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Newark Assembly Plant: Glycol Ether Reduction In Newark Assembly Plant Glycol Ether Reduction in Surface Preparation Materials ________________________________________________________________________ The Newark Assembly Plant manufactures and assembles passenger vehicles. During 1995, Newark manufactured the Chrysler Concorde and Dodge Intrepid model lines. The Newark Assembly Plant receives automobile components from Chrysler stamping and engine manufacturing plants as well as other mechanical and electronic components from numerous suppliers. The production of vehicles required many different operations including welding, brazing, conversion coating, adhesive application, painting and automotive fluid filling as well as ancillary operations such as machine maintenance and wastewater treatment. Auto bodies receive surface preparation, primers and topcoat paint for both corrosion protection as well as for consumer preferance. Surface preparation is critical for inter- coat adhesion as well as finished paint quality. Part of the surface prep process is the Body Washer. The Body Washer consists of a high pressure water and surfactant spray process used to clean the body of the vehicle. The purpose of washing the body is to remove drawing compounds, stamping lubricants as well as dirt and debris that may be present on the metal surface of the body. This is done prior to the body moving into the metal finishing area. Previously a surfactant mixture which contained glycol ethers was used for washing the bodies. Through product reformulation, a substitute surfactant was developed which contained no glycol ethers. This product substitution resulted in a reduction of approximately 75,000 pounds of glycol ethers. After the body comes out of the metal finishing area, the same product containing glycol ethers was used in the pre-wipe area prior to entry into the phosphate system. In this area, a single misting ring applies a concentration of surfactant to the vehicles. The purpose of this is to remove any body sealers or other dirt that may have accumulated on the vehicle body during or after metal finishing. The new reformulated surfactant was substituted for use in this area as well. The product substitution in the pre-wipe area resulted in an additional reduction of approximately 75,000 pounds of glycol ethers. Part of this process involved the identification of opportunities for material use reduction. This assessment uncovered numerous pump leaks, which were repaired with follow-up including an on-going maintenance program. This Internet document provided by the Michigan Department of Environmental Quality, 1-800-662-9278. Substances Targeted: Glycol Ethers Targeted Reduction(s): 100% reduction in surface preparation materials, in all applications where the surfactant is used. Results and Advantages: Reductions achieved were: C 158,415 pounds of glycol ethers eliminated from the plant = 91% reduction from 1994 to 1995. C Reduced emissions to Air, Land, and Water. Advantages: C Approximately $500,000 in cost savings related to material cost. C Lower emissions to air and water. C Reduced employee exposure. Objective: To reduce glycol ether emissions through product substitution. Environmental Hierarchy: Pollution Prevention (P2) P2 Approach: Product Substitution, Process change & optimization Environmental Media: Water (POTW), Air (fugitive and point), Land (treatment- solidification & disposal) Capital Investment: None. Barriers Encountered: The product substitution was successful in areas where automated equipment was used. There are areas where manual wiping by employees is needed. The employees felt that the new product was not as Aaggressive@ in removing the sealers and dirt, and consequently they had to put a little more Aelbow grease@ into using the new product. Therefore the new product was met with some resistance. The advantages of the new product were explained, and a compromise with the employees was achieved. Some of the old material had to remain on hand for use in Aextreme@ manual clean-ups. However, the old material is now used more sparingly and in lower concentrations. Future Opportunities: The plant will be undergoing model change-over in the next year, including a new paint shop. When the new product is launched, it is intended at that time that the old surfactant which contains glycol ethers will be eliminated from use, and the process training for the employees will be with the new glycol-ether free material. This Internet document provided by the Michigan Department of Environmental Quality, 1-800-662-9278..
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