source identifies the need to blend additives and/or stabilizers into the recovered
solvents to increase their useful life. Some cleaning solvents (e.g., TCA and MEK), however,
are not considered well suited to on site re-stabilization as the process may be too time-
consuming, labor intensive, and expensive for many facilities to pursue.4
Countercurrent rinsing is another method for extending the life of cleaning solvents.
Countercurrent rinsing uses spent cleaning solvent to complete an initial cleaning of the
equipment This step is then followed by rinsing the surface with clean solvent (either recycled
or virgin) to remove the remaining soils.5
4.43 Cleaning Rags
Frequently, the recycling of cleaning rags is dependent upon the chemical used. Rags
contaminated with solvents such as TCA, toluene, MEK, or heptane are treated as hazardous
wastes and require proper disposal Most facilities visited allow operators to decide when a rag's
useful life has been reached Those facilities using non-halogenated cleaners may be able to
clean rags either in-house or at a commercial cleaning operation. However, recycling cleaning
rags may introduce lint and dirt into the coatings which can cause a quality problem, and the cost
of cleaning the solvent-coated rags may be prohibitive.
CH-93-100 4-5
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4.5 ALTERNATIVE CLEANING MATERIALS
4.5.1 Mineral Spirits
Mineral spirits is a volatile, colorless petroleum solvent with a petroleum odor. A
commonly used mineral spirit derivative is Varsol, a branded petroleum solvent blend
manufactured by Exxon. A list of physical and chemical properties for Varsol is provided in
Section 2.8.3 of this document
In limited cases, Varsol has been found to be an effective cleaning solvent replacement
for toluene and MEK. Although Varsol does tend to leave a residue on the equipment being
cleaned, which can become a quality issue (e.g., leaving a film or leaving a tacky surface), some
facilities indicated that the amount of residue left on the rollers was minimal and would either
dry or be removed by the makeready substrate as it passed over the rollers.6
4.5.2 Citrus Based Cleaners and Terpenes
In recent years, the use of citrus based and terpene cleaners has received some attention
from the coated and laminated substrate manufacturing industry. Citrus based and terpene
cleaners are solutions of such chemicals as d-limonene and methylpyrrolidone. These cleaners
are not regulated under Title HI of the dean Air Act Amendments as hazardous air pollutants.
In most cases, these cleaners are also exempt from Title I regulations for VOCs.7
Some facilities have tried citrus based cleaners as replacements for toluene and MEK.
However, these facilities commented that the citrus based cleaners were expensive, did not clean
well, and produced a strong, undesirable odor. Another drawback is that the spent citrus cleaner
may still be considered hazardous waste due to the coatings that are being removed and therefore
must be disposed of properly.
4.53 Di-Basic Esters (DBEs)
Di-basic esters are chemical combinations of the refined methyl esters of adipic, glutaric,
and succinic acids. A typical mixture of DBE consists of 17 percent dimethyl succinate, 17
CH-93-100 4-6
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percent dimethyl adipate, and 66 percent dimethyl glutaratc.8 DBE is a combustible mixture
which may contribute to smog. When heated it decomposes and emits an irritating odor and
fumes.8 Because DBE is not an air toxic or a VOC and is less toxic than many currently used
cleaning materials, it may be an effective alternative cleaner. It is reported to be effective in
cleaning equipment used to coat products with polyurethane adhesives, however its use as a
cleaner within the coated and laminated substrate industry is not documented.4
4.6 EQUIPMENT MODIFICATIONS
4.6.1 Improved Shielding
Many facilities have modified process equipment to reduce the possibility of splashes and
spills. These modifications include the addition of edge guards and shields over application
areas. By reducing the amount of coating splashed on the outside of equipment or spilled on the
floor surrounding the equipment, the frequency of cleaning is reduced. However, the addition
of guards and shields can limit operator access to certain areas of the equipment, making repairs
more difficult
4.6.2 Surface Coating
Many facilities coat rollers with a nonstick materials such as teflon, silicone, or plasma-
coatings. These nonstick coatings allow the adhesive-coated substrate to pass over the roller
without sticking or leaving adhesive on the roller, thus reducing the required cleaning frequency.
One difficulty associated with coated rollers is durability. When the coating is nicked or
scraped, it loses its effectiveness. This is particularly a problem with silicone-coated rollers.
Ceramic/plasma-coated rollers also have drawbacks: static buildup on these rollers can ignite if
sparked and the entire line can catch fire. One solution is to avoid placing the plasma coated
rollers in series, which will prevent static buildup.9
CH-9V100 4-7
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4.63 Surface Wrapping
Another technique used to avoid cleaning is the application of a surface wrapping to the
outside of the equipment One facility covers the coating line equipment with foil This facility
reduced its equipment cleaning by removing the wrapping, disposing of it, and reapplying a new
wrap. Other facilities apply this same principle to the floors surrounding the coating line
equipment Floors may be covered with off-specification substrate material which would
otherwise be waste or with absorbent felt mats (which must be purchased, but require fewer
changeovers than off-specification substrates). In any of these cases, it is important to evaluate
the quantity of solid waste (equipment wraps or covers) generated in relation to reduced cleaning
emissions.
Another surface wrapping technique is the application of tetrafluoroethylene (TFE) film
tape to rollers to prevent the coatings from sticking to the rollers. However, TFE film tape is
one of the most expensive film tapes and its use could be cost prohibitive.
4.6.4 Substrate Edge Guides
The installation of pneumatic or electronic substrate edge guides can also assist in
reducing material waste and cleanup. The guides are often placed at several locations on a
coating line to regulate the movement of the web and to prevent the web from sliding back and
forth along the rollers. In keeping the web straight, the guides also ensure that the coating is
applied to the web without running past the edges and onto the floor or equipment
4.7 ULTRASONIC CLEANING
Ultrasonic cleaning is a technology currently used to clean metal parts. It was developed
as a possible replacement for solvent cleaning.10 Ultrasonic cleaning involves the use of sound
waves in an aqueous solution to create tiny bubbles which implode and "scrub" the part clean.
This method of cleaning is used in a variety of industries required to clean metal parts, including
limited applications within the coated and laminated substrate industry. The benefits of an
ultrasonic cleaning system include rapid cleaning, low operating cost, and high levels of
CH-9J-100 4-8
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cleanliness. From an environmental perspective, the use of aqueous ultrasonic cleaning solutions
reduces the VOC emissions associated with equipment cleaning and reduces the hazardous waste
generated by the facility.11
Ultrasonic energy uses sound waves above the range of human hearing (generally above
18,000 kilohertz). The ultrasonic waves are produced by a generator which creates high
frequency electrical current and a transducer which transforms the electrical current into
mechanical waves. The vibrations are transmitted to the cleaning liquid, which then contacts the
surfaces to be cleaned.12
Once the waves have reached a significant amplitude, cavitation occurs. Cavitation is
defined as the formation and collapse of vapor cavities in a flowing liquid.13 The result is the
production of thousands of extremely small, high-intensity shock waves that penetrate and "clean"
the duty part A benefit of ultrasonic cleaning is that the size of the bubbles allows cleaning the
most intricate part without having to disassemble it12
Several properties of the cleaning fluid can influence the effectiveness of ultrasonic
cleaning, temperature, dissolved gas in the liquid, surface tension, viscosity, ultrasonic power,
ultrasonic frequency, and part exposure. Temperature has the most significant effect on
ultrasonic cleaning. As temperature increases for most cleaning fluids, the cavitation intensity
increases, providing better cleaning. However, if the liquid reaches its boiling point, cavitation
will not occur. Dissolved gas in the cleaning fluid decreases the cavitation intensity because the
gas pocket provides a cushion that will not allow the full cavitation intensity to reach the part
to be cleaned. Cleaning fluids with high surface tension will create higher cavitation intensity
due to the greater energy that is released when the bubbles implode. The higher the viscosity
of the cleaning fluid the more energy required to cavitate. The ultrasonic power that is used to
generate the sound waves can become too strong and damage the parts to be cleaned. Identifying
the sufficient amount of power is very important Maintaining the proper ultrasonic frequency
is also important As the frequency is increased, more power is needed to produce the same
cavitation intensity. The final variable in the cleaning process is pan exposure: it is very
important for parts to be placed correctly in the bath to prevent air pockets from forming and
reducing the efficiency of the cleaning.12
An ultrasonic cleaning system is shown in Figure 4-1. The system contains three basic
elements: a generator, a transducer, and a tank filled with the cleaning solution. The generator
CH-93-100 4-9
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9
?
8
Transducers Cleaning solution
Generators
\
I
Tank
Figure 4-1. Ultrasonic Cleaning System.
-------
produces the high frequency electrical current The transducer converts the current into
mechanical vibrations. Some cleaning systems also include rinsing and drying stations.10 The
capital costs of such a system range from $10,000 to $150,000, depending mainly on tank size.11
The application of ultrasonic cleaning to equipment associated with the coated and
laminated substrate manufacturing industry requires carefully selecting the cleaning solution.
Typical cleaning solutions used in the metal parts cleaning systems have limited applicability to
the removal of adhesives from the rollers, carriages, application heads, and other pieces of
coating equipment One facility tested over 200 different cleaning solutions before finding a
cleaner capable of removing the wide variety of coatings.
4.8 WATERBASED ADHESIVES
The substitution of waterbased adhesives for solvent-based adhesives has been a subject
of interest with the coated and laminated substrate industry due to the reduction in VOC
emissions associated with the adhesive. Simplified equipment cleaning is another benefit of
waterbased adhesives. While still wet, waterbased adhesives can be cleaned with warm water
or a soap solution. However, if the adhesive is allowed to dry, the equipment cleaning methods
would be the same as those for a solvent-based adhesive.14
4.9 REFERENCES
1. Fromm, Carl H. and Budaraju, Srinivas, "Reducing Equipment-Cleaning Wastes,"
Chemical Engineering, Volume 95, Number 10, July 18, 1988.
2. Rexham trip report See Appendix C.
3. Davis, Darryl. Pollution Prevention Strategies in the Fiberglass Boat Building and Open
Mold Plastics Industries, East Carolina University, 1987.
4. Source Reduction Research Partnership, Metropolitan Water District of Southern
California, Environmental Defense Fund. Source Reduction and Recycling of
Halogenated Solvents in the Adhesives Industry. 1990.
CH-93-100
4-11
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5. McMinn, B.W. and Marsosudiro, PJ. Control of VOC Emissions from Ink and Paint
Manufacturing Processes, EPA-450/3-92-013 (NTIS PB92-190230). Office of Air Quality
Planning and Standards, Research Triangle Park, NC. April 1992.
6. TesaTuck trip report, See Appendix C.
7. Product information from Inland Technology Incorporated, Tacoma, WA. Solvent
Alternatives. Undated.
8. Sax, N. Irving and Richard J. Lewis, Dangerous Properties of Industrial Materials, Vol.
II, New York, 1989.
9. 3M Company trip report, See Appendix C.
10. "Ultrasonic Cleaning: Tiny Bubbles Do the Work", Modern Metals, Volume 44, Number
9, October 1988.
11. Barnett, K.W. and Most, CE. Ultrasonic Cleaning of Rotogravure Cylinders. EPA-
450/3-89-024 (NTIS PB89-216360). Office of Air Quality Planning and Standards,
Research Triangle Park, NC. June 1989.
12. Fuchs, F. John, "Ultrasonic Cleaning", Metal Finishing, Volume 82, Number 1, January
1984.
13. Perry, Robert H., Chilton, Cecil H., Perry's Chemical Engineers Handbook, Sixth Edition,
McGraw-Hill Book Company, New York, NY, 1984.
14. Bond, Karen. "Rubber-to-Metal Waterborne Eliminates Emissions and Odors," Adhesives
Age, Volume 32, Number 2, February 1990.
CH-9J-100 4-12
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CHAPTERS
SUMMARY AND EVALUATION OF DEMONSTRATION OPPORTUNITIES
5.1 GENERAL
The objective of Phase I of the Improved Equipment Cleaning in the Coated and Laminated
Substrate Manufacturing Industry project is to identify both potentially demonstrable pollution
prevention technologies and criteria characteristic of a facility in which the technologies could
be applied. This section outlines characteristics of such potential demonstration technologies and
sites. The information that is presented is based on data collected through several sources
including literature searches, industry questionnaires, plant visits, pollution prevention experts,
and industry and trade association personnel.
5.2 TECHNOLOGY SELECTION CRITERIA
The selection and overall effectiveness of a demonstrable pollution prevention technique
depends on several factors including potential environmental impact, cost, applicability,
availability, and longevity. This section applies these criteria to several of the pollution
prevention alternatives discussed in Chapter 4. Table 5-1 presents a summary of the potential
demonstration technologies.
5.2.1 Potential Environmental Impact
"Pollution prevention is any practice which reduces die amount of any hazardous substance,
pollutant, or contaminant entering the waste stream or otherwise released to the environment
(including fugitive emissions) prior to recycling, treatment, or disposal; and reduces the hazards
to public health and the environment associated with the release of such substances, pollutants,
or contaminants."1 Pollution prevention includes equipment or technology modifications, process
or procedure modifications, reformulation or redesign of products, raw material substitution, and
improvements in housekeeping, maintenance, training or inventory control. However, when
considering implementing any of these technologies, it is necessary to evaluate the potential
CH-93-100
5-1
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TABLE 5-1. TECHNOLOGY SELECTION CRITERIA
Pollution Prevention
Alternatives
Impacted Media
Air
Water
Land
Technology Cost
Capital
Annual Operating
Applicability and Longevity
Segment
Longevity
Availability
Cleanup Avoidance
Job Scheduling/Production
Campaigning
Run Dry
+
+
+
+
•f
+
None
None
Facility Dependent
Facility Dependent
Dedicated Line
All
Immediate and Indefinite
Immediate and Indefinite
Yes
Yes
Best Practices
Solvent Storage Techniques
Cleaning Materials
Accessibility
Mechanical Pre-Cleaning
Cleanup Centralization
+
•f
+
+
+
+
+
+
-
+
Minimal
Minimal
Minimal
High
Minimal
Minimal
Minimal
High
All
All
All
All
Immediate and Indefinite
Immediate and Indefinite
Immediate and Indefinite
Immediate and Indefinite
Yes
Yes
Yes
Facility
Dependent
Recycling
Solvent Recovery
Countercurrent Rinsing
+
+
+
+
+,-
+
High
High
Moderate
Moderate
Large Mfgs
Centralized
Cleaning
Immediate and Indefinite
Immediate and Indefinite
Facility
Dependent
Facility
Dependent
Alternative Cleaning Materials
Mineral Spirits
Citrus Based Cleaners
Dibasic Esters
+
+
+
+
-
-
+
+
+
Minimal
Minimal
Minimal
Minimal
Minimal
Minimal
Facility Dependent
Facility Dependent
Facility Dependent
Facility Dependent (upon
Product Testing)
Facility Dependent (upon
Product Testing)
Facility Dependent (upon
Product Testing)
Facility
Dependent
Facility
Dependent
Facility
Dependent
(Continued)
-------
TABLE 5-1. TECHNOLOGY SELECTION CRITERIA (Continued)
Pollution Prevention
Alternatives
Impacted Media
Air
Water
Land
Technology Cost
Capital
Annual Operating
Applicability and Longevity
Segment
Longevity
Availability
Equipment Modifications
Improved Shielding
Surface Coating
Surface Wrapping
+
+
+
+
+
+
+
-
-
Moderate
Moderate
Moderate
None
Minimal
Minimal
Facility Dependent
Facility Dependent
Facility Dependent
Immediate and Indefinite
Immediate and Indefinite
Immediate and Indefinite
Facility
Dependent
Facility
Dependent
Facility
Dependent
Alternative Technologies
Ultrasonic Cleaning
+
+
+
High
Moderate
Centralized
Cleaning
Immediate and Indefinite
Facility
Dependent
-------
environmental impacts (i.e., possible effects) on all media (i.e., air, water, and land). For
example, one must evaluate the relative environmental benefits (or disadvantages) achieved by
reducing air emissions from equipment cleaning by moving from aromatic or ketone cleaners to
aqueous cleaners, which will result in additional pollutant loading to the facility wastewater
stream.
One way to assess potential environmental impacts is through the development of a life
cycle analysis (LCA) which looks at the product/production process from the extraction of the
raw materials to the product's ultimate recycle or reuse. In this sense, an LCA is a "cradle-to-
cradle" approach, rather than the Resource Conservation and Recovery Act's (RCRA's) "cradle-
to-grave" approach. LCAs involve project definition, data gathering, model development, result
analysis and reporting, and result interpretation. Although an LCA for the pollution prevention
technologies discussed in Chapter 4 is beyond the scope of this project, some general
observations can be made. The impacted media are presented in Table 5-1.
B.22 Technology Cost
The cost of implementing a pollution prevention technology includes total capital
investment and total annual operating costs. Total capital investment includes costs required to
purchase equipment, costs of labor and materials for installing that equipment, costs for site
preparation and buildings, and other costs referred to as indirect installation costs (e.g.,
engineering and construction and field expenses). If the technology is an adjustment to a current
installation, then the costs are referred to as retrofit costs.
Total annual costs include raw material expenses, operating labor, maintenance, utilities,
replacement parts, waste treatment and disposal, capital recovery, and overhead.2 For the purpose
of this report, the cost section of Table 5-1 is divided into capital and annual costs. Specific cost
categories are listed in the appropriate cost columns.
CH-93-100 5-4
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5.2.3 Applicability and Longevity
Applicability refers to the range/segments of the coated and laminated substrate industry
to which the technology applies. For example, the technology may be applicable to masking tape
plants but not to label facilities, or the technology may be applicable to large facilities, but not
to small, toll coating plants. Longevity refers to the length of time required to achieve initial
results and the length of time during which the technology will be applicable. For example, a
facility may implement a technology which will achieve results within one year and will be
appropriate for four years based on the current manufacturing equipment and methodologies
practiced at the plant Table 5-1 identifies the industry segment (i.e., dedicated line or toll
coating facility) for which the technology is most applicable. Table 5-1 also indicates the
anticipated useful life of the technology.
5.2.4 Availability
Technology availability includes the ability of facilities to purchase, or otherwise acquire
and implement, the desired technology within a reasonable period of time (e.g., one year). One
commonly used example of availability is that of add-on control devices such as incinerators.
Some industry segments that have recently been required to install incinerators are facing a six-
month waiting time from placement of order to receipt of equipment This backlog is based on
the ability of the equipment manufacturing firms to make and ship a desired product
53 SITE SELECTION CRITERIA
Selection criteria exist for potential demonstration sites as well as for pollution prevention
technologies. Facility selection criteria include industry segmentation (i.e., size of facility and
product and process diversity), available resources, location, and timing. This section will
identify the characteristics of facilities likely to participate as demonstration host sites.
CH-93-100 5-5
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5 J.I Industry Segmentation
As discussed in Chapter 2, industry segmentation is determined by facility size and product
diversity. Generally, facilities within the coated and laminated substrate manufacturing industry
operate in one of two different segments. The first segment consists of large facilities operating
coating lines dedicated to one type of product, such as masking tape or label stock. For example,
one coating line at one facility produces 16 grades of filament tape. The differences between the
grades are based on the type of film (e.g., polyester or polypropylene), the type and number of
nylon or rayon strands per square inch, and the thickness of the coating applied. The second
industry segment consists of the batch-processor, or those plants that manufacture comparatively
small batches of a wide variety of products (usually with a high value-added component). This
category includes plants that make and market their own line of products, and batch-processors
that offer contract coating services. For example, one coating line at a batch facility may process
short-run, wide-width products including dry photo masking agents and reproduction materials.
Batch facilities are often small, employing less than 50 people.
Both segments of the coated and laminated substrate manufacturing industry use essentially
the same cleaning methods even though the segments differ substantially in the range of
substrates, coatings, and application equipment used at the plants. As a review of the information
presented in Chapter 2, the primary differences between the cleaning conducted at a dedicated
line facility and a batch plant are frequency and degree of cleaning. Dedicated line facilities may
run their lines 24 hours per day, 7 days per week, and 52 weeks per year. Lines are typically
shut down one shift per week for preventative maintenance and cleaning. In contrast, batch
processors generally do not clean equipment on any specific schedule. Due to the relatively short
production runs and the custom nature of the specialty products that these facilities manufacture,
cleaning between each job or product changeover is critical
For the reasons presented above, demonstrations should be conducted at one facility
operating in each of the two industry segments. The focus at the dedicated line facility might
include the implementation and evaluation of a cleaning solvent substitute, improved operating
practices, and process modifications. The focus at the batch coating facility would be geared
toward improving the efficiency of cleaning operations by reducing the amount of cleaning
solution necessary to achieve the required degree of cleanliness. A second objective at this
CH-93-100 5-6
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facility would be to identify better methods of administering the cleaning solution. A
demonstration within each of the industry segments will assist not only dedicated line facilities
and batch processors, but also those facilities that have characteristics of each:
5.3.2 Resource Availability
In order to conduct a successful demonstration, the host facilities must be willing to commit
company resources (e.g., time, labor, capital, and equipment) to the project A demonstration
team will spend approximately one week at the host site facility. Demonstration preparation will
be approximately two days, the actual demonstration will be completed within the remaining
three days and training, and follow-up will require approximately one day during a separate trip.
The demonstration and training segments are expected to occur during first shift operations, while
preparation may include activities during all normal operating hours (e.g., three shifts, if
applicable). Additionally, the host facilities will be expected to spend time coordinating with the
demonstration team.
The host facilities will be expected to provide the technical oversight necessary to prepare
for, conduct, and follow-up on the demonstration. The labor component will consist of
production operator cooperation and oversight during on-site operations, as well as a technical
coordinator for both on-site and off-site operations. Another critical labor component will consist
of management commitment to the success of the demonstration. It is also assumed that the host
facilities will purchase and install any necessary equipment to complete the demonstration.
Another resource component necessary to ensure success of the demonstration will be the
willingness of the host facility to work with the federal, State, and regional branches of EPA and
industrial trade associations to disseminate the demonstration results. Result dissemination will
include facility publicity and access to costing figures, raw material (e.g., cleaning solvent
purchase records), equipment specifications, and production and maintenance records.
533 Timing
The preparation and demonstration phases of this project will be conducted during June,
July, and August of 1993.
OB-9MOO 5-7
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5.4 REFERENCES
1. Pollution Prevention Act of 1990, 42 U.S.C. §13101, et seq.
2. Vatavuk, W.M. OAQPS Control Cost Manual, Fourth Edition, EPA-450/3-90-006 (NTIS
PB90-169954). Office of Air Quality Planning and Standards, Research Triangle Park, NC.
January 1990.
CH-93-100 5-8
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APPENDIX A
COATED AND LAMINATED SUBSTRATE INDUSTRIES WITH ANNUAL SALES
GREATER THAN $1 MILLION
CH-93-100 A-l
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TABLE A-l. COATED PAPER, PACKAGING FACILITIES (SIC 2671) WITH
1992 ANNUAL SALES GREATER THAN $1 MILLION
Saks in
Name Address $ Millions
Bemis Company Inc.
Consolidated Papers Inc.
Instrument Systems Corp.
Printpack Inc.
DataCard Corp.
Arrow Industries Inc.
Minnesota Mining and Manufacturing Co.,
Medical Imaging Systems
Cellu-Craft Inc.
MUprint Inc.
Shields Bag and Printing Co.
Star Tex Corp.
Consolidated Papers Inc., Stevens Point Div.
Central Products Co.
Packaging Industries Inc.
Papercon Inc.
Daubert Industries Inc.
Bonar Plastics Ltd, Bonar Packaging Inc.
PlaconCorp.
Ideal Tape Company Inc.
Barrows Paper Corp. Packaging Div.
Superpac Inc.
Adcbem Corp.
Worthcn Industries Inc.
Jefferson Smurfit Corp., laminating and
Coating Co.
Western Summit Manufacturing Corp.
dear Lam Packaging Inc.
Bihrite Inc^ Tape Products Div.
625 Marquette Ave, Minneapolis MN 55402 1,128
PO Box 8050, Wisconsin Rapids WI 54495 949
100 Jericho Quadrangle, Jericho NY 11753 459
PO Box 43687, Atlanta GA 30378 302*
PO Box 9355, Minneapolis MN 55440 300
PO Box 810489, Dallas TX 75381 185
8124 Pacific Ave, White City OR 97503 120
1403 4th Ave, New Hyde Park NY 11040 65
9045 N Deerwood Dr, Milwaukee WI 53223 65
PO Box 9848, Yakima WA 98909 60
PO Box 1089, Lakevflle MN 55044 42
PO Box 227, Stevens Point WI 54481 40*
531 N Stiles St. Linden NJ 07036 36
2450 Alvarado St, San Leandro CA 94577 36
2700 Apple Valley NE, Atlanta GA 30319 35
1 Westbrook Corporate, Westchester JL 60154 32
PO Box 818, Tyler TX 75710 30
PO Box 8246, Madison WI 53708 30
1400 Middlesex St, Lowell MA 01851 30
1722 53rd St, Fort Madison IA 52627 30
PO Box 189, Southampton PA 18966 25
625 Main St,Westbury NY 11590 25
3 E Spit Brook Rd, Nashua NH 03060 24
1228 E Tower Rd, Schaumburg IL 60173 24
9120 Juniper St, Los Angeles CA 90002 20
1950 Pratt Blvd. Elk Grove Village IL 60007 19*
105 Whittendale Dr. Moorestown NJ 08057 18*
(continued)
CH-93-100
A-2
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TABLE A-l. COATED PAPER, PACKAGING FACILITIES (SIC 2671) WITH
1992 ANNUAL SALES GREATER THAN $1 MILLION (continued)
Sales in
Name Address $ Millions
Minnesota Mining and Manufacturing Co.,
Packaging Systems Div.
Release Technologies Inc.
Flex Products Inc.
Kleartone Inc.
Noipak Corp.
Tapecon Inc.
Pioneer Paper Corp.
Peacock Papers Inc.
Tolas Health Care Packaging Corp.
Zom Packaging Inc.
Lustreprint Corp.
SuBastion Industries Inc., Prescotech
Foxon Packaging Corp.
Arcon Coating Mills Inc.
Hobar Company Inc.
Creative Environments Inc.
PO Box 5517, Greenville SC 29606
1400 Harvester Rd, West Chicago IL 60185
2793 Northpoint Pkwy, Santa Rosa CA 95407
695 Summa Ave, Westbury NY 11590
70 Blanchard St, Newark NJ 07105
10 Latta Rd, Rochester NY 14612
50 Triangle Blvd. Carlstadt NJ 07072
273 Summer St, Boston MA 02210
114 Pheasant Run, Newtown PA 18940
1315 Hwy 34, Farmingdale NJ OT727
622 Northumberland, Buffalo NY 14215
PO Box 4362, Evansvilk IN 47711
235 W Park St, Providence RI 02901
PO Box 486, Oceanside NY 11572
PO Box 2363, South San Francisco CA 94080
33 W 54th St, New York NY 10019
17*
16*
11*
11
10
9
9
9
6
6
6
4*
3
3*
3
1*
* Indicates an estimated financial figure.
Source: Gale Research, Inc. Ward's Business Directory of US. Private and Public Companies, Volume 5. Detroit,
ML 1992.
CH-93-100
A-3
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TABLE A-2. COATED AND LAMINATED PAPER, NEC FACILITIES (SIC
2672) WITH 1992 ANNUAL SALES GREATER THAN $1
MILLION
Name
Address
Saks in
$ Millions
Minnesota Mining and
Manufacturing Co.
Boise Cascade Corp., White Paper
Div.
Appleton Papers Inc.
Nashua Corp.
PLC Enterprises Inc.
Mosinee Paper Corp.
International Paper Co., Bleached
Board Div.
Anchor Continental Inc.
Simpson Plainwell Paper Co.
Avery Dennison Corp., Fasson RoD
Div.
American Tape Co.
Shofbrd Mills Inc., Tape Div.
James River Corporation of Virginia,
Riegd Packaging Div.
Tesa Tuck Inc.
James River Corporation of Virginia,
Otis Div.
Fbrtifiber Corp.
Fitchburg Coated Products Inc.
Minnesota Mining and
Manufacturing Co., Tape
Manufacturing Div.
Manco Inc.
Wheeler Group Inc.
Avery International Corp., Fasson
Specialty Div.
Bomarko Inc.
3M Or, St Paul MN 55144
PO Box 50, Boise ID 83728
PO Box 359, Appleton WI 54912
PO Box 2002, Nashua NH 03061
300 Plaza Dr, Vestal NY 13850
1244 Kronenwetter Dr, Mosinee WI 54455
PO Box 7069, Pine Bluff AR 71611
PO Drawer G, Columbia SC 29250
200 Allegan St, Plainwell MI 49080
7670 Auburn Rd, Painesvflk OH 44077
317 Kendall Ave, Marysville MI 48040
PO Drawer 1530. Hickory NC 28603
Frenchtown Rd, Milford NJ 08848
1 Le Fevre Ln, New RocheDe NY 10801
PO Box 10, Jay ME 04239
4489 Bandini Blvd. Los Angeles CA 90023
PO Box 1106, Scranton PA 18510
Hwy 71 S, Nevada MO 64772
830 Canterbury Rd, Westlake OH 44145
PO Box 2945, Hartford CT 06104
9292 9th St, Rancho Cucamonga CA 91730
PO Box K, Plymouth IN 46563
13,021
2,610*
775
590
260
210
160*
110
100*
99*
92
91*
90
74
73
70
70
63*
60
53*
50
49
(continued)
CH-93-100
A-4
-------
TABLE A-2. COATED AND LAMINATED PAPER, NEC FACILITIES (SIC
2672) WITH 1992 ANNUAL SALES GREATER THAN $1
MILLION (continued)
Saks in
Name Address $ Millions
MPI Label Systems
Hazen Paper Co.
James River Corporation of Virginia,
Wyomissing Div.
Kanzalri Specialty Papers Inc.
Holland Manufacturing
Phomat Reprographics Lac.
James River Corporation of Virginia,
Premold Div.
Devon Tape Corp.
Custom Tapes Inc.
Tape Inc.
Drug Package Inc.
CrowellCorp.
ADM Corp.
TimeMed Labeling Systems Inc.
Riverside Paper Corp.
DRG Medical Packaging Inc.
Temple-Inland Inc., Rexford Paper
Company Div.
Data Documents Inc., Label Div.
Label Art Inc.
M and C Specialties Co.
Tidi Products Inc.
Sun Process Converting Inc.
Topflight Corp.
Hamilton Hybar Inc.
ExceUo Specialty Co.
PO Box 70, Sebring OH 44672
PO Box 189, Holyoke MA 01041
PO Box 742, Reading PA 19603
PO Box 2002, Ware MA 01082
IS Main St, Succasunna NJ 07876
29350 Stephenson Hwy, Madison Heights MI 48071
Box 6001, West Springfield MA 01090
1511 TonneUe Ave, North Bergen NJ 07047
7125 W Gunnison St, Harwood Heights IL 60656
PO Box 11067, Green Bay WI 54307
901 N Service Rd, O'Fallon MO 63366
PO Box 3227, Newport DE 19804
100 Lincoln Blvd. Middlesex NJ 08846
144 Tower Dr. Burr Ridge IL 6*0521
PO Box 179, Appleton WI 54911
4101 Lien Rd, Madison WI 53704
PO Box 411, Milwaukee WI 53201
3403 Dan Morton Dr, Dallas TX 75236
1 Riverside Way, Wilton NH 03086
90 James Way, Southampton PA 18966
PO Box 2150, Rialto CA 92376
505 Bonnie Ln. Elk Grove Village IL 60007
160 E 9th St, York PA 17405
4123 Carolina Ave, Richmond VA 23222
4495 Cranwood Pkwy, Cleveland OH 44128
48
46
42
40
39
35
34
28
28
27
26*
25
24
21
20
20*
20
19*
18
18
17
15
15*
14*
13
(continued)
CH-93-100
A-5
-------
TABLE A-2. COATED AND LAMINATED PAPER, NEC FACILITIES (SIC
2672) WITH 1992 ANNUAL SALES GREATER THAN $1
MILLION (continued)
Saks in
Name Address $ Millions
American Cyanamid Co., Engineered
Materials Dept
Shamrock Scientific Systems Inc.
Highland Supply Corp.
Salem Label Company Inc.
Betham Corp.
Best Label Company Inc.
Permalite Repromedia Corp.
Paper Coating Co.
Handy Wacks Corp.
Fibre Leather Manufacturing Corp.
Laminated Papers Inc.
Fast Coast Finishing Co.
International Tape Products Co.
Graphic Arts Finishers
Litton Industrial Automation
Systems Inc., Identification
Products
East-West Label Company Inc.
Universal Label Printers Inc.
Avon Tape Inc.
Salinas Valley Wax Paper Company
Inc.
Alfax Paper and Engineering Co.
Dielectric Polymers Inc.
Dora-Process Co.
Keystone Packaging Service
Qoikstik Label Manufacturing Co.
Blue Ribbon Label Corp.
21444 Golden Triangle, Saugus CA 91350
34 Davis Dr, Bellwood IL 60104
1111 6th Si, Highland IL 60104
PO Box 39, Salem OH 44460
87 Lincoln Blvd. Middlesex NJ 08846
13260 Moore St, Cerritos CA 90701
230 E Alondra Blvd. Gardena CA 90248
3536 E Medford St, Los Angeles CA 90063
PO Box 26, Sparta MI 49345
686 Belleville Ave, New Bedford MA 02745
54 Winter St, Holyoke MA 01040
Box 39. Fairview NJ 07022
5 Lawrence St, Bloomfield NT 07003
32 Cambridge St, Charlestown MA 02129
6750 S Belt Circle Dr, Bedford Park IL 60638
1000 E Hector St, Consbohocken PA 19428
12521 McCann Dr, Santa Fe Springs CA 90670
PO Box 1423, Brockton MA 02403
PO Box 68, Salinas CA 93902
35 Washington St, Westborough MA 01581
218 Race St, Holyoke MA 01040
4000 Wiimetka Ave N, Minneapolis MN 55427
555 Warren St. Phillipsburg NJ 08865
210 Broadway. Everett MA 02149
241 Hudson St. Hackensack NJ 07601
(continued)
13*
13*
12
12
12
12
10
8*
8
7
6*
6*
6
5
5
5
5
5
5
5
5
4
4
4
4
CH-9MOO
A-6
-------
TABLE A-2. COATED AND LAMINATED PAPER, NEC FAOLITDZS (SIC
2672) WITH 1992 ANNUAL SALES GREATER THAN $1
MILLION (continued)
Sales in
Name Address $ Millions
Penmar Industries Inc. 1 Bates Ct, Norwalk CT 06854 4
Alcop Adhesive Label Co. 826 Perkins Ln, Beveriy NJ 08010 3
Mask-Off Company Inc. PO Box 1 148, Monrovia CA 91017 3
Markel Finishing Corp. 400 Bostwick Ave, Bridgeport CT 06605 3*
Hurst Label Co. PO Box 6903, Burbank CA 91510 3
Thomas Tape Co. PO Box 207, Springfield OH 45501 3
JL Darling Corp. 2212 Port Tacoma Rd, Tacoma WA 98421 2
Dermi-Klene Company Inc. 1901 S Bon View Ave, Ontario CA 91761 I
KeDer Ticket Co. 554 36th St, Union City NJ 07087 <1*
* Indi«tci *n ««*"«•«»< fi"»""«| figure.
Source: Gale Research, Inc. Ward" s Business Directory cfU£. Private and Public Companies, Volume 5. Detroit,
ML 1992.
CH-93-100 A-7
-------
APPENDIX B
COATED AND LAMINATED SUBSTRATE FACILmES AND
ASSOCIATED TRIS EMISSIONS
CH-9J-100 B-l
-------
w
TABLE B-l.
FacUity
3M
3M, BRISTOL PLANT
3M CENTER
ADHESIVES RESEARCH INC.
ALUSUISSE FLEXIBLE PACKAGING INC.
AMERICAN NATIONAL CAN CO.
AMERICAN NATIONAL CAN CO.
AMERICAN NATIONAL CAN CO.
AMERICAN NATIONAL CAN CO.
AMERICAN NATIONAL CAN CO.
AMERICAN NATIONAL CAN CO.
AMERICAN NATIONAL CAN CO.
AMERICAN NATIONAL CAN CO.
AMERICAN NATIONAL CAN CO.
AMERICAN TAPE CO.
AMERY TECHNICAL PRODUCTS INC.
ARLON INC., FLEXIBLE TECHNOLOGIES DIV.
AVERY LABEL BASE MATERIALS
BOMARKO INC.
CELLU-CRAFT MIDWEST INC.
CELLU-CRAFT PRODUCTS CO.
CELLU-CRAFT SOUTH
CONSOLIDATED ALUMINUM CORP.
DELUXE PACKAGES
DENNISON MFG. CO.
DIXICO INC.
DIXICO INC.
DRG MEDICAL PACKAGING INC.
FASSON MERCHANT PRODUCTS DIV.
SIC 2671 - COATED PAPER,
PACKAGING
Total
Air Release MEK Release
Parent Company Name in Ibs/yr in Ibs/yr
3M
3M
3M
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
AVERY INTERNATIONAL
NA
NA
NA
NA
NA
NA
AVERY DENNISON
NA
NA
NA
AVERY DENNISON
75,875
2,280,115
84,267
92,455
91,540
384,278
321,837
299,606
142,185
118,251
86,049
20,134
9,270
1,680
3,258,683
14,390
69,000
182,380
205,000
11,179
41,857
16,488
456,249
23,084
478,317
304,995
62,126
51,250
105,832
5,200
26,250
6,100
66,476
73,402
128,574
207,355
91,450
45,455
28,261
1,680
14,390
69,000
15,436
120,612
8,819
Toluene Release
in Ibs/yr
43,600
1,900,250
37,600
1,608
292,828
186,795
68,783
53,373
72,7%
23,754
20,134
9,270
3,258,683
55,000
16,488
85,652
469,493
300.984
60.608
51,250
105,832
(Continued)
-------
TABLE B-l. SIC 2671 - COATED PAPER, PACKAGING (Continued)
w
Facility
HARGRO FLEXIBLE PACKAGING
HARGRO FLEXIBLE PACKAGING CORP.
HARGRO INDUSTRIAL PKG.
INTERNATIONAL PAPER CO.
JATTE PACKAGING INC.
JAMES RIVER CORP.
JAMES RIVER CORP.
JAMES RIVER II INC.
JAMES RIVER II INC., COATED PRODUCTS DIV.
J.S.C.-SMURFIT LAMINATIONS
KLEARTONE INC.
LABELON CORP.
LEPAGE'S INC.
LITHOGRAPHIC INDUSTRIES INC.
LITHOTYPE CO.
MANVILLE FOREST PRODUCTS PLANT 20
PACQUET ONEIDA INC.
PILLSBURY GREEN GIANT FILM CONVERTING
RITRAMA DURAMARK
R. J. REYNOLDS TOBACCO CO. WHTTAKER
PARK 641
STRAUBEL PAPER CO.
TENNESSEE PRESS INC.
WESTVACO ENVELOPE DIV.
ZIMMER PAPER PRODUCTS INC.
Parent Company Name
NA
NA
NA
INTERNATIONAL PAPER
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
MANVILLE CORP.
NA
NA
NA
NA
NA
NA
NA
NA
GRAND TOTAL
Total
Air Release
in Ibs/yr
214,680
74,797
18,524
70,500
91,100
178,000
152,000
9,178
54,070
11,800
1,663
138,770
44,215
6,613
15,800
66,780
3,152
52,851
164,000
9,978
11,327
48,000
32,800
32,535
10,791,505
MEK Release
in Ibs/yr
1,909
11,410
65,400
66,060
6,613
17,240
27,107
9,465
11,000
1,124,664
Toluene Release
in Ibs/yr
198,000
7,114
13,000
42,000
152,000
26.300
5330
42,324
49,540
25,744
164,000
513
14,000
5,400
32,535
7,892,581
Source: TRIS 1990
NA - Not Available/Applicable
-------
TABLE B-2. SIC 2672 - COATED AND LAMINATED PAPER, NEC
FACILITY
PARENT COMPANY NAME
TOTAL
AIR RELEASE
IN LBS/YR
MEK RELEASE
IN LBS/YR
TOLUENE
RELEASE
IN LBS/YR
3M
3M CENTER
3M, CV & AP CONSUMER PRODUCTS PLANT
3M TAPE MFG. DIV.
ACME STEEL CO., PITTSBURG WEST PLANT
ADCHEM CORP.
ADCHEM INDUSTRIES INC.
ANCHOR CONTINENTAL INC.
APPLETON PAPERS INC.
APPLETON PAPERS INC. HARRISBURG PLANT
ARLON INC.
* AVERY DENNISON BUILDING 3
AVERY DENNISON BUILDING 7
AVERY DENNISON FASSON FILMS DIV.
AVERY DENNISON FASSON ROLL DIV.
AVERY DENNISON M A PF DIV.
AVERY DENNISON SPECIALTY TAPE DIV.
AVERY LABEL BASE MATERIALS
CAMVAC INTERNATIONAL INC.
CENTRAL PRODUCTS CO.
COMPAC INDUSTRIES INC.
CORONET PAPER CORP.
DAUBERT COATED PRODUCTS INC.
DECORA MFG., DECORA DIV.
EASTERN FINE PAPER INC.
ESSELTE DYMO HIGHLAND PLANT
FASSON MERCHANT PRODUCTS DIV.
3M
3M
3M
3M
ACME STEEL CO.
ADCHEM CORP.
ADCHEM INDUSTRIES INC.
LINCOLN GROUP
APPLETON PAPERS INC.
WIGGINS TEAPE APPLETON
BAIRNCO CORP.
AVERY DENNISON
AVERY DENNISON
AVERY DENNISON
AVERY DENNISON
AVERY DENNISON
AVERY DENNISON
AVERY INTERNATIONAL
BOWATER INDUSTRIES PLC.
ALCO STANDARD CORP.
COMPAC CORP.
NA
DAUBERT INDUSTRIES INC.
UTDLITECH INC.
SHELBURNE HOLDING CORP.
ESSELTE PENDAFLEX CORP.
AVERY DENNISON
419,050
84,267
20,106,008
2,554,780
25
27,150
9,900
3,374,938
45,889
724
44,250
831,874
756,300
15,595
690,200
1,901.670
9,180
182,380
30,406
2
8,364
3,450
334,300
43,005
23,158
125,110
105,832
33,000
11,747,612
70,000
5,600
1,850
12,161
71,400
69,000
495
1,863,000
3,080
18,422
12,300
25,339
2,166
40,175
9,589
22,250
16,000
7,469,813
676,000
18,200
6,050
3359,653
11,426
678,000
337,800
14,250
650,000
11,800
6,400
11.984
8364
3,450
322,000
15,114
19,935
122344 (a)
(Continued)
-------
TABLE B-2. SIC 2672 - COATED AND LAMINATED PAPER, NEC (Continued)
FACILITY
PARENT COMPANY NAME
TOTAL
AIR RELEASE
IN LBS/YR
MEK RELEASE
IN LBS/YR
TOLUENE
RELEASE
IN LBS/YR
W
u\
GRAPHIC CONTROLS CORP.
GRAPHICS TECHNOLOGY INTERNATIONAL
INC.
HOOD COATINGS INC
INTERNATIONAL PAPER CO.. MOSS POINT
MILL
IVEX COATED PRODUCTS CORP.
KANZAKI SPECIALTY PAPERS
LAMOTITE
LITHO COLOR PRINTING CORP.
LITTLE FALLS COLOR PRINT
LUDLOW CORP.
LUDLOW TECHNICAL PAPERS
MANVILLE SALES CORP.
MASK-OFF CO. INC.
MEYERCORD INTERNATIONAL INC.
MOORE BUSINESS FORMS & SYSTEMS DIV.
MORGAN ADHESIVES CO. (MACTAC)
NASHUA CORP. CPD
NASHUA CORP. LABEL DIV.
NORESIN INC.
NORESIN INC.
NORTHERN ENGRAVING CORP.
ORCHARD DECORATIVE PRODUCTS
OREGON OVERLAY DIV.
PEARL BOOKBINDING CO. INC.
GRAPHIC CONTROLS CORP.
SPECIALTY COATINGS GROUP,
INC.
NA
INTERNATIONAL PAPER
IVEX CONVERTED PRODUCTS
CORP.
KANZAKI USA INC.
REXHAM
NFC PARTNERS
SULLIVAN PAPER CO.
TYCO LABORATORIES INC.
TYCO LABORATORIES INC.
MANVILLE CORP.
NA
MEYERCORD CO.
MOORE BUSINESS FORMS INC.
BEMIS CO. INC.
NASHUA CORP.
NASHUA CORP.
NA
NA
NA
BORDEN INC.
SIMPSON INVESTMENT CO.
NA
186,590
450.000
51,621
339,303
339,710
9,000
1,159,704
177,409
24.196
236,015
2,350
7,698
24,095
2,700
422.695
766,525
301,426
1,162.500
145,329
41,105
50,531
6,373
1.119,270
500
18,200
44.963
150,144
3,750
5,123
151,535
450,000
51,621
305,000
51,693
27,265
24,196
236,015
4,170
6,255
8,450
2,700
759,302
292,404
717,000
50,531
5,373
(Continued)
-------
TABLE B-2. SIC 2672 - COATED AND LAMINATED PAPER, NEC (Continued)
w
FACILITY
PERMALITE REPROMEDIA CORP.
PRECISION COATINOS INC.
REICHHOLD CHEMICALS INC.
REYNOLDS METALS CO., PLANT #1
ROCK-TENN PAPERBOARD PRODUCTS
SANCAP LINER TECHNOLOGY INC.
SIMPSON PAPER CO.
STRAUBEL PAPER CO,
SULLIVAN PAPER CO.
THILMANY
W. H. BRADY COATED PRODUCTS DIV.
PARENT COMPANY NAME
NA
NA
REICHHOLD, INC.
REYNOLDS METALS CO.
ROCK TENN CO.
NA
SIMPSON INVESTMENT CO.
NA
NA
INTERNATIONAL PAPER CO.
W. H. BRADY CO.
GRAND TOTAL
TOTAL
AIR RELEASE
IN LBS/YR
113,310
776,200
489.972
39,520
160,920
64,000
25,400
11,327
45,229
1,069,100
423,050
41,972,480
MEK RELEASE
IN LBS/YR
150,000
24,950
53,350
14,435,669
TOLUENE
RELEASE
IN LBS/YR
98,307
290,000
14,570
45,229
370,000
302.300
18,044,749
Source: TRIS 1990
NA - Not Available (Applicable)
NEC - Not Elsewhere Classified
(a) Emissions are summed from SICs 2671 and 2672
-------
TABLE B-3. MISCELLANEOUS COATED AND LAMINATED SUBSTRATE MANUFACTURING FACILITIES
FACILITY
PARENT COMPANY
NAME
TOTAL AIR RELEASE
IN LBS/YR
MEK RELEASE
IN LBS/YR
TOLUENE RELEASE
IN LBS/YR
SHUFORD MILLS, HICKORY, NC
FLEXCON, SPENCER, MA
COATING SCIENCES, INC.,
BLOOMFffiLD, CT
THE OCTOBER COMPANY,
EASTHAMPTON, MA
TESATUCK, MIDDLETOWN, NY
REXHAM, MATTHEWS, NC
SHUFORD MILLS, INC.
FLEXCON
COATING SCIENCES, INC.
THE OCTOBER COMPANY
TESATUCK, INC.
REXHAM INDUSTRIAL
1,931^24
194,492
33,985
18,945
228,750
614,515
32,319
3,342
300,970
1,931324
132,473
20,052
18,945
228,750
299,968
Source: 1990 TRIS
W
-------
APPENDIX C
TRIP REPORTS
Site Page
Anchor C-2
3M C-21
TesaTuck C-30
Nashua C-36
Rexham C-48
Shuford C-55
Flexcon C-64
CH-93-100 C-l
-------
Environmental Solutions through Technology
TRC Environmental Corporation
100 Europe Drive, Suite 150
Chapel Hill, NC 27514
tr (91 9) 968-9900 Fax (91 9) 968-7557
Date: January 8, 1993
Subject: Site Visit - Anchor Continental Incorporated
Pressure Sensitive Tape Manufacturer
EPA Contract 68-D9-0173, Work Assignment Number 3/309
TRC Reference No. 1637309
From:
To:
Geary D. McMinn and David D. Ocamb
TRC Environmental Corporation
Mike Kosusko
Organics Control Branch
Air and Energy Engineering Research Laboratory (MD-61)
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
I.
Purose
As part of the overall effort by the U.S. Environmental Protection Agency (EPA) to identify
areas for preventing the creation of pollution associated with manufacturing entities, EPA is currently
reviewing the pollution prevention opportunities associated with equipment cleaning in the adhesives-
coated and laminated paper industry. TRC Environmental Corporation (TRC) is supporting EPA in
this effort by developing prevention strategies for laminated paper equipment cleaning under Work
Assignment Number 3/309, EPA Contract Number 68-D9-0173.
Anchor Continental Incorporated (Anchor), a pressure sensitive tape manufacturing facility,
was selected for a site visit to collect information on the pollution prevention opportunities available
for this industry segment The focus of pollution prevention efforts in this industry is on emissions
of volatile organic compounds (VOCs) and air toxics. The purpose of the visit to Anchor was to
gather information on their pressure sensitive tape manufacturing processes and to identify, with input
from the plant experts, any opportunities for preventing VOC emissions resulting from the cleaning
of equipment Specific objectives of the trip were to collect information necessary to characterize
the plant production processes, equipment cleaning requirements and practices, and cleaning solvent
recovery and disposal methods; and to witness first-hand any pollution prevention opportunities for
pressure sensitive tape equipment cleaning operations.
This trip report includes four sections. Section n identifies the location of the Anchor
facility. Section HI presents the individuals who participated in the site visit Section IV includes
the technical information compiled during the site visit In addition, the attached Appendix presents
facility plot plans for the various Anchor production processes.
Offices io California, Colorado, Connecticut, Illinois, Louisiana, Massachusetts, New Jersey, New York, North Carolina, Pennsylvania, Texas,
Washington, Washington, D.C., and Puerto Rico A TRC Company
...... ™ — «,™.,,^..
C9
•*•
-------
n. Place and Date
Anchor Continental Incorporated
2000 South Beltline Boulevard
Columbia, SC 29250
(803) 376-5468
December 18, 1992
IIL Attendees
Anchor Continental Incorporated
Rick G. Carnell, Environmental Affairs Manager
TRC Environmental Corporation
David D. Ocamb, Senior Environmental Engineer
Geary D. McMinn, Environmental Scientist
IV. Discussion
The discussion began with the purpose of the visit, addressing EPA's goals for pollution
prevention analysis for pressure sensitive tape manufacturing, and future preventive activities.
During this meeting the following major areas were considered:
• The general plant description
• Manufacturing and site activities at the Columbia plant including adhesives mixing, paper
tape manufacturing, reinforced tape manufacturing, cloth tape manufacturing, and stencil
products manufacturing
• Equipment cleaning practices
• General emissions information
• Pollution prevention opportunities specific to the Anchor facility
• Prevention opportunities that may be applied to the overall industry (e.g., reformulation of
adhesives and changes in cleaning)
The meeting was followed by a tour of the production operations. Each specific topic addressed in
the meeting is discussed in detail below.
A. Anchor History and General Plant Description
Anchor Continental began manufacturing pressure sensitive tapes approximately sixty years
ago. Anchor currently operates two plants, one in Covington, Ohio, and the headquarters plant in
Columbia, South Carolina. The Columbia facility operates 5 days per week, 24 hours per day, and
produces four types of pressure sensitive products:
C-3
-------
• Paper Tapes
Duct (Cloth) Tapes
Reinforced (Film) Tapes
Stencil Products
Although specific product characteristics (e.g., adhesive strength or color) vary according to
customer specifications, there are general product characteristics for each of the different product
groups.
Anchor manufactures several types of saturated paper tapes including masking tapes and some
packaging tapes. The VOC content of the coatings in these tapes (i.e., saturant, release coat, and
adhesive), and the resulting VOC emission rate, varies viscosity and with the desired performance
characteristics. For instance, a product, such as automotive tape, which must withstand elevated
temperatures for an extended period of time tends to be manufactured with natural rubber. When
dissolved in a solvent such as toluene, natural rubber results in a high viscosity (high solids, low
solvent) material Other materials (e.g., synthetic rubbers) result in low solids formulations and yield
high VOC coating contents and high VOC emission rates.
Duct or cloth tapes are laminates of cloth and a polyethylene film. While the 100 percent
solids adhesive on such tapes contains no solvents, the release coat does contain a solvent Solvent
vapors from the release coat station and oven are destroyed in a catalytic oxidation unit Duct tape,
as its name applies, is used in ducting insulation and carpet pad splicing.
Reinforced (film) tapes are manufactured in the same manner as paper tape except that the
saturated paper substrate of the paper tape is replaced with a polyester film. The film contains glass
fiber strands which provide superior strength. Film tapes have become popular in packaging and box
sealing, electrical, and pipe wrapping applications.
Stencil products are manufactured using a calendered, solvent-based adhesive coating process.
An adhesive-coated film and a rubber sheet are laminated and wound into a roll. The stencil
products are used in a variety of etching (e.g., glass) and sand blast (e.g., monument) applications.
The solvent vapors resulting from the drying of the adhesive coat are destroyed by catalytic
oxidation.
Figure A in the Appendix shows the layout of the Anchor - Columbia facility. The tape and
stencil products are manufactured on a total of five process lines in either the production building,
the rubber division building, or the latex saturator building. Adhesives and release coats are
formulated in the mixing area. The mixed adhesives and release coats are transferred to the area
storage vessels for use in the various tape production processes. In addition, a centralized equipment
cleaning room is located at the south end of the production building. The majority of the movable
equipment used throughout the production facility (e.g., rollers, dip trays, and knives) is directed to
this central room for dedicated cleaning.
C-4
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As shown on the plot plan in the Appendix Figure B, the main production building contains
three of the five facility process lines as well as other specialized processes. Line 1 is a low VOC
line regulated by New Source Performance Standards (NSPS). Line 2 is grandfathered from NSPS
regulations, has fewer restrictions on the VOC content in the processing materials, and, therefore,
can run tapes that produce higher emissions. Line 3 runs only reinforced and paper tape. The main
production building also houses an intermediate coating line which saturates raw paper with
polyurethane to provide the paper with greater tensile strength.
The remaining two tape process lines are located in the rubber division as shown in Appendix
Figure C. Duct (cloth) tape and stencil products are manufactured on dedicated process lines. The
rubber division contains two small scale banburys (rubber mixing units) which are used to mix the
rubber substrate and mill/extrude the rubber sheeting and adhesive stocks.
Appendix Figure D shows the layout of the saturator building. This building contains a hot-
melt line and an intermediate coating line used to manufacture latex-saturated tape backing for paper
tapes. In the latex-saturation process, raw paper is saturated with latex to provide greater tensile
strength. The saturating process involves passing the paper through a latex saturant bath and then
drying the saturated paper in drying ovens. The saturated paper is then directed to other tape process
lines for production of the desired tape product The hot-melt uses a solventless thermoplastic
adhesive to produce specialty tapes.
B. Adhesive Mixing
Adhesive mixing is a basic manufacturing requirement for the solvent-based adhesives used
in the tape products produced by Anchor. Anchor mixes adhesives to meet tight tolerances dictated
by customer specifications. Figure 1 is a flow diagram representing the Anchor process for adhesive
mixing. As shown, adhesive mixing begins with stock preparation. Stock is prepared by blending
natural and synthetic rubbers, hydrocarbon resins, oils, and fillers in a banbury. The banbury output
is then directed to mills where a sheet of adhesive stock is extruded, cut, and then palletized for
further processing.
The pallet sheets are then sent to the mixing department where they are loaded into mixers
approximately 10,000 gallons in size. Toluene is added to dissolve the stock. Heptane is also used
with toluene for manufacturing certain stencil adhesives. The solvent is pumped into the mixers with
additional resins, rubber (self polymerizing), and oils to complete the adhesive formulation. Table 1
presents a breakdown of me adhesive ingredients employed by Anchor. The actual mix ratios are
considered confidential.
Once an adhesive is formulated, the finished material is pumped to storage tanks in the
appropriate manufacturing building or transferred via tote vessels to specific process lines for future
use. In order to ensure the proper adhesive quality, Anchor uses in-line filtration. Filter bags
separate remaining suspended solids (the natural and synthetic rubber) from the coating mixture. The
filter bags are changed once per shift for each coating line.
C-5
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STOCK PREPARATION -
* Banbury mix rubber/fillers
* Mill bcnbury stock
* Palletize stock, send to mixing
T
MIXING
* Solvent
* Rubber stock
* Resins
* Oils
T
BULK STORAGE
* To coatina lines
TOTE TANKS/DRUMS
* Small volume coatina
Figure 1. Adhesives Mixing Flow Diagram.
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TABLE 1. ANCHOR ADHESIVES RAW MATERIALS
Chemical Name Chemical Name
Styrene/butadiene copolymer Petroleum hydrocarbon resin
Zinc dibutyl dithiocarbonate Heptane
Tetrakis (methylene(3,5-Di-tert-butyl-4- Styrene-isoprene-styrcne block copolymer
hydroxyhydrocinnamate))
Polyterpene resin Aliphatic hydrocarbon resin
Zinc oxide Zinc isopropyl xanthate
Mineral oil Natural rubber
Polyalphamethyl styrene Sodium aluminum silicate
Diphenylmethane diisocyanate Toluene
Ground limestone Hydrated amorphous silica
Ground silica Zinc dibutyl dithiocarbonate
C. Paper Tape Manufacturing
A process flow diagram for paper tape manufacturing is presented in Figure 2. To
manufacture paper tape, the raw paper is bought from a vendor either as latex saturate or
polyurethane saturate. The compositions of the purchased saturates are presented in Table 2. If a
desired color and/or bond (tie) is required, the paper is processed in an intermediate coating area
before applying a release and adhesive coat A tie coat improves the bond of the adhesive to the
paper.
After color and/or tie coats are applied, the release coat is applied to the non-bonding surface
of the product The composition of the release coat is presented in Table 3. The release coat is
applied by passing the paper through a roller system containing a release coat The release coat is
transferred from the roller to the top side of the paper. The roller system maintains the tension of
the paper to ensure even coating application. A doctor blade, a long knife-like piece of metal,
removes any excess coating from the paper. The removed coating returns to the coating bath for
reuse. The release coat is pumped from the release coat storage tanks on the process line which are
fed from the larger storage tanks located in the mixing area. The tape passes through multi-stage
natural gas-fired dryers to dry the release coat
Adhesive, pumped from bulk storage tanks located in the mixing area, is applied after the
release agent After exiting the release coat dryers, the paper passes through rollers to maintain the
tension for applying the adhesive. A large roller dipping into a "bath" of adhesive comes into
contact with the clean, non-release coat, side of the papercoated paper. A doctor blade is used to
remove excess adhesive from the paper after contacting the roller. The adhesive-coated paper then
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INTERMEDIATE COATING
* lie coat
* Color coat
•PAPER FROM VENDOR
* Latex saturate
* Polyurethane
saturate
COATINGS
* Adhesive from
mixing/bulk storage
* Release coat
COATING
* Apply release coct
* Apply adhesive
T
SLITTING
* lube (core) making
* Slitting (automatic
-------
TABLE 2. ANCHOR PURCHASED SATURANTS COMPOSITION
Saturant Type Chemical Name
Latex Saturant Carfooxy-modified butadiene/styrcne polymer emulsion
Polyurethane Saturant Toluene diisocyanate
Toluene
Hydrocarbon resin
Polyether blend
TABLE 3. ANCHOR RELEASE COAT RAW MATERIALS
Chemical Name Chemical Name
Acrylic ester copolymer Isopropyl alcohol
Silicone catalyst Silicone solution
Polyamide resin Toluene
proceeds through another set of dryers. The paper tape is then ready for Quality Assurance
Inspection, slitting, roll-up, and packaging for distribution.
D. Reinforced Tape Manufacturing
Other types of tapes have the same basic process flow as paper tapes but are manufactured
using slightly different raw materials and substrates. The general process flow diagram for reinforced
tape manufacturing is presented in Figure 3. In general, reinforced tapes have a polyester backing
instead of saturated paper backing. Fiberglass strands are incorporated to give superior strength
compared to paper tape. These strengtheners are tie-coated or laminated, to the polyester film. The
release coat is applied on the opposite side of the tie-coat with the adhesive being placed over the
reinforcing threads. The remaining processing activities for reinforced tape include drying, Quality
Assurance Inspection, slitting, roll-up, and packaging for distribution.
E. Duct (Cloth") Tape Manufacturing
Figure 4 presents the process flow diagram for duct tape manufacturing. Duct tape
manufacturing is similar to paper tape manufacturing except that the adhesive is calendered in a solid
form to join together to the laminate, the polyethylene film and the cloth substrate. The result is a
cloth and film web which then has the release coat applied on the film side. No solvent is present
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FIBERGLASS STRANDS
POLYESTER FILM
COATINGS
* Adhesive from
mixing/storage
* Release coat mix
T
COATING
* lie—coat application to film
* Apply reinforcing threads onto tie—coat
* Apply release coat opposite side
* Apply adhesive over reinforcing threads
SLfTflNG
* Tube (core) making
* Slitting (automatic
-------
CLOTH
POLYETHYLENE FILM
T
CALENDER/COATING
* Apply 100% .solids adhesive to
cloth/film web
* Apply release coat to film
T
SUTTING
* Tube (core) making
* Slitting (automatic & duplex)
* Bulk pack at slitter or load on peg
carts for packing
ADHESIVE STOCK
* Banbury mix base
stock
* Mill base stock &
resins
PACKING
* Bulk pack (bulk & sleeves)
* Inalvtducl roll wrap (film wrap)
* Box
SHIPPING
Figure 4. Duct (Cloth) Tape Manufacturing Process Flow Diagram.
C-ll
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in the duct tape adhesive which is 100 percent solids. However, toluene is present in the release
coat Anchor employs a catalytic oxidizer to destroy any toluene or other emissions generated during
drying.
F. Stencil Products Manufacturing
The process for manufacturing stencil products is different from tape manufacturing. The
stencil products process flow diagram is presented on Figure 5. The process begins by blending
rubber stock in a banbury and then milling and calendering the banbury output to create rubber
sheets. The sheets are placed on a conveyor for cooling. Adhesive is transferred from the mixing
area by tote vessels. The adhesive is applied to a release liner. This adhesive-coated release liner
is then laminated with the rubber sheets, trimmed to proper size, and wound in rolls. The stencil
products are then finished in the same way as other Anchor tape products.
G. General Equipment Cleaning Practices
Anchor does not perform equipment cleaning on any specific schedule. When a process is
down, the equipment is disassembled (that which can be), moved to the centralized equipment
cleaning room attached to the main production building, and given a toluene bath. Process
equipment is soaked and cleaned in one of two 100-gallon toluene vats in the cleaning room. The
vats are filled with toluene as needed; the toluene is changed once per week. Toluene is pumped
off and recycled as part of the overall adhesive mixing process. Approximately 180 gallons are
recycled. Anchor estimates using mass balance that 20 gallons per week of toluene are lost as waste
and fugitive emissions. Further discussion of the reclamation process can be found in Section H of
this report
Stationary equipment (e.g., rollers) that cannot be moved to the centralized cleaning room is
cleaned in a two-step process. First, the equipment is wiped down with a dry rag. Next, it is
cleaned with a toluene-soaked rag. Drip trays are located under the adhesive coaters on each coating
line. In addition to catching excess adhesive, these trays contain toluene which is used for spot
cleaning. Scrapers, similar to putty knives, are dipped into toluene in the drip tray or solvent safety
can and then used to remove dried adhesive from the process equipment rollers.
The toluene-soaked rags and excess toluene are collected in five-gallon safety cans located
near the machinery. The safety cans are sealed, grounded containers which hold the toluene and
toluene rags to prevent spills and reduce emissions. Once these cans are full, the operator is required
to take them to a 55-gallon drum located in the disposal area (located in the mix area). Toluene-
contaminated rags and toluene that cannot be reclaimed are sent off-site for disposal. Any other
spent solvents (e.g., heptane) and waste, solvent-based coatings used in the facility are sent off-site
for disposal.
In the past, Anchor attempted to use Varsol, a mineral spirits solvent substitute, for general
equipment cleaning in an attempt to reduce toluene use and resulting emissions from clean up.
However, Anchor found Varsol to be less effective than toluene for equipment cleaning. Anchor
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RELEASE LINER
RUBBER STOCK
* Banbury mix
* Mill
COATINGS
* Adhesive
(tote tanks)
T
CALENDERING
* Create rubber "sheet"
T
COATING
* Apply adhesive to reiecse liner
T
LAMINATING
* Combine rubber sheet to cohesive
coated reiecse liner
* Trim to desired width
FINISHING
* Rnal visual inspection
* Unwind end cut to length, wind
onto ceres and box
SnlPPlNG
Figure 5. Stencil Products Manufacturing Process Flow Diagram.
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believes that Varsol is inappropriate for the production line because it leaves a film on the adhesive
and release coat rollers which reduces the uniformity of the applied coats and subsequently prevents
the adhesive from attaching to the tape. Varsol is currently used to clean spills and leaks on floors
and machinery in the packaging department It is also used for daily floor cleaning. The Varsol-
soaked cleaning rags (not classified as hazardous waste) are disposed of in the facility (burned in the
plant boiler) according to Anchor's South Carolina Department of Health and Environmental Control
(DHEC) permit The permit prohibits burning toluene-soaked rags.
H. General Emissions Information
Toluene is used as a solvent in the mixing of the adhesives and in cleaning the process
equipment Toluene is released from the centralized cleaning room as well as from the "on-the-spot"
cleaning applications within the facility. These releases are predominantly fugitive emissions.
Cleaning equipment involves wiping the excess adhesives with a rag, scraping the equipment
component if necessary, and then wiping the area with a toluene-soaked rag.
Anchor employs both a toluene recycle/reclamation and an off-site disposal program. The
containers holding toluene and toluene-soaked rags are a source of fugitive emissions. After cleaning
parts and removing sludge, the centralized cleaning room, which houses the two 100-gallon vats,
recycles approximately 180 gallons per week of toluene. In addition, an average of 148 gallons of
sludge per month is sent off-site for disposal. Approximately 200 gallons per month of toluene are
reused while only 20 gallons per week are non-reusable. Roughly 88 gallons of toluene per week
from other sources are reusable. Approximately six drums per year of toluene rags are sent off-site
for disposal.
Spent Varsol is sent off-site for disposal while rags contaminated with Varsol are burned in
the boilers. Approximately 125 gallons of Varsol per week are generated from plant wide sources.
Varsol rags are burned at the rate of two drums per week. Varsol is also used to wash filter bags
which become contaminated with adhesive on the production lines. Filter bags are incinerated at the
rate of one drum per week.
L Pollution Prevention Opportunities
Potential pollution prevention opportunities include: (1) replacement of all toluene cleaning
with Varsol; (2) identification of a cleaning solvent substitute to replace toluene; (3) elimination of
the toluene/adhesive drip trays on the coating lines, and (4) using sealed cleaning solvent buckets
for on-the-spot cleaning.
The most effective technique for Anchor to reduce emissions would be to eliminate toluene
as a cleaning solvent Even though Anchor has previously replaced a large portion of the toluene
with Varsol, complete replacement of toluene by Varsol is unreasonable since Varsol has a limited
application for cleaning in the pressure sensitive tape industry. As mentioned earlier, Varsol can
leave a film on the coating rollers which reduces the effectiveness of the adhesive application. As
such, identification of a new cleaning solvent to use in conjunction with Varsol remains the only
viable opportunity for reducing toluene usage and emissions from equipment cleaning. To pursue
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this preventive opportunity, the cleaning solvent suppliers could be surveyed to determine if an
effective toluene replacement exists in the market place today. One consideration in using a solvent-
substitute is subsequent disposal of the aqueous waste.
An additional pollution prevention (and emissions reduction) opportunity available at Anchor
would be to replace the toluene/adhesive drip trays and provide the operators with sealed cleaning
solvent buckets for on-the-spot cleaning. Process operators generally use putty-like cleaning knives
to spot clean areas on calenders, mills, and coating rollers. The operators generally have a drip tray
present where a small volume of toluene is maintained. The putty knives are dipped into the tray
to moisten the knife prior to the on-the-spot cleaning. By using a small, sealed cleaning bucket in
place of toluene in an open drip tray, the operators can use toluene for spot cleaning while
simultaneously reducing fugitive emissions.
Additional measures such as using a toluene dilution (e.g., 75 percent toluene and 25 percent
water) could have an impact on emissions from the cleaning process. Alternative technologies such
as using a mist sprayer rather than a continual toluene drip may reduce the amount of adhesive lost
in the application process and reduce the amount of toluene needed for clean up. Finally, a
combination of the above techniques may be applied to reduce the emissions of toluene from the
pressure sensitive tape industry.
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APPENDIX
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I---.".."." ^ : 5'='-•' J"*'"'r iV" .- .
.. 1 • s : a;* f »v..:: ': ~ ...
I_-.IL:I_I.- V.VI. J_r_i.!• V .:
PLANT UYOUT
|i*t I* y •» I «r
II-H. li..l
Figure A. Site Plan for the Anchor Continental Incorporated
Columbia, South Carolina Facility
-------
r
p
I—»
oo
v;
COATING DMSION
W. .inti 1.^
Figure B. Anchor Production Building Plot Plan
-------
9
t—•
VO
o
D
TITTl
PL I—Pv_LjV...I KJ ... _
fnnn
-irnnir
Jwb«
-------
Figure D. Anchor Saturator Building Plot Plan
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TRC
TRC Environmental Corporation
100 Europa Drive, Suite 150
Chapel Hill, NC 27514
Environmental Solutions through Technology w (919) 968-9900 Fax (919) 968-7557
Date: March 31, 1993
Subject: Site Visit - 3M Company
Pressure Sensitive Tape Manufacturer
EPA Contract 68-D9-0173, Work Assignment Number 3/309
TRC Reference Number 1637309
From: Beth W. McMinn and Jill B. Vitas
TRC Environmental Corporation
To: Mike Kosusko
Organics Control Branch
Air and Energy Engineering Research Laboratory (MD-61)
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
I. Purpose
As part of the overall effort by the U.S. Environmental Protection Agency (EPA) to identify
areas for preventing the creation of pollution associated with manufacturing entities, EPA is currently
reviewing the pollution prevention opportunities associated with equipment cleaning in the adhesives-
coated and laminated paper industry. TRC Environmental Corporation (TRC) is supporting EPA in
this effort by developing pollution prevention strategies for laminated paper equipment cleaning
under Work Assignment Number 3/309, EPA Contract Number 68-D9-0173.
The Minnesota Mining and Manufacturing Company (3M) in Bristol, Pennsylvania, a pressure
sensitive tape manufacturing facility, was selected for a site visit to collect information on the
pollution prevention opportunities available for this industry segment The primary focus of pollution
prevention efforts in this industry is on emissions of volatile organic compounds (VOCs) and air
toxics. The purpose of the visit to 3M was to gather information on their pressure sensitive tape
manufacturing processes and to identify, with input from the plant experts, any opportunities for
preventing pollution resulting from the cleaning of equipment Specific objectives of the trip were
to collect information necessary to characterize the plant production processes, equipment cleaning
requirements and practices, and cleaning solvent recovery and disposal methods; and to witness first-
hand any pollution prevention opportunities for pressure sensitive tape equipment cleaning operations.
This trip report includes four sections. Section n identifies the location of the 3M facility.
Section in presents the individuals who participated in the site visit Section IV includes the
technical information compiled during the site visit
Offices
-------
H. Place and Date
3M Company
Green Lane
Bristol, PA 19007
(215) 945-2800
February 11, 1993
EL Attendees
3M Company
Belinda M. Wirth, Environmental Engineer
Bob McKinnell, RCRA Coordinator
TRC Environmental Corporation
Beth W. McMinn, Project Manager
Jill B. Vitas, Task Leader
IV. Discussion
The discussion began with TRC describing the purpose of the visit, addressing EPA's goals
for pollution prevention analysis for pressure sensitive tape manufacturing and future preventive
activities. During this meeting the following areas were discussed:
Market Profile
• Manufacturing Supplies
• Manufacturing Process Profile
• Equipment Cleaning Experience
• Emissions Reduction and Control Experience
• Pollution Prevention Experience
The meeting was followed by a tour of the production operations. Each topic addressed in the
meeting is discussed in detail below.
A. 3M History and Market Profile
3M Company has approximately 70 plants in the United States, 14 of which manufacture
pressure sensitive tapes and labels (i.e., operate under Standard Industrial Classification codes 2671
and 2672). In total, the company employs nearly 50,000 people in the United States. 3M is the
largest pressure sensitive tape manufacturer with almost 85 percent of the market share and 1991
sales of nearly $13 billion.
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The 3M Bristol facility, whose primary Standard Industrial Classification (SIC) code is 2672
(Coated and Laminated Paper, Not Elsewhere Classified), began operation in 1948 when 3M
Company purchased the central building and land. Since that time, 3M has expanded, adding both
buildings and land, to reach its current 70-acre site as shown on Figure 1. The Bristol plant is now
operating with both a facility and employee cap. The facility's primary product has always been
pressure sensitive tape. The Bristol plant currently operates within 3M's Masking and Packaging
Division and produces film and filament packaging tapes for both consumer and industrial markets.
Nearly 90 percent of the plant's output is sold to industrial markets. Additional plants in this
division are located in Bedford Park, Illinois and Greenville, South Carolina. Approximately 40
percent of the tapes produced at the Bristol facility contain solvent-based adhesives, while the
remaining 60 percent contain hot melt adhesives and typically a solvent-based release coat In
addition to manufacturing tapes, the Bristol plant makes fire retardant and marine caulks.
B. Manufacturing Supplies
The 3M Bristol plant uses more than 200 raw materials in their manufacturing processes.
While the majority of these compounds are used in the caulk formulations, over 120 materials are
used in primers, release coatings, and adhesive blends. The 3M facility uses toluene and mineral
spirits to clean the equipment and floors.
C. Manufacturing Process Profile
The manufacturing process at the Bristol facility begins with the formulation of the coatings.
A release coating prevents an adhesive from sticking to a surface. For tapes, the release coating
prevents the adhesive-coated surface from sticking to the backside of the tape during manufacturing
and winding. 3M uses a release coating step in the manufacture of film and filament packaging
tapes. These low solids coatings are composed of resins, solvents, and additives. The release
coatings are manufactured in fixed or portable agitated mix tanks and transferred via a dedicated
manifold system to the release coating application head.
3M also manufacturers primers which bond the natural rubber based adhesive to the film
substrate. Raw materials in the primers include rubbers, solvents, and additives. The primers are
manufactured by the same process as the release coatings.
The 3M Bristol facility compounds both hot melt and rubber based (natural and synthetic)
adhesives. The adhesives are made in blenders and high-speed shear dispersers, called moguls, and
then transferred via dedicated transfer lines to the applicable coating heads. The adhesive
manufactured for the filament tape line uses natural or synthetic rubber dissolved in solvent mixtures
for the specified viscosity. Adhesive for the film tape line has a synthetic rubber (hot melt) base.
The 3M Bristol plant operates two coating lines. The 5W line is dedicated to the manufacture
of filament tape, while the 6W line produces colored film tapes. The Bristol plant is the only 3M
plant in the United States that makes filament tape, a type of heavy-duty polyester or polypropylene
packaging tape reinforced with filament strands. The 5W line operates 24 hours a day, 6 days a
week, and 40 weeks per year with a maximum capacity of 115 yards per minute and an average
C-23
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Ib-.
ri i
n
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tl«| I
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F
")-:
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I KM «... I ...... J, I
, .. __ . l._ ...... I...
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III
PLOT PLAN
Figure 1. 3M Bristol Facility Plot Plan.
-------
capacity of 80 square yards per minute. The line is typically shut down on Fridays for preventive
maintenance and cleaning. Sixteen different grades of tape are manufactured on the 5W line. The
differences between these grades are based on the type of film (i.e., polyester or polypropylene), the
type and number of nylon or rayon strands per square inch, and the thickness of the coating applied.
The highest grade (and profit margin) products are produced in the greatest quantity (e.g., 3.8 million
square yards per year).
The general process flow for the 5W line follows. Rolls of polyester or polypropylene film
are placed on an unwinder. The film passes through a gravure coater that applies a solvent-based
primer which averages 98 percent VOC (5.9 pounds VOC per gallon of coating less water). Solvents
used in the 5W coating formulations include xylene, toluene, heptane, ethanol, and cyclohexylamine.
After the film substrate is primed, it passes through a hot air impingement dryer with an airflow of
6,000 scfm. The exhaust from this primer oven is released to the atmosphere. The dry, primed film
is then release coated with a gravure roller (96 percent VOC and 6.9 pounds VOC per gallon of
coating less water) and moved through a second hot air impingement dryer. The exhaust from the
release coat oven is also released to the atmosphere. The film then moves to a primary adhesive
application stage where an adhesive averaging 4.9 pound VOC per gallon (81 to 82 percent VOC)
is applied. Following the adhesive coating, the film enters a two-stage oven equipped with inert gas
solvent recovery. Once dry, the film and nylon or rayon filament strands are laminated and adhesive
coated. The second adhesive coating step is followed by a pass through two stages of a six zone
oven also equipped with an inert gas solvent recovery system, a third adhesive coating application,
and a final pass through the remaining four stages of the oven. Solvent recovery in the adhesive
ovens on the 5W line is estimated to be 83 to 86 percent efficient The product is then wound,
followed by slitting and packaging.
The 6W line operates 24 hours a day, 7 days a week, and 45 weeks per year with a line
capacity of 425 yards per minute. The line is typically shut down for four to eight hours on
Tuesdays for preventive maintenance and cleaning. The 6W line is capable of manufacturing 50 to
60 varieties of film tape products. Products are distinguished by film type, color, and film thickness.
Eighty percent of the films run on the 6W line are polypropylene, 18 percent are polyester, 1 percent
is polyvinyl chloride (PVC), and the remaining 1 percent are made with miscellaneous substrates
(e.g. kraft paper, cellophane, etc.). The polypropylene and polyester film tapes and kraft paper tapes
are used in box sealing applications. Tapes made with cellophane and PVC films are used for
specialty applications such as taping clothing bags. All of the products produced on the 6W line are
sold to industrial customers. Two of 3M's other facilities located in Greenville, South Carolina and
Cynthiana, Kentucky make the same product for consumer markets using similar equipment
configurations.
Coating stations on the 6W line consist of two precoaters and one functional adhesive
applicator. The configuration of this line allows 3M personnel to use any combination of these three
coating stations. A brief description of the 6W line and its current operating parameters follows (see
Figure 3). Clear or colored films are loaded onto an unwinder. The film is guided by idling rolls
to Station 1, an enclosed coating operation, where a gravure roller is used to apply primers. This
coating station operates on average one day (i.e., 24 hours) per month. Waterbased primers are
C-25
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applied 16 to 20 hours each month while solvent-based coatings account for the remaining 4 to 8
hours of operation. The solvent-based (e.g., toluene, xylene, heptane, and isopropanol) coating
formulations are typically pigmented and are used to change the properties of the film. From Station
1, the web moves into an enclosed release coat (low adhesive backsize - LAB) application station
(Station 2). This station also uses a gravure roller. Station 2 is used 100 percent of the time that
the line is operating. Each of these two precoat stations (i.e., the primer and the LAB) is followed
by a single stage oven. The next coating application station applies the functional hot melt adhesive
using die application. The coated film is then wound and moved to the slitting operations. No
emissions control device is used on this line as the hot melt formulation contains no solvents.
Exhaust from both of the ovens is vented directly to the atmosphere.
D. Emission Reduction and Control Experience
Emission control devices used by the 3M Bristol facility include the following:
• Inert gas solvent recovery ovens following adhesive application on the 5W filament tape line
• Baghouses in the rubber compounding and milling areas
• Baghouses in the converting area for detackifying operations
• Condensers on the release and primer blenders
The solvent (i.e., heptane) that is recovered from the two adhesive solvent recovery ovens is
recycled back into the adhesive. 3M has also installed (but is not operating) duct work to capture
the air stream from the open web area (prior to the web entering zones seven and eight of the inert
gas solvent recovery oven) on Line 5W to improve the capture efficiency resulting in an overall
control efficiency of over 90 percent Plant officials hope to route the flash-off stream to the
facility's boiler for heat recovery. The facility is currently waiting on permission from the State of
Pennsylvania.
In addition, 3M Company has plans to transfer the LAB coating of polypropylene that occurs
at Station 2 on Line 6W to another facility with a sophisticated solvent recovery unit The Bristol
facility would then receive primed and LAB coated polypropylene films from a sister facility and
apply only the hot melt adhesive on the 6W line. The elimination of these steps at the Bristol plant
would allow the facility to reduce solvent emissions originating at the 6W line. Emissions at the
other 3M facility would not be significantly affected by the added coating application processes.
Table 1 shows the Bristol facility's 1991 reportable Toxic Release Inventory (TRI) emissions. Table
2 shows 1992 VOC emissions broken down by coating line.
E. Equipment Cleaning Experience
Because the 3M Bristol facility operates coating lines dedicated to one product category
(individual products may have different coating formulations), extensive cleaning is limited to
production downtime or significant product changeovers. Normally, downtime, which consists of
scheduled downtime for preventative maintenance (i.e., Tuesdays for 6W and Fridays for 5W),
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TABLE 1. 3M BRISTOL FACILITY 1991 TRI EMISSIONS
Chemical
Toluene
Xylene
Ethylbenzene
Cyclohexane
Methyl Ethyl Ketone
Methanol
Zinc Compounds
Quantity (pounds/year)
910,000
12,000
1,200
102,605
1,400
7,600
11 to 499
Source
Stack
Stack
Stack
Stack
Stack
Stack
Fugitive
TABLE 2. 3M BRISTOL FACILITY 1992 VOC EMISSIONS (TONS)
Coater 1st Qtr. 2nd Qtr. 3rd Qtr. 4th Qtr. Total
5W
6W
Total
202.5
79.6
282.1
172.4
97.7
270.1
202.7
96.9
299.6
135.5 713.1
110.6 384.8
246.1 1,097.9
downtime due to lack of line utilization, or quality imposed line shutdowns, is 1 percent of operating
time. Production is scheduled to run compatible batches in sequence. When a product change is to
occur, the production operator will add only enough coating to the application troughs to coat the
length of film remaining on the substrate web. This allows the substrate web and the coating to end
at approximately the same time. As the first web finishes, the second web is threaded and new
coating formulations are added to the application troughs. In some cases, excess coating is drained
from the application pans and coating lines back into storage drums. The drummed material is
retained for future use. Although mere is some product contamination with either scenario, the
substrate coated with the mixed coatings is the last portion of the first roll or the first part of the
succeeding web. In either case this portion of the web, the makeready substrate, is discarded.
Makeready is generated regardless of substrate and coating. This method of process changeover,
characteristic of large facilities running dedicated production lines, minimizes coating waste and,
consequently, minimizes required cleanup. For example, the 6W line often runs pigmented
adhesrves. Production jobs are scheduled to run from white to darker colors. These changeovers
C-27
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may generate several thousand yards of makeready film, most of which (i.e., all of the
polypropylene) is sold as scrap.
More significant product changeovers require more cleaning. In some cases, lines are
stopped, application rolls are wiped down, and application trays are removed and replaced with clean
trays. The removed trays are then cleaned with toluene and made ready for the next product
changeover. In-process cleaning is done as needed when coatings, especially adhesives, spill or
splash onto equipment housings.
Cleaning operations at the Bristol facility may be separated into three primary categories (i.e.,
in-process equipment cleaning, centralized parts cleaning, and miscellaneous cleaning) using three
types of cleaning solvents (i.e., mineral spirits, toluene, and heptane). The type and method of
process equipment cleaning is based on the adhesive or coating formulation rather than on the type
of film or substrate. The coating application rollers on both the 5W and the 6W lines are cleaned
using similar methods. The cleaning frequency, however, is slightly different Adhesive application
rollers are the most frequently cleaned piece of equipment, followed by the LAB application rollers.
All of the coating rollers on the SW line and the prime coat application roller on the 6W line are
wiped with a non-static rag soaked in toluene and then cleaned with a caustic solution. Spot
equipment cleaning (e.g., sides of dams and troughs and coating application heads) on both lines is
done with toluene-soaked rags. Larger jobs, including the cleaning of piping, pumps, ovens, and
equipment housings, are done with rags and mineral spirits. If material has solidified on the
equipment, toluene may be used instead of mineral spirits. The hot melt adhesive roller on the 6W
line is cleaned using dry methods such as mechanical scraping.
The Bristol facility operates four centralized parts cleaning areas. One area is dedicated to
the cleaning of pressure tanks, mix tanks, and tote tanks. These large pieces of equipment are
transferred into the cleaning room equipped with exhaust fans and an air make-up fan. The outside
of the equipment is manually cleaned with rags, brushes, and mineral spirits, while internal tank
components are cleaned manually with heptane, mops, and squeegees. The other centralized cleaning
areas use parts washers and are used to clean coating application heads, coating troughs, material
piping, and miscellaneous equipment parts. The parts to be cleaned are placed in the solvent bath,
soaked, and men scrubbed with brushes. Two of these stations use mineral spirits and the third uses
toluene. All of the solvent employed in parts cleaning operations is used for a period ranging from
three days to three weeks. Once they are no longer usable, the spent solvents are combined, declared
waste, and transferred to drums which are sent off-site for fuel blending. (The waste solvent has a
BTU value of 18,500). Cleaning rags that are no longer usable are also combined and sent off-site
as hazardous waste.
Miscellaneous cleaning includes the cleaning of product and raw material storage tanks,
process lines, and floors. Routine floor cleaning is performed as needed using mineral spirits. In
general, storage tanks and process lines are dedicated and, therefore, do not require cleaning. The
Bristol facility has been using high pressure water for these difficult and occasional (yearly) cleaning
jobs. A licensed contract facility, OHM, uses a solution of high pressure (12,000 psi) water, heptane,
isopropyl alcohol, and salts to clean dry adhesives from process equipment, storage tanks, floors, and
C-28
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other equipment parts. The wash water is contained and disposed of as hazardous waste (D001,
Waste Flammable Liquid). Because this type of service is rather expensive (/.«., approximately $800
per day) and because it is costly to dispose of the waste (due to the low BTU value), 3M plans to
discontinue this method of cleaning. No replacement cleanup methods have been identified.
In 1990, the Bristol plant generated 1,366,000 pounds of solid hazardous waste (e.g., rags and
adhesive/coating waste) and 847,000 pounds of waste cleaning solvent Projected 1993 figures are
23,800 pounds of solid hazardous waste and 26,000 pounds of waste solvent
F. Pollution Prevention Experience
Much of 3M's pollution prevention experience at the Bristol plant consists of avoiding
cleanup and following "best management" practices. The facility uses centralized cleaning areas
which limits operator access to cleaning solvents. In addition, 3M recovers the solvent that
volatilizes in the 5W ovens and recycles it back into the adhesive formulation.
The Bristol facility has attempted to use citrus based cleaners in slitting and packing
operations. Although the cleaners performed well and resulted in no quality problems, they were
cost prohibitive. The Bristol facility has not attempted to use citrus based cleaners on the coating
lines.
The Bristol facility has experimented with silicon-coated, non-stick rollers, but due to
durability problems, these rollers have not been used in the production process. An alternative for
silicone, which the Bristol plant does use, is flame-applied plasma coatings which prevent adhesive
buildup on winding, idling, and tension rollers. Adhesive remaining on these rollers can be easily
removed by hand. One difficulty that the Bristol facility faces with plasma-coated rollers is that they
tend to encourage static buildup. The buildup of static is a concern because if there is a spark the
entire line could catch on fire. To avoid this dilemma, 3M configures the equipment so that plasma-
coated rollers are not in series. Thick films are more susceptible to static than are thin films.
The 3M research and development laboratories in St Paul, Minnesota are currently developing
and evaluating low VOC coatings. The Bristol facility recently replaced the heptane-based precoat
on the 6W line with a waterbased acrylate for a short production-scale run. Although the coating
did meet the production specification, it resulted in several manufacturing difficulties. Foam formed
in the application pan. Some of the foaming effects which resulted from agitation caused by the
gravure coater could be eliminated with an alternative application method such as flow bar coating.
Other difficulties include poor stability with heat and over time, increased dry temperatures, and
inefficient material transfer.
C-29
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TRC
TRC Environmental Corporation
100 Europe Drive, Suite 150
Chapel Hill, NC 27514
Environmental Solutions through Technology tf (919) 968-9900 Fax (919) 968-7557
Date: April 14, 1993
Subject: Site Visit - TesaTuck, Inc.
Pressure Sensitive Tape Manufacturer
EPA Contract 68-D9-0173, Work Assignment Number 3/309
TRC Reference No. 1637309
From: Beth W. McMinn and Jill B. Vitas
TRC Environmental Corporation
To: Mike Kosusko
Organics Control Branch
Air and Energy Engineering Research Laboratory (MD-61)
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
I.
As part of the overall effort by the U.S. Environmental Protection Agency (EPA) to
identify areas for preventing the creation of pollution associated with manufacturing entities, EPA
is currently reviewing the pollution prevention opportunities associated with equipment cleaning
in the adhesives-coated and laminated paper industry. TRC Environmental Corporation (TRC)
is supporting EPA in this effort by developing prevention strategies for laminated paper
equipment cleaning under Work Assignment Number 3/309, EPA Contract Number 68-D9-0173.
TesaTuck Incorporated (Til), a pressure sensitive tape manufacturing facility, was
selected for a site visit to collect information on the pollution prevention opportunities available
for this industry segment The focus of pollution prevention efforts in this industry is on
emissions of volatile organic compounds (VOCs) and air toxics. The purpose of the visit to TO
was to gather information on their pressure sensitive tape manufacturing processes and to
identify, with input from the plant experts, any opportunities for preventing VOC emissions
resulting from the cleaning of equipment Specific objectives of the trip were to collect
information necessary to characterize the plant production processes, equipment cleaning
requirements and practices, and cleaning solvent recovery and disposal methods; and to witness
first-hand any pollution prevention opportunities for pressure sensitive tape equipment cleaning
operations.
This trip report includes four sections. Section n identifies the location of the TO
facility. Section HJ presents the individuals who participated in the site visit Section IV
includes the technical information compiled during the site visit
Offices in California, Colorado, Connecticut, Illinois, Louisiana, Massachusetts, New Jersey, New York, North Carolina, Pennsylvania, Texas,
Washington, Washington, D.C., and Puerto Rico A TSC Company
Pnnnd on Recyded Paper C"30
-------
Place and Date
TesaTuck Incorporated
Crotty Road
Middletown, NY 10940
(914) 692-2826
February 12, 1993
Attendees
TesaTuck. Incorporated
Mark Harrison, Director of Environmental Affairs
Stanley Williams, Plant Manager
TRC Environmental Corporation
Beth McMinn, Project Manager
Jill Vitas, Task Leader
IV. Discussion
The discussion began with TRC reviewing the purpose of the visit and addressing EPA's
goals for pollution prevention analysis for pressure sensitive tape manufacturing and future
preventive activities. During this meeting the following major areas were considered.
• Market profile and general plant description
• Manufacturing supplies
• Manufacturing process profile
• Equipment cleaning experience
• Emission reduction and control experience
• Pollution prevention opportunities
The meeting was followed by a tour of the production operations. Each specific topic addressed
in the meeting is discussed in detail below.
A. Market Profile and General Plant Description
TTI was bought by Tesa Incorporated, a German-owned company, in the 1970's. TTI
owns the Middletown plant, and two others in the United States: one in Carbondale, Illinois and
one in Sparta, Michigan. The Middletown facility was built in 1980 and the equipment that TTI
currently uses was installed in 1986. Approximately 260 employees are located at this facility,
C-31
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of which 214 are production staff. The Middletown facility operates 6 days per week (the plant
is closed every Saturday after 4:00 pm through Sunday), 24 hours per day.
At the Middletown facility, TTI manufactures both commercial and industrial grade
masking and duct tapes. Industrial grade masking tapes (painting tapes) serve the original
equipment manufacturer (OEM) and marine markets. Currently 70 percent of the products
manufactured at the Middletown facility contain solvent-based coating, with the remaining 30
percent using waterbased coatings.
The Middletown facility is located on 37 acres within two connected buildings that total
approximately 180,000 square feet Masking tape is manufactured on two process lines; one that
applies the saturant and release coatings and one that applies the adhesive. Adhesives and release
coatings are formulated in the mixing area. The mixed adhesives and release coatings are
transferred to the process lines via dedicated pipe/manifold systems. The duct tape process line
is located in a separate building, where all mixing, coating, and packaging are done in one
continuous process line.
B. Manufacturing Supplies
TTI uses a variety of hydrocarbon resins in their coating formulations. Toluene is the
main solvent used in the adhesive formulations, although small amounts of heptane and isopropyl
alcohol are also used. For cleaning, TTI uses mineral spirits, which can be incorporated into the
formulation with no quality problems.
C. Manufacturing Process Profile
Adhesive Mixing
Adhesive mixing is a basic manufacturing requirement for the solvent-based adhesives
used in the masking tape products manufactured at TTL The adhesive provides the bond between
the tape and the substrate. Adhesive mixing begins with stock preparation. Stock is prepared
by blending natural and synthetic rubbers, hydrocarbon resins, oils, and filters in a compounding
tank. The output is then directed to a two-roll sheeting mill where a sheet of adhesive stock is
extruded, cooled, cut, and chopped into pellets for further processing.
The pellets are then sent via conveyor to the mixing area where they are loaded into large
mixers. Toluene, heptane, and spent mineral spirits are added to dissolve the stock into a slurry
with 48 percent by weight solids. The solvent is pumped into the mixers with additional resins,
rubber, and oils to complete the adhesive formulation.
The finished adhesive formulation is then either pumped into a storage tank for later use
or pumped directly to the coating equipment through a manifold system.
C-32
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Paper Tape Manufacturing
A coating block diagram is presented in Figure 1. To manufacture paper tape, the raw
paper is bought from a vendor.
The waterbased saturant is applied to the raw paper by a reverse roll coater (i.e.,
Coater 1). Once the saturant has been applied, the substrate web passes through a floating air
oven. A thermal oxidizer is used to destroy any toluene or other emissions generated during the
drying process. The web is dried to a specific weight The waterbased release coat is then
applied via a reverse gravure roller (i.e., Coater 2). The web passes through another floating air
oven which is also vented to the thermal oxidizer. At this point, the web is wound and
transferred to the adhesive coating line where a solvent-based adhesive is applied by a heated
reverse roll coater (i.e., Coater 3). The fully coated web then passes through a final oven to dry.
Once the adhesive has been applied and dried the finished tape is allowed to cool, then
slit and packaged to be sent to the warehouse for shipping.
Duct (Cloth) Tape Manufacturing
Duct tape manufacturing is similar to paper tape manufacturing except that the adhesive
is calendared in a solid form to the laminated polyethylene film and cloth substrate. The result
is a cloth and film web which has the release coat applied on the film side. No solvent is present
in the duct tape adhesive, which is 100 percent solids. However, toluene is present in the release
coat TTI employs a thermal oxidizer to destroy the toluene or other emissions generated during
diving of the release coat
D. Equipment Cleaning Experience
TesaTuck regularly shuts down on Saturday at 4:00 p.m. During the shut down, operators
thoroughly clean the equipment and floors surrounding the equipment Where it is possible, the
equipment is wiped down with a rag soaked with mineral spirits. Til uses an aqueous detergent
and water to clean the saturant head and drip tray. The gravure cylinders are sent to E7E
Products in South Carolina to be ultrasonically cleaned every 6 months.
Mineral spirits has proved to be the best cleaner because of its low cost and ease of use.
It is kept in small safety containers near the equipment so that the operator can access it easily.
Spent mineral spirits is introduced back, into the adhesive formulation. The film that is left on
the equipment from the mineral spirits does not cause a quality problem because the first 20 feet
of the run will remove it and will be discarded. This "makeready" substrate would be disposed
of regardless of the substance used to clean the equipment The spent mineral spirits from the
duct tape line is recycled to the masking tape adhesive formulations. TTI uses approximately
1,000 gallons of mineral spirits per quarter. Due to the environmental impacts of the toluene,
TTI strictly enforces the use of mineral spirits instead of toluene even though the toluene
C-33
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cm oz.ee
\sa? £
S oLvC^
TP STogAftE
9
STA.
Figure 1. Tesa Tuck Coating Block Diagram.
-------
provides better cleaning. Accumulated spent mineral spirits (that are not used in the adhesive)
are distilled and used as paint thinner when the operators paint the floors and fences in and
around the facility.
The equipment cleaned the most frequently at the facility is the saturator application head,
which is cleaned continuously with water. The equipment that requires the most cleaning solvent
(mineral spirits) is the adhesive coating application head and the calendar application head (duct
tape line).
The process lines and adhesive mixing tanks are cleaned by flushing with toluene and
using the spent cleaning solvent in the next batch. The paper tape reverse gravure roller is
continuously and automatically cleaned with a water spray.
has tried to use citrus based cleaners. Due to the high cost and poor cleaning power,
they were not considered to be feasible. In addition, spent citrus based cleaners are considered
to be hazardous waste.
E. Emission Reduction and Control Experience
Currently, TTI has three thermal oxidizers that control VOC emissions from the ovens on
the three process lines. Hoods have been installed over the open web areas to provide for
approximately 100 percent capture of the solvent emissions. Each of these hoods is ducted to
the incinerators.
TTI is gradually reducing toluene usage by replacing it with heptane. TTI hopes to
replace 50 percent of the toluene with heptane, since heptane is not a listed hazardous air
pollutant and because heptane is less harmful to the environment
F. Pollution Prevention Opportunities
Possible pollution prevention opportunities at TTI include the conversion to waterbased
adhesive formulations and greater use of coated rollers.
In the discussion of waterbased adhesive formulations, TTI identified that production
would decrease due to the length of time needed to dry the waterbased formulations. In order
to maintain production at the current level, additional dryers would be needed.
The use of coated rollers for the idlers and take-up rollers in the process line has become
industry standard. These rollers provide the necessary tension on the web while preventing the
adhesive from sticking to the roller itself. TTI purchases their coated rollers from Plasma
Coating Corporation in Waterbury, Connecticut
C-35
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Environmental Solutions through Technology
TRC Environmental Corporation
100 Europe Drive, Suite 150
Chapel Hill, NC 27514
» (91 9) 968-9900 Fax (91 9) 968-7557
DATE: April 1, 1993
SUBJECT: Site Visit - Nashua Corporation - Label Division
Label and Label Stock Manufacturer
EPA Contract 68-D9-0173, Work Assignment Number 3/309
TRC Reference No. 1637309
FROM: Geary McMinn and Scott Snow
TRC Environmental Corporation
TO: Mike Kosusko
Organics Control Branch
Air and Energy Engineering Research Laboratory (MD-61)
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
I.
Purpose
As part of the overall effort by the U.S. Environmental Protection Agency (EPA) to
identify pollution prevention opportunities associated with manufacturing entities, EPA is
currently reviewing equipment cleaning practices in the adhesives-coated and laminated paper
industry. TRC Environmental Corporation (TRC) is supporting EPA in this effort by developing
alternative pollution prevention strategies for adhesive-coated and laminated paper equipment
cleaning under Work Assignment Number 3/309, EPA Contract Number 68-D9-0173.
Nashua Corporation, a label and label stock manufacturing facility, was selected for a site
visit to collect information on the pollution prevention opportunities for emissions of volatile
organic compounds (VOCs) and air toxics available in this industry segment The purpose of the
visit to Nashua was to gather information on their label stock manufacturing processes and to
identify and discuss, with input from the plant engineers, any opportunities for preventing
emissions resulting from the cleaning of equipment Specific objectives of the trip were to
collect information necessary to characterize the plant production processes, equipment cleaning
requirements and practices, use of waterbased adhesive technology, waterbased equipment retrofit
considerations, and cleaning solvent recovery and disposal methods; and to identify any pollution
prevention opportunities for label stock equipment cleaning operations.
This trip report includes four sections. Section n identifies the location of the Nashua
facility. Section EQ presents the individuals who participated in the site visit Section IV
includes the technical information compiled during the site visit
Offices in California, Colorado, Connecticut, Illinois, Louisiana, Massachusetts, New Jersey, New York, North Carolina, Pennsylvania, Texas,
Washington, Washington, D.C., and Puerto Rico A TRC Company
Pnnleef or Pecyded faster C-36
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H Place and Date
Nashua Corporation
Label Division
3838 South 108th Street
Omaha, Nebraska 68144
(402) 397-3600
February 12, 1993
Attendees
Nashua Corporation - Label Division
Dan Abraham, Process Engineer
TRC Environmental Corporation
W. Scott Snow, Mechanical Engineer
Geary D. McMinn, Environmental Scientist
IV. Discussion
The discussion began with TRC personnel stating the purpose of the visit, addressing
EPA's goals for the pollution prevention analysis for pressure sensitive tape and label
manufacturing, and identifying future preventive activities. During the meeting the following
major topics were discussed:
• Market profile and general plant description
• Manufacturing supplies
• Manufacturing process profile
• Equipment cleaning practices
• Emission reduction and control experience
• Pollution prevention opportunities
• Waterbased formulation experience
The meeting was followed by a tour of the site. Each specific topic addressed in the meeting
is discussed in detail in this report
C-37
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A. Nashua Market Profile and General Plant Description
Nashua Corporation began operating the Omaha, Nebraska, plant in 1966. The plant was
originally built in 1959 and operated by the International Paper Company. The facility currently
employs approximately 100 administrative and management personnel and 200 to 300 hourly
production personnel. The unionized Omaha plant operates 24 hours per day, 5 to 7 days per
week depending upon customer demand. The Omaha plant produces pressure sensitive labels,
roll-stock, and custom label products. The Omaha facility, a tape plant in Albany, New York,
and a coated products facility at the headquarters in Nashua, New Hampshire, all operate within
Nashua's Coated Product's Group.
Figure 1 shows the layout of the Nashua - Omaha facility. There are three coating lines
in the plant located in the coating room east of the glue filtering room. All three coating lines
at the Omaha facility have been grandfathered from environmental regulations. Line 1 is an
adhesive coater/laminator and currently coats with both solvent-based and waterbased adhesives.
During 1991, Line 1 ran 100 percent solvent-based adhesives, however, it currently runs
approximately 50 percent solvent-based and 50 percent waterbased products. Nashua engineers
expect that by the end of 1993, Line 1 will function with 100 percent waterbased products.
Line 2 is the release coating machine and presently applies both a solvent-based release coating
and a 100 percent solid-catalyzed silicone release coating. Line 3 is another adhesive
coater/laminator and currently runs 100 percent waterbased coatings that contain ammonia as a
pH stabilizer (concentration of less than 1.0 percent in solution). Nashua currently collects and
recovers solvent vapors from the drying ovens of Line 1 with a carbon adsorption system at
approximately 80 percent efficiency.
Raw paper, the material used to manufacture label stock, was identified by Nashua as the
highest cost item used in the manufacturing process at approximately $0.50 to $0.75 per pound
depending on grade and specification. The raw paper which is saturated with release coating is
called label stock. Adhesive, which provides tack for the labels, is then applied to the label stock
and a laminated backing is added. Adhesive costs approach $1 per wet pound or $2 per dry
pound. Nashua indicated that approximately 0.33 pounds of adhesive is typically applied per
pound of paper. After lamination, the label material is ready for either shipment as a final
product or further processing in the label-converting area. The majority of business for the
Omaha plant is label stock manufacturing.
B. Manufacturing Supplies
Nashua considers the chemical composition of their coatings and supplies confidential.
They indicated that their 100 percent solids release coating contains no VOCs and the solid is
considered the carrier. For the solvent-based silicone release coating, silicone is diluted with
tolusol, a heptane/toluene blend, which is considered the carrier. Their waterbased adhesive
coatings also contain no VOCs and water is the carrier. Nashua identified that there is no direct
correlation between VOC content of their adhesives and bond strength; however, a small amount
of water or solvent remains in the cured coating to prevent the product from becoming too dry
C-38
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N
i
BOILER ROOM
WASTE TANK
SHOP
GLUETANKS |-|J |\|H HH'I +_
2
r • • r*^ •
MAINTENANCE '
AND LAB I i^i—
COATING ROOM
\
SOLVENT ROOMS
CHEMICAL CLEANING ACRYLIC TANK
AND
OTHER RAW
MATERIAL
STORAGE
GLUE
FILTERING
FINISHING ROOM
• U
SLITTING ROOM
17
WAREHOUSE
PRESSROOM
T OFFICES
o L_ir
DC "
Figure 1. Nashua Plant Layout
-------
(thus lowering the tack). Nashua indicated that after drying, a small amount of water is added
to their waterbased products by a mist system to prevent the loss of tack.
C. Manufacturing Process Profile
General Process Description
The manufacturing of labels at Nashua - Omaha consists of three basic steps: adhesive
mixing, label stock manufacturing, and label converting. When the desired end-product does not
require converting, the last step in this process is omitted. Adhesives are brought into the plant,
mixed, and stored in process holding tanks. Figure 2 presents a flow diagram of the label and
label stock production processes. Master rolls of raw paper are first coated with a silicone
release liner and adhesive, and then are laminated with face stock. After these steps, the label
stock is cut and sized in the slitting room and is either sent to warehousing and shipping or
processed in the label converting operations. The Omaha facility produces between 200,000,000
to 300,000,000 square yards per year of label stock and release backing. The facility receives
and exports materials by both rail and track.
Adhesive Mixing
The purpose of label adhesives is to provide a bond between the substrate and the label
stock. Nashua indicated that they use a variety of adhesives in their manufacturing process. The
formulation of their solvent-based adhesives involves combining adhesive stock, natural rubbers,
acrylic products, and other materials in large steel mixing tanks. Solvents used in their solvent-
based adhesives include toluene and heptane. Waterbased adhesives are mixed in tanks with a
fiberglass lining which promotes easier stripping and cleaning. After mixing, the adhesives are
pumped through stainless steel canister filters to process holding tanks.
In order to achieve the proper level of initial tack, Nashua strives to manufacture a final
product that contains less than 3 percent water for waterbased adhesives or less than 1 percent
solvent for solvent-based adhesives. Ammonia, which elevates the pH and serves as a stabilizer,
is also present in small quantities (less than 1 percent) in waterbased adhesives.
Label Stock Manufacturing
The first step in label stock manufacturing is to create a coated release liner. The solids
silicone or the silicone-tolusol mixture is applied to master rolls of raw paper on the Line 2
coating machine. The coated release liner is then dried in an oven heated by steam coils for
approximately 5 to 10 seconds. Any vaporized solvent is vented by the oven exhaust systems
to the atmosphere. After diving, the coated release liner is wound onto rolls and transported to
either Line 1 or Line 3 for coating/lamination. Excess silicone can be frozen in air tight
containers for future use.
C-40
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Raw Paper
Master Roll
Silicons
Coating Process
Released to Air
Adhesive
Coating Process
Charcoal Activated
Carbon Bed
Lamination
Process
i
Sliting Process
Raw Paper
Master Roll
Finished
Roll Stock
Converting
Process
i
( Finished Labels J
i
Warehousing
i
Shipping
Figure 2. Finished Label Production Process.
C-41
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Nashua stated that their process lines run either solvent-based or waterbased adhesives,
but typically require a downtime of approximately 24 hours to setup the coating heads when
converting adhesives. Line 1 uses solvent-based adhesives consisting of natural rubber and resins
dissolved in toluene or waterbased adhesives. Line 3 uses only waterbased adhesives which are
purchased ready to use. Nashua adds some ingredients to improve the initial tack of these
adhesives.
The release liner is unwound and the silicone-coated surface is coated with an adhesive
and cured in an oven. The drying ovens on Line 1 are similar to Line 2's except that the
emissions are ducted to a carbon adsorption system. The reclaimed solvent can then be re-used
in compounding adhesives. Line 3 dryers use direct fired burners and cannot process solvent-
based adhesive products. As the coated paper travels out of the oven, it is moisturized by a
water spray mist and then laminated under pressure rollers with the label face stock creating a
three-layer lamination (face stock, adhesive, and release liner). Wind and unwind rollers are
wrapped with double-sided tape to help the product stick to the rollers.
Once the product has finished drying and been rewound, it is transferred to the slitting
room for cutting and sizing. Nashua has several high-speed slitting machines which cut the rolls
of paper into narrow widths for use on its own printing presses or for shipment as finished
product Excess edge portions of the paper known as off-cuts are removed by a trim system
which conveys the cut-offs to a cyclone separator, and ultimately to a dumpster for transport to
the city landfill. The special cut rolls are moved to the pressroom for custom orders or the finish
room (if the product is being sold to competitors or other processors) for packaging before
warehousing and shipment as a finished product The warehouse holds custom orders and stock
label products awaiting shipment
Label Converting Operations
The slit laminate which is to be processed further is moved to the pressroom. In the
pressroom, the laminate is loaded onto label presses where it may be die cut, perforated, and/or
printed. The waste matrix from the die cut is removed, rolled, and sent to the city landfill The
inks used in the printing presses are waterbased. A printing plate is required for use with the
press. Nashua uses a photochemical etching process to make these plates in the preparation
department This process uses a perchloroethylene/butanol mixture as the etching solvent
Nashua reclaims this solvent with a distillation unit
After converting, the printed labels are wound into rolls or fan-folded into sheets and
boxed. The finished products are sent to the warehouse for storage and shipping.
C-42
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D. Equipment Cleaning Practices
The function of an equipment cleaning product in the adhesives-coated and laminated
paper industry is to break the bond between the adhesive and the metal (or other surface) being
cleaned. Water solutions alone are normally ineffective for cleaning purposes. Nashua has found
that products such as mineral spirits, 1,1,1-trichloroethane (TCA), and toluene successfully break
the adhesive bonds. Nashua has also tested many other materials for equipment cleaning,
including mineral oils, xylenes, and citrus products. Table 1 provides a summary chart of
cleaning products Nashua is currently using and has proposed to use to clean process equipment
The VOC content of cleaning products is estimated by the manufacturer and Nashua accepts these
estimates for emissions calculations.
Nashua is currently trying to replace toluene in their cleaning operations in order to
reduce toxic emissions. Toluene is not recycled by Nashua due to its fire and explosive risk,
evaporation, and low purchase cost TCA, another effective cleaner, which costs approximately
$3 to $4 per gallon, is recycled on site using a distillation unit Approximately 2,268 gallons of
TCA are recycled a year. Nashua will be replacing TCA due to the phase out requirements of
the Montreal Protocol. Nashua has found that citrus based products are costly (up to $10 per
gallon), do not effectively clean acrylic-based adhesives, and exude a strong, undesirable odor.
Nashua uses several techniques to satisfy their various cleaning requirements. Equipment
is not cleaned on any specific time schedule, however, when tines are down for changeover, the
rollers, filters, and other equipment are normally cleaned. Larger parts (such as application
rollers and adhesive filters) are cleaned in the glue rooms (Figure 1). The cleaning solvents
Nashua uses are stored in tanks and drums on site. Dip cans containing cleaning solvent are
located in the plant near the machinery which they service. Most cleanup involves a wipe down
using solvent-ladened cleaning rags. Nashua indicated that their operators have full access to the
cleaning solvent storage areas.
The fiberglass adhesive mixing tanks are cleaned by cutting the adhesive residue with a
high-pressure water blaster. The blaster cuts pieces of the adhesive off the tank wall which are
then peeled away a section at a time. The adhesive residue is collected at the bottom of the tank
and removed for shipment to the landfilL The mixing tank cleaning system also uses a pit
located under the tanks that captures the blaster water and transfers it to a special holding tank
for delivery to the city water treatment system. During the mixing of adhesives in the fiberglass
tanks, layers of different adhesives are deposited on the tank walls. Within these layers,
microscopic "bugs" grow. According to Nashua, the "bugs" present no product contamination
and are welcomed at the city landfill due to their ability to breakdown waste material
Nashua uses dedicated lines to transport the adhesives from the mixing tanks to the
process holding tanks. The waterbased adhesive lines are never exposed to air, therefore, the
adhesive does not harden in them as quickly as it does in the solvent-based lines. These
waterbased lines normally operate until a significant reduction in flow is identified, at which time
they are replaced rather than cleaned. Polyvinyl chloride (PVC) piping was chosen for these
C-43
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TABLE 1. SUMMARY OF CLEANING PRODUCTS USED AND PROPOSED AT
NASHUA - OMAHA
Cleaning Products
Area Cleaned Used Proposed
Water-based adhesive mixing tanks W
Solvent-based adhesive mixing tanks Tol Tol
Water-based coating lines H2O
Solvent-based coating lines Tol
Rollers (all) Tol, TCA MS
Drip on edge of paper TCA MO, MS
Dryers (Water- and solvent-based lines) MS
Filters (stainless steel) Tol, TCA MS
Floor cleaning in production/mixing area MS H2O
Press plate etching Perch O
Press roller cleaning IP A
Description of Terms:
H2O - Hot water and scrapper
IP A - Isopropyl Alcohol - (solution is approximately 10 percent IP A)
MO - Mineral Oil
MS - Mineral Spirits
O - Octusol (Dupont replacement for Perch)
Perch - Perchloroethylene/Butanol mixture
Tol - Toluene
TCA - Trichloroethane
W - High pressure water wash
C-44
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lines due to removal convenience and low cost Nashua stated that some PVC piping has been
replaced after approximately three years in operation.
Nashua indicated that their largest daily cleaning problem is the metallic filters used to
filter the adhesive when transferred from the mixing tank to the process holding tanks. These
filters are removed from the lines and cleaned in a toluene bath using a scrub brush. The baths
are changed approximately once every two weeks and the waste toluene is sent off site for
disposal. Eventually, Nashua plans to have mineral spirits or another viable product replace the
toluene in the cleaning bath. The product that does the best cleaning job on the filters will also
be used to clean the application roller. The process holding tanks for the solvent-based adhesives
are flushed with solvent This remaining solvent and any dissolved adhesive remain in the tank
and mix with the next batch of adhesive. No product quality problems have been noted with this
cleaning procedure.
Nashua uses a putty knife and a hot water spray to clean splashes and spills on the
machinery that applies waterbased adhesives. Waste adhesive which contains less than 20
percent water is sent to the landfill. Splashes and spills on the solvent-based adhesive machinery
are cleaned with a putty knife and TCA soaked rags. A TCA drip is used on the edges of the
application roller to prevent adhesive from flowing over the paper edge. In the future, mineral
spirits or a viable alternative will be used as an alternative to TCA.
Mineral spirits are used to mop the floor of the mixing and production areas and are also
used to clean the solvents trapped in the dryer oven hoods. In the pressroom, TCA and toluene
are used to remove dried, waterbased inks and adhesive from the presses and tooling. Isopropyl
alcohol (approximately 600 gallons a year) is also used to remove inks from the rollers.
E. Emissions Reduction and Control Experience
Nashua intends to replace the toluene and TCA used for cleaning processes by the end
of 1993. Most emissions of toluene are fugitive and Nashua does not control or recycle toluene
because of the explosive and fire hazards, the high cost of capturing toluene emissions, and the
relatively low cost of virgin toluene solvent Approximately 3,000 gallons of toluene are used
on an annual basis with 1,800 gallons being sent off site for disposal as hazardous waste.
Nashua currently reclaims TCA by a distillation system. Approximately 2,268 gallons
(2,160 gallons from release coat and 108 gallons from adhesive line cleaning) of a total 2,520
gallons of TCA are recycled annually with 200 gallons shipped off site as hazardous waste.
Nashua indicated that approximately 10 gallons of TCA are used for cleaning process holding
tanks after every product changeover. Approximately 600 gallons per year of isopropyl alcohol
are used to clean the printing press lines.
Solid waste from the Nashua facility includes paper waste from the cutting and slitting
processes, which is compacted and sent to the landfill Hazardous waste shipped off site includes
approximately 3,500 pounds per month of waste adhesive, silicone, paper, TCA, oil from
C-45
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machines, and perchloroethylene still bottoms (used in etching printing plates). Rags and
absorbent socks (called "pigs") contaminated with VOC solvents arc considered hazardous waste
and disposed of properly, while those containing no VOCs are sent to the landfill.
Nashua's city sewer discharge limit allows for 100 ppm of total recoverable petroleum
hydrocarbons in their wastewater discharge. Nashua conducts tests once per month at the plant
outfall to assure compliance. Normally, the concentration ranges from 20 to 30 ppm. In the
past, adhesive mixes clogged the discharge system, however, to avoid this, the wastewater is
currently stored in special tanks and shipped by truck to the city treatment facility, where it can
be treated and sold as fertilizer. By the end of 1993, Nashua predicts that 95 percent of their
wastewater will be disposed of at the city treatment facility.
Nashua indicated that they recycle approximately 10 to 15 percent of total raw paper
input Once the paper has been coated with silicone or adhesive, it cannot be recycled and is
transported to the landfill.
Other control experiences at Nashua - Omaha include floor vents, special coated
application and non-application rollers, and plant boilers. For proper ventilation, floor vents are
used in the adhesive holding area and equipment cleaning area to collect and evacuate indoor air
to the atmosphere. Also, Nashua is currently testing different types of coated rollers (e.g., teflon,
plasma, graphite) for the adhesives application and non-application processes. These rollers are
designed to simplify the equipment cleaning process by employing a less sticky surface. Finally,
the plant boilers are located at the north end of the plant and are the only equipment in the plant
requiring air emissions permits.
F. Pollution Prevention Opportunities
Potential pollution prevention opportunities include the replacement of all toluene and
TCA cleaning with a viable non-VOC solution.
Nashua is currently in the process of converting their adhesive coatings to 100 percent
waterbased solutions. Since these products contain water and not solvents as carriers, most of
the process emissions from the coating lines should be eliminated. However, equipment cleaning
of these waterbased lines will remain a potential TCA fugitive emissions source. To prepare for
this changeover, alternative cleaning solutions have been, and are currently being, tested at
Nashua. These include products such as mineral spirits, mineral oils, and citrus based products.
At the time of this site visit, no viable alternative had been found to completely replace the
toluene and TCA used in equipment cleaning.
Nashua's emissions reduction programs are extensive. Any safety cans which contain
toluene or TCA located next to the production equipment are spring closed. Also, tank cleaning
baths are covered and allow enough room for large equipment pieces to avoid overfilling the
tanks. Nashua encourages its operators to scrape equipment before using chemicals as a final
wipe. Finally, mats are provided around machinery to capture any spills which may exceed the
C-46
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capacity of the drip tanks, thus avoiding extensive floor cleanup. An outside service is employed
to clean these mats.
G. Waterbased Formulation Experience
<*
As previously mentioned, Nashua - Omaha has extensive experience in waterbased
adhesives and plans to phase out all solvent-based coatings by the end of 1993. The major
reason for this is to comply with requirements of the Clean Air Act of 1990. Other reasons
include fewer permitting/paperwork requirements, less restrictions by New Source Review or
New Source Performance Standards, and elimination of most hazardous waste regulatory
requirements.
Equipment additions were needed to change from solvent-based to waterbased adhesives.
First, a different configuration of rollers and a different gravure set-up are required on the coating
machines. The application roller must be designed to allow a greater thickness of waterbased
adhesive to remain on the substrate. Waterbased coatings do not penetrate most substrates as
well as solvent-based coatings and therefore must be thicker to penetrate any given substrate.
Coating speeds must be reduced to accommodate the longer drying times required by waterbased
adhesives. All mixing tanks, holding tanks, filters, pumps, and piping must be retrofitted to
prevent contamination from previously used solvent-based adhesives. Nashua has also coated the
waterbased adhesive tanks with fiberglass to allow for cleanup with high-pressure (3,000 to 5,000
psi) water. Pumps used to transport waterbased adhesives must have lower horsepower and
compression rates due to the lower viscosity and higher surface tensions of waterbased adhesives.
Nashua does not anticipate losing much business due to the solvent-to-water adhesive
changeover because they have been able to find or formulate new waterbased adhesives to replace
most of the solvent-based products. However, some products require certain characteristics of
natural rubber that waterbased adhesives have been unable to provide (e.g., extremely cold
bonding, wet bonding, and peel and re-peel ability).
Economic and environmental incentives are die primary reasons for Nashua's conversion
from solvent-based to waterbased adhesives. Although waterbased adhesives cost more than
solvent-based adhesives (more specialized adhesives may double the cost), adhesives costs are
not the driving costs: raw paper costs drive the end-product cost Nashua expects the increased
adhesive cost to have some effect on their cost to customers. Although the adhesives changeover
would result in possibly changing waste streams by increasing water usage or by adding
waterbased products, the overall effect should be a reduction in total waste. The reduced waste
disposal costs and permitting costs are two economic benefits. Nashua advised that any facility
wishing to switch to waterbased adhesives must first set goals and then invest the time and
research to attain them.
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TRC
TRC Environmental Corporation
100 Europa Drive, Suite 150
Chapel Hill, NC 27514
Environmental Solutions through Technology « (919) 968-9900 Fax (919) 968-7557
Date: March 19, 1993
Subject: Site Visit - Rexham Industrial
Coated and Laminated Substrate Manufacturer
EPA Contract 68-D9-0173, Work Assignment Number 3/309
TRC Reference No. 1637309
From: Beth W. McMinn and Jill B. Vitas
TRC Environmental Corporation
To: Mike Kosusko
Organics Control Branch
Air and Energy Engineering Research Laboratory (MD-61)
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
I. Purpose
As part of the overall effort by the U.S. Environmental Protection Agency (EPA) to identify
areas for preventing the creation of pollution associated with manufacturing entities, EPA is currently
reviewing the pollution prevention opportunities associated with equipment cleaning in the adhesives-
coated and laminated paper industry. TRC Environmental Corporation (TRC) is supporting EPA in
this effort by identifying and developing prevention strategies for coated and laminated substrate
equipment cleaning under Work Assignment Number 3/309, EPA Contract Number 68-D9-0173.
Rexham Industrial (Rexham), a coated and laminated substrate manufacturing facility, was
selected for a site visit to collect information on the pollution prevention opportunities available for
this industry segment The focus of pollution prevention efforts in this industry is on emissions of
volatile organic compounds (VOCs) and air toxics. The purpose of the visit to Rexham was to
gather information on their coated and laminated substrate manufacturing processes and to identify,
with input from the plant experts, any opportunities for preventing VOC emissions resulting from
the cleaning of equipment Specific objectives of the trip were to collect information necessary to
characterize the plant production processes, equipment cleaning requirements and practices, and
cleaning solvent recovery and disposal methods; and to witness first-hand any pollution prevention
opportunities for coated and laminated substrate equipment cleaning operations.
This trip report includes four sections. Section n identifies the location of the Rexham
facility. Section HI presents the individuals who participated in the site visit Section IV includes
die technical information compiled during the site visit
Offices in California, Colorado, Connecticut, Illinois, Louisiana, Massachusetts, New Jersey, New York, North Carolina, Pennsylvania, Texas,
Washington, Washington, D.C., and Puerto Rico A TRC Company
Printed on Recycled Paper C~48
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Place and Date
Rexham Industrial
P.O. Box 368
Matthews, NC 28106-7003
(704) 847-9171
March 5, 1993
ffl. Attendees
Rexham Industrial
Gordon Miller, Manager of Safety and Environmental Affairs
U.S. Environmental Protection Aeency
Michael Kosusko, EPA Work Assignment Manager
TRC Environmental Corporation
Beth W. McMinn, Project Manager
Jill B. Vitas, Task Leader
IV. Discussion
The opening conference began with EPA and TRC discussing the purpose of the visit, the
background of the coated and laminated substrate manufacturing project, EPA's goals for pollution
prevention analysis, the handling of confidential business information, and the resulting trip report
The opening meeting then proceeded with a question and answer period during which time EPA and
TRC discussed the following topics:
• Market profile and general plant description
• Manufacturing supplies
Manufacturing process profile
• Equipment cleaning experience
• Emission reduction and control experience
• Pollution prevention opportunities
The meeting was followed by a tour of the production operations. Each specific topic addressed in
the meeting is discussed in detail below.
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A. Rexham Market Profile and General Plant Description
Rexham is a wholly owned subsidiary of Bowater PLC of England. They currently
own/operate 34 facilities in North America. Rexham sees a strong health, safety, and environmental
compliance record as a competitive advantage. Their customers seem to be looking for "green"
suppliers.
Rexham is made up of four divisions: Industrial Films, Printing and Packaging, Plastics, and
Medicals. The Matthews facility is the Industrial Films Division Headquarters. The facility is
considered a custom converter, producing coated and laminated products in four categories:
electronics/photographies, miscellaneous products, graphic arts, and medical supplies. One of
Rexham's electronic products is a dry photo masking agent Photographic products consist of
masking agents and photographic substrates. Balloon hull material, a seven-ply laminate, is one
example of products included in the miscellaneous category. The graphic arts products include
materials for reproductions and proofs. The main products in the medical supplies category are
surgical barriers.
The Matthews facility began operation in 1963. Since that time it has increased its operating
schedule to an anticipated 7 days per week, 24 hours per day, 360 days per year in 1993. Rexham
currently employs 275 people at the Matthews facility, of which 160 are production staff involved
in the manufacturing of the coated products. Figure 1 shows the layout of the facility.
B. Manufacturing Supplies
Rexham's primary raw materials consist of coating formulations, solvents, and substrates.
Rexham can work with many different coating formulations with a variety of resin bases, including
but not limited to, acrylics, urethanes, and polyesters. The majority of the formulating and cleaning
solvents used at the facility consists of methyl ethyl ketone (MEK) and toluene, with smaller
quantities of tetrahydrofuran, some esters, and some alcohols.
The Rexham facility has the capability of handling a variety of substrates, including films,
paper, foils, and foam. Currently, about 90 percent of Rexham's products are manufactured with
plastic film substrates, 9 percent with paper substrates, and the remainder is with foils and foam.
Rexham cleans process equipment with the solvent that is incorporated in the coating
formulation. For those processes that include mixtures of different solvents, Rexham typically will
clean with the solvent in the highest concentration in the formulation.
C. Manufacturing Process Profile
Although specific steps vary by product type, Rexham's general manufacturing process
includes the following steps. Incoming dry raw materials are stored in their original shipment
containers (e.g., bags and fiber drums) in Warehouse 1 or 2. Wet raw materials are stored in
designated drum storage or staging areas located throughout the plant These materials are moved,
as necessary, to the central mix room where the required coating formulation materials are blended
C-50
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Figure I. Rexham facility layout.
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with variable-speed dispersers in mix tanks or drums. Due to the large number of products it
manufactures, Rexham's mixing process can be very simple or very complex, and is modified to
satisfy customer needs. Approximately 50 percent of the coatings used at the Matthews facility are
premixed by a supplier, 10 to 15 percent are mixed in-house from raw materials, and the remainder
are purchased blends that Rexham modifies by adding performance enhancing chemicals. Rexham's
equipment is capable of handling coatings of any chemical composition (i.e., 100 percent solids,
waterbased, solvent-based, ultra-violet formulations).
The mixed coatings are then pumped from 55-gallon drums or mix tanks through a manifold
system to the coating application system. Substrate webs are also moved to the coating lines. The
coating is applied to the substrate web by an application roller. Once the coating has been applied,
it enters a zoned oven which allows for uniform drying. After the substrate is dried, it passes
through a nip roller where it is laminated (if needed). If multiple coatings are necessary the previous
steps are repeated. The product is then wound, slit according to customer requirements (if
necessary), and then packaged and sent to Warehouse 1 or 2 for shipping. Rexham operates on a
"just-in-time" inventory concept, which allows for production of an order within 28 days of receipt
Rexham operates eight coating lines, each configured to run a particular type of product
Table 1 contains a general description of each of the configurations Rexham uses.
TABLE 1. REXHAM COATING LINE CONFIGURATIONS
Number of Machines Machine Width Run Length Number of Coatings
1
1
2
1
2
pilot coater
narrow
wide
wide
wide
wide
short
short
long
long
long
multiple configurations
1
1
1
2
multiple
D. Equipment Cleaning Experience
Rexham does not perform equipment cleaning on any specific schedule. However, due to the
relatively short production runs and the custom nature of the specialty products that Rexham
manufactures, cleaning between jobs is critical. Therefore, at the end of each job, all application
equipment is thoroughly cleaned. Typically the coating line operator requests a drum of either virgin
or reclaimed cleaning solvent (e.g., primarily MEK or toluene - See Section B) from the mix room.
Although Rexham has attempted to use alternative cleaners, such-as mineral spirits, it describes the
cleaning results as "inadequate." The cleaning solvent drum is brought to the coating line equipment
and the operator pumps a small amount into a bucket The operator wets a rag in the bucket and
C-52
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then wipes down die equipment The used rag is discarded in a hazardous waste drum which is sent
off-site for disposal. The spent cleaning solvent is transferred to a "dump" drum which is either sent
to the on-site still for recycling or sent off-site for disposal as hazardous waste. The Rexham still
currently reclaims solvent at the rate of 50 gallons per hour, 24 hours per day, 5 days per week.
A machine that is anticipated to be idle for several days undergoes a cleaning regime similar
to the process described for cleaning between jobs. This cleaning job, however, is more thorough,
involves the disassembling of equipment, the cleaning of pumps, equipment housings, and ovens, and
requires approximately 30 man-hours (e.g., five people each at six hours) to accomplish.
Rexham operates a central cleaning area with a solvent (MEK) bath and two ultrasonic
cleaning units. The ultrasonic cleaners are used to clean the coating cylinders and very dirty
adhesive reservoir pans and application roller carriages. Rexham tried many cleaning solutions in
the ultrasonic cleaner before finding one which would remove all the coatings from the rollers.
Where it is possible, the floors around the coating lines are covered with off-specification film
substrates. Although this film is normally mopped with cleaning solvent at the end of each shift, it
does reduce the quantity of solvent that would otherwise be used to clean the floors. As the film
floor coverings are ripped and become unprotective, they are disposed of as solid waste and replaced
with another layer of off-specification film.
E. Emission Reduction and Control Experience
Rexham is aware of EPA's 33/50 program but has made a corporate decision not to formally
participate. However, the company will meet the goals of the program over the next few years.
Solvents are used in the mixing of the coatings and in cleaning the process equipment
Solvent fugitive emissions result from the baths in the central cleaning area as well as from the "on-
the-spot" cleaning applications within the facility.
The oven exhaust from two coating lines is currently ducted to a 4-bed carbon absorber. The
removal efficiency of the carbon absorber is reported to be greater man 92 percent Oven exhaust
from two additional lines is ducted to a REECO™ regenerative thermal oxidizer (RTO), rated at
20,000 standard cubic feet per minute, and achieving a destruction efficiency reported to be 96
percent This control system achieves the Lowest Achievable Emission Rate (LAER) recognized by
EPA. The remaining four lines are ducted to a direct-fire incinerator, considered by EPA to be
Reasonably Available Control Technology (RACT) for the industry.
Rexham is planning to install total enclosures on all of their coating lines to capture and
control all VOC emissions from the process. Total enclosures will also reduce operator exposure.
With the enclosure design that Rexham will construct, Rexham does not anticipate difficulties with
operator access to lines and equipment
C-53
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F. Pollution Prevention Opportunities
Potential pollution prevention opportunities include: (1) reduction in the use of solvent to
clean the floors, (2) reduction in amount of solvent used to clean the equipment, and (3) running the
process line dry when possible.
The most effective preventive technique for Rexham would be to reduce or eliminate the use
of solvent for floor cleaning. The operators currently cover the floor with off-specification film
substrate, which is eventually disposed of as solid waste. Mopping the substrate-covered floors each
shift with solvent may not be necessary.
Another opportunity for Rexham would be to optimize the amount of cleaning solvent needed
to achieve the required cleaning specifications. Operators would be restricted to this amount of
solvent It is anticipated that the optimum amount of cleaning solvent would be considerably less
than what is currently being used.
One additional pollution prevention technique would be to run the line dry. "Running dry"
a line is an operating technique, occurring at the end of a production run, that involves adding only
enough coating to the application troughs to coat the length of substrate remaining on the web. This
allows the substrate web and the coating to end at approximately the same time. In some facilities,
excess coating is drained from the application pans and coating lines back into storage drums. The
drummed material is retained for future use. This production technique minimizes coating waste and,
consequently, minimizes required cleanup. It also requires operator attention and planning.
Currently, Rexham uses waterbased formulations only at customer request Rexham said that
the industry is headed toward waterbased formulations to reduce emissions, but that phase-in of this
approach will be gradual.
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RADIAN
MEMORANDUM
t
DATE: September 30, 1992
SUBJECT: Trip Report - Shuford Mills
FROM: John Keith and Trent Zirkle, Radian Corporation
TO: Improved Equipment Cleaning Project File
I. PURPOSE
The purpose of the visit to Shuford Mills was to learn about
the methods of cleaning adhesives coating equipment and the
resulting multi-media wastes generated from the cleaning. The
visit was also intended to develop a working relationship between
Shuford Mills and the U.S. Environmental Protection Agency (EPA),
Air and Energy Engineering Research laboratory (AEERL) for
potential demonstration projects.
II. PLACE AND DATE
Place: Shuford Mills
Hickory, North Carolina
Date: June 25, 1992
III. ATTENDEES
Shuford Mills
William Little
Andy Stimpson
Bob Hollieway
Radian Corporation
John Keith
Trent Zirkle
*M298-62/als.021
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IV. DISCUSSION
1. Project Background
The U.S. EPA AEERL is conducting research and development
projects for various industrial processes to identify, develop,
and demonstrate applicable technologies that reduce waste
generation (i.e., pollution prevention technologies). The
adhesives and coated paper manufacturing industry has been
selected for a pollution prevention research project focussed on
reducing air emissions and multi-media waste generated by
equipment clean-up. Three of the 17 targeted chemicals
identified in the EPA's 33/50 Program; methyl ethyl ketone (MEK),
toluene, and xylenes, are typically used as solvents during
equipment clean-up in this industry. AEERL has contracted Radian
to conduct the initial phase of the research project to; identify
current cleaning methods, technologies, and generated wastes;
identify current similar research efforts; and determine
pollution prevention (alternative) technologies. Shuford Mills
has expressed interest in participating in this research project.
2. Shuford Mills Background
The Shuford Mills Tape Division manufactures a variety of
pressure sensitive tapes. Pressure sensitive tapes do not
require water or heat to activate the adhesive; only a light
rubdown pressure is required to make the tape stick. The major
product at Shuford Mills' Hickory, North Carolina plant is
masking tape. Approximately 500 to 600 people are employed at
the Hickory plant.
3. Operation
At Shuford Mills' Hickory plant, manufacturing involves
three distinct coating operations: saturation, backsizing or
release coating, and adhesive coating. In the saturation step, a
paper backing material is saturated with a water based liquid
«M298-62/als.021 C-56
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latex material. During backsizing, a water-based coating is
applied to one side of the paper to prevent delamination and
tearing, to provide water resistance, and to aid in unwinding and
slitting. In the adhesive step, a solvent based adhesive is
applied to the substrate on the opposite side of the backsize.
The three coating operations are sequential but not
continuous. Each coating step is performed on a separate process
line. However, each coating operation consists primarily of the
same major processes. A roll of paper is unwound and the coating
is applied. The coated paper then passes through a drying oven
where most of the moisture and/or organic vapors are volatilized.
For solvent based adhesives, the captured vapors are sent to a
carbon adsorberfor recovery. The release coating is water based,
and the water is emitted to the atmosphere during drying. After
exiting the dryer, the coated paper is then re-wound onto a roll.
Shuford Mills has three saturation lines. As shown in
Figure 1, raw paper is unwound and run through a trough of latex-
based saturant. The saturated paper exits the trough and passes
by a doctoring blade. The doctoring blade controls the thickness
and quantity of saturant applied to the paper. The rollers and
dams (or ears) are only cleaned during shutdown, about once per
week. A toluene-soaked rag is used to wipe the equipment clean.
The toluene is stored in covered, five gallon buckets next to the
rollers. Toluene left on the rag either evaporates or is
returned to the bucket where the rag is stored. Due to coating
material that accumulates in the toluene cleaning solvent in the
bucket, the toluene must be periodically replaced. The "spent"
toluene is recycled as make-up solvent for the coatings
formulations.
The second coating operation, backsizing, is shown in
Figure 2. Coating is applied to the paper via a small coated
roller. The roller contacts a bath of coating material and
transfers the coating material to the paper as the roller
*M298-62/«ls.021 C-57
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Raw Paper
Saturated Paper
2
00
Drying Oven
Salurant
Figure 1. Saturation
-------
Saturated and Backslze Paper
Saturated Paper
Drying Oven
Figure 2. Backsizing
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rotates. A doctoring blade controls the thickness of the coating
material applied. Any rollers that may come in contact with the
• coated side of the paper are wrapped with a thin cellophane-like
plastic sheet. This sheet can be removed and discarded, instead
of using solvent to clean the roller.
The coating material on a given backsize line may be changed
up to ten times per week. When product quality allows, the
rollers and troughs are not cleaned every time the coating
material is changed. Flow of one coating material to the trough
is stopped. Most of the coating material left in the trough is
applied before flow of the next coating material starts. This
results in a brief period when the coating material is "mixed."
When product quality dictates a more thorough cleaning to
prevent the mixing of coating materials, a toluene-soaked rag is
used to clean the application roller and trough. The toluene is
handled in the same way as described for the saturation
processes.
The third coating operation, adhesive coating, is shown in
Figure 3. Adhesive is applied via a coated roller. The roller
is coated by contact with adhesive from a holding trough. The
tip of the trough is butted against the roller. A slow-rotating
metering roller controls the thickness of the adhesive applied.
As with backsizing, the adhesive on a given line may be changed
up to ten times per week. When product quality allows, the
equipment (rollers, trough, ears) are not cleaned every time the
adhesive is switched. As with the backsize, brief periods of
"mixed" adhesive will be applied.
When product quality dictates that no "mixed" adhesive be
used, flow of the adhesive to the trough is stopped by closing a
valve on the feed pipe to the adhesive header. Figure 4 shows
the adhesive feed equipment and the trough. After the feed pipe
is closed off, the valve from the header to the trough is closed.
The adhesive left in the header is drained into a bucket and
4M298-62/als.021
C-60
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Saturated.Backslzed, and
Adhesive Coated Paper
Adhesive Header
Metering Roll
2
Saturated and Backslze Paper
Drying Oven
Figure 3. Adhesive Coating
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£
to
From Adhesive Storage
Adhesive
Rotating Pipe Joint
Drain Pipe
Residual Adhesive1
Collection Drum
Drum
(Material Recycled as Raw Adhesive)
Side View
From Adhesive Storage
Header
Valves
^ Drain Pipe
I I
.X.
Trough
Roller
1
Residual Adhesive
Collection Drum
Front View
Adhesive Header (Not To Scale)
Drum
Figure 4. Blow-Up of Adhesive Header
-------
recycled. While the paper is still being run through the
rollers, a putty knife is used to scrape as much coating
materialas possible from the trough and ears to the point where
the trough and the roller meet. This allows the scraped coating
material to be applied to the substrate. Finally, a toluene-
soaked rag is used to wipe the equipment clean.
4. Solvent Usage
Toluene is the only cleaning solvent used at Shuford Mills.
All spent toluene from cleaning is recycled as make-up solvent in
product formulations. No estimate of the amount of toluene used
for cleaning was made. Shuford Mills is planning to install a
metering system to track where toluene is used. The largest
cleaning use of toluene occurs when the substrate tears during
the adhesive coating process. When this happens, coating
materials get on a dry rubber roller. Approximately 2.5 to 3
gallons of toluene are needed to clean this roller. No estimate
of how often the substrate tears was available.
*K298-62/als.021
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RADIAN
COMVOKATIOM
MEMORANDUM
DATE: September 30, 1992
SUBJECT: Trip Report - FLEXcon Company, Inc.
FROM: John Keith, Radian Corporation
TO: Improved Equipment Cleaning Project File
I. PURPOSE
The purpose of the visit to the FLEXcon Company, Inc.
(FLEXcon) was to learn about the methods of cleaning adhesives
coating equipment and the resulting multi-media wastes generated
from cleaning. The visit was also intended to develop a working
relationship between FLEXcon, U.S. Environmental Protection
Agency, Air and Energy Engineering Research laboratory (AEERL),
and the Massachusetts Office of Technical Assistance (MOTA) for
potential demonstration projects.
II. PLACE AND DATE
Place: FLEXcon Company, Inc.
Spencer, Massachusetts
Date: May 4, 1992
III. ATTENDEES
U.S. EPA AEERL
Michael Kosusko
Mass OTA
Paul Richard, Jr.
FLEXcon
Darwin Irish
Charles Schultz
Radian Corporation
John Keith
3M298-62/«U.021
C-64
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IV. DISCUSSION
1. Project Background
The U.S. EPA AEERL is conducting research and development
projects focussed on various industrial processes to determine,
develop, and demonstrate applicable technologies that reduce
waste generation (i.e., pollution prevention technologies) with
special interest on air emissions of 17 targeted chemicals. The
adhesives and coated paper manufacturing industry has been
selected for a pollution prevention research project focussed on
reducing air emissions and multi-media waste generated by
equipment clean-up. Three of the 17 targeted chemicals; methyl
ethyl ketone (MEK), toluene, and xylenes, are used as solvents
during equipment clean-up. AEERL has contracted Radian to
conduct the initial phase of the research project to; identify
current cleaning methods, technologies, and generated wastes,
identify current similar research efforts, and determine
pollution prevention (alternative) technologies.
FLEXcon, through Mass OTA, has expressed interest in
participating in this research project. MOTA is a State funded
program that offers free technical assistance to industry..
2. FLEXcon Background
FLEXcon manufactures adhesive coated products. The
substrates that the coatings are applied to are mostly paper, but
include some synthetic plastic films. FLEXcon has 13 production
lines in Spencer, Massachusetts, with additional production
capability in Connecticut and Minnesota, and warehousing
operations in Kansas. FLEXcon employs approximately 900
employees in Spencer, Massachusetts.
3M298-62/«ls.021
C-65
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Massachusetts industries are subject to compliance with the
Massachusetts Toxic Use Reduction Act (TURA). TURA mandates that
industries monitor and reduce the generation of multi-media
wastes prior to any control, capture, or recycling/reuse efforts.
In response to TURA, FLEXcon has implemented a company wide
pollution prevention program to reduce the generation of wastes.
FLEXcon's program is modeled after their quality control program
and uses employee teams made up of operations staff, management,
maintenance, engineering, and research and development staff.
The teams focus on different production areas to identify,
monitor, and reduce multi-media waste generation.
FLEXcon's efforts to date include; tracking the amounts of
solvents used and wastes generated during clean-up, working with
adhesive vendors to identify alternative formulations or products
that have reduced solvent content (e.g., water based adhesives)
and investigation into a distillation unit to reclaim waste
solvents for reuse.
3. Operations
A generic process schematic of an adhesives coating line is
shown on Figure 1. The FLEXcon coating lines were the same,
schematically. The substrate is run past the application roller
where the coating is applied. The coated substrate then moves
through an oven with different temperature zones. The coating
dries, and, in the case of resin based coating, cures in the
oven. Most of the solvents in the adhesive coating volatilize in
the oven. The final coating on the product typically contains
less than 0.5 percent solvent by weight. The coated product is
pressed onto a silicone coated backing is rolled and moves to
cutting and sheeting operations. In cutting and sheeting, the
large rolls of product are rerolled and cut into smaller rolls or
cut into sheets and stacked.
3M298-62/«ls.021
C-66
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To Air Emissions
Control Device
Adhesive
Solvent
Emissions
/ 1 \
Substrate
Adhesive
Application
Oven
(drying & curing)
Backing
&
Rolling
Cutting
&
Sheeting
Finished
n
Figure 1. Schematic of Adhesives Coating Operation
-------
Doctor Blade
oo
Flush Bottle
Copllcatlon
•
Roll
Drum of Adhesive
Figure 2. Adhesive Application Equipment Schematic
-------
For adhesive coated paper production, most equipment cleanup
occurs at the application section of the coating line. Figure
2shows the configuration of the adhesive application equipment
used at FLEXcon. The adhesive is pumped from a drum to a
reservoir that allows the adhesive to contact each of the two
rollers. The reservoir is made up of three pieces; the trough,
and two dams. The positioning of the reservoir directly impacts
the thickness of the adhesive applied. The space between the
metering roll and application roll and the speed of the metering
roll, application roll, and the substrate also control the
thickness and quality of the coating. The doctor blade removes
excess adhesive from the surface of the metering roll before
emersion into the reservoir. The two flush bottles provide a
continuous drip of toluene which dissolves and flushes away any
adhesive at the dam a metering roll interface. Without the
toluene flush adhesive builds up on the ends metering roll.
Excessive build up of adhesives can force the rolls apart which
impacts the thickness of the coating.
The wastes generated by cleaning are waste adhesive and
toluene and associated emissions from the flush bottles, and the
waste adhesive and MEK and associated emissions from cleaning the
three reservoir components, rolls, doctor blade, pump, and hoses.
Additionally, the waste collection tray is also cleaned during a
"super" clean-up which occurs less frequently.
A clean-up was not conducted during the site visit so no
specific details regarding clean-up can be presented. However,
the general clean-up method was described after the tour.
The pump and hoses are cleaned by flushing them with MEK.
The three reservoir components are removed and soaked in a MEK
bath. The rolls and doctor blade are wiped with rags saturated
with MEK. Clean-up generates approximately 15 gallons of MEK
waste. During a super clean-up the waste collection tray is
wiped down with MEK, and the doctor blade is removed and soaked
in an MEK bath along with the three reservoir components.
3M298-62/«ls.021
C-69
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TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
EPA-600/R-94-007
3. RECIPIENT'S ACCESSION NO.
4. TITLE AND SUBTITLE
Improved Equipment Cleaning in Coated and
Laminated Substrate Manufacturing Facilities
(Phase I)
5. REPORT DATE
January 1994
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
Beth W.
Me Minn and Jill B. Vitas
8. PERFORMING ORGANIZATION REPORT NO.
CH-93-100
9. PERFORMING ORGANIZATION NAME AND ADDRESS
TRC Environmental Corporation
100 Europa Drive, Suite 150
Chapel Hill, North Carolina 27514
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
68-D9-0173, Task 3/309
12. SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
Air and Energy Engineering Research Laboratory
Research Triangle Park, NC 27711
13. TYPE OF REPORT AND PERIOD COVERED
Task Final; 11/92 - 6/93
14. SPONSORING AGENCY CODE
EPA/600/13
is. SUPPLEMENTARY NOTES AEERL project officer is Michael Kosusko, Mail Drop 61, 919/541-
2734.
16. ABSTRACT'
The report gives results of a Phase I study to characterize current equip-
ment cleaning practices in the coated and laminated substrate manufacturing indus-
try, to identify alternative cleaning technologies, and to identify demonstrable tech-
nologies and estimate their emissions impacts. It presents information from sources
including literature searches, industry questionnaires, plant visits, pollution pre-
vention experts, and industry and trade association personnel. (NOTE: Phase II ac-
tivities will be the actual demonstration of selected alternative technologies, and
Phase III will be to transfer related technology by means of conference papers, jour-
nal articles, and newsletters, prepared and presented at industrial workshops, pol-
lution prevention conferences, and other events where industrial application of pol-
lution prevention technologies is discussed. Facilities within this industry tend to
operate in one of two segments: (1) large facilities operating coating lines dedicated
to one type of product, such as masking tape or label stock; or (2) batch processors
or plants that manufacture comparatively small quantities of a wide variety of high
value-added products. Both segments of the industry use essentially the same clea-
ning methods, even though the segments differ substantially in the range of sub-
strates, coatings, and application equipment used at the plants.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS
c. COSATI Field/Group
Pollution
Cleaning
Coatings
Laminates
Manufacturing
Emission
Solvents
Polymers
Pollution Control
Stationary Sources
13 B
13H
11C
11D
05C
14G
11K
07D
18 DISTRIBUTION STATEMENT
Release to Public
19. SECURITY CLASS (This Report 1
Unclassified
21. NO. OF PAGES
195
20. SECURITY CLASS (Thispage)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
C-70
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