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Summary
Traditional approach
Cleaner production initiatives
Benefits recommended and implemented
Benefits recommended and being considered
Where to find additional information
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August 1998
Summary
The installation of new technology has eliminated the use of
solvents and thinners in applying stains and lacquers on to wood
panels used in furniture production. The new technology has reduced
dissipation of solvents and thinners into the atmosphere because
of the curtain coater which reduces the consumption of lacquers
and stains by 30-40% and the UV roller which reduces solvent usage
by approx 80%. The resultant savings in labour are approx 20-25%
whilst the savings in materials are approx 40%. The quality of
the product is also improved and production efficiency increased.
The new technology enables the industry to 'catch up' with emerging
overseas competitors and provides opportunity for developing export
markets. Total savings: $30,000 per annum.
Business Profile
Coating Australia Pty. Ltd. was established in 1997 to
increase competitiveness and improve business practices in the
furniture industry. The business is focussing on assembling and
polishing furniture made from solid timber, timber veneer and
particle board.
Financial assistance provided
The EPA's Cleaner Industries Demonstration Scheme provided
an interest free loan of $69,000.
Technology installed
Solventless timber polishing equipment.
Cleaner production motivators
Increased production while minimising manual spraying and
thereby labour.
Compete internationally with the demand in South East Asian markets
to produce environmentally friendly products.
Reduce the dissipation of hazardous substances into the atmosphere.
Traditional approach
- The SA furniture industry uses approx 1.2 ML of paint and
solvent per annum.
- Traditional polishing errors such as runs, patches missed,
consume a lot of paints, solvents and thinners.
Final products vary in appearance because the degree of staining
varies between different polishers.
- Operators are exposed to chemicals.
- Rate of production of a spraying machine is limited by factors
such as finishing features, required quality, shape of the piece,
gun movement and number of guns used for spraying. It is a labour
intensive process and there are few qualified polishers in SA.
- A polished piece of furniture is very soft and there is a
high rework rate between the assembly process and the polishing
process.
Waste Management
Processes generating waste
A team assembled the furniture and prepared it for polishing;
then up to five polish applications of lacquer combined with solvent
and thinner, and then sprayed on to furniture item. Solvents and
thinners dissipated directly into the air via exhaust system.
The ratio of lacquer to solvent and thinner on average approx
28:72.
Waste stream description
Solvent and thinner fumes dissipated into environment.
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| Process
Flow Diagram |
Cleaner production initiatives
New polishing techniques
The lacquer line comprises several sections including:
- conveyor
- roller coater drying tunnel
- curtain coater
- exhaust system
- drying rack
- drying oven.
The UV rollercoater eliminates the use of solvents and thinners
by rolling the lacquer (UV material) directly on to the piece
of timber. UV light applied to the timber cures the lacquer within
seconds and the timber is ready to be assembled into the piece
of furniture. This method is used especially for drying the less
visible areas of furniture such as underneath surfaces, and for
commercial desks. The drying time is in the range 5-10 seconds.
The airless high output pressure spraying equipment, especially
for base coat lacquers, allows more lacquer to be applied within
a specific time and very little product bouncing since the sprayed
lacquer droplets are larger and not mixed with high pressure air.
Benefits recommended and implemented
Solventless timber polishing equipment
| Environmental |
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| Air quality |
- Reduced dissipation of solvents, paints and thinners;
emissions ventilated into an air exhaust system.
- Lacquer oversprays caught by filters located in different
places on the machine preventing discharge of solid particles
into the atmosphere.
- Airless guns reduce overspray and hence fumes within
the finishing area.
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| Storage, usage and handling chemicals |
- Minimised volume of lacquers and stains used in the
process by 30-40%, reduced the explosive hazard and substantially
reduced storage of hazardous substances on the premises.
- Usage of environmentally friendly substances (water-based
stains and paints, UV lacquers).
- Optimising the process by using mechanical spraying
instead of gun spraying has reduced the amounts of paint
used and increased the quality of the product.
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| Economic |
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| Investment |
- $150,000 (includes the EPA contribution)
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| Operational and maintenance costs |
- Reduced manufacturing costs.
- Automatic spraying does not require qualified painters.
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| Productivity |
- Reduced production time: much faster process than traditional
polishing.
- Much improved production efficiency, far better product
quality and superior finish.
- Greater export opportunities, positive effect on developing
potential export markets for Australian furniture manufacturers
- Significantly improved physical and chemical features
of finished products, especially mechanical strength;
finish much harder than with traditional spray polishing.
- More consistency in stain colour.
- Less rework, less polishing errors and rejects.
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| Savings, outcomes |
- Increased profitability of 5%.
- The curtain coater reduces the consumption of lacquers
and stains by 30-40%. The UV roller saves approx 80% solvent
usage.
- The savings in labour approx 20-25%; savings in materials
approx 40%.
- Total saving in turnover of about 20%.
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| Payback period |
- The payback period likely to be less than 5 years.
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| OHS |
- Health risks to the operators reduced substantially
since no operator required during spraying process.
- Skin contact with hazardous chemicals and inhalation
of solvents and solids extensively eliminated.
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Benefits recommended and being considered
- Ecolabelling of products to educate the community.
- New unconventional printing methods.
Where to find additional information
Thomas Mentzel
General Manager
Coating Australia Pty Ltd
9 William Street
Mile End SA 5031
Phone: (+61 8) 8352 1166
This page was last modified 21-04-2006
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