Case Study: Henredon Furniture Industries
Location: Industry: Pollution Prevention Application: Annual Savings (1993): Payback Period: PPP Challenge Grant Award Contact: Morganton, NC (Burke County) Furniture Manufacturing (SIC 2511) Equipment/Material Substitution $84,450 from HVLP Guns 2 months $30,000 Joe Harrill, Manager, Safety, Health, and Employee Development (704) 437-5261
Background
As a high-end furniture manufacturer, Henredon Furniture Industries applies stains and other finishes to chairs, benches, and other furniture pieces. To comply with State and Federal air toxic and volatile organic compound (VOC) emission standards, Henredon embarked upon a two-phase research and development effort to reduce its materials usage and emissions via increased coating transfer efficiency and implementation of wood coatings with low volatile content. Henredon also installed metal baffle-type filters to replace paper/cardboard filters.
Waste Reduction Activities
• Henredon completed the first phase of its waste reduction effort through installation of high-volume, lowpressure (HVLP) spray and air-assisted airless equipment in all finishing facilities. Employees were trained in the new application techniques. Throughout the equipment conversion and subsequent training activities, Henredon maintained product quality and production levels. • Phase two of Henredon’ efforts to reduce emissions involved the evaluation and implementation of s alternative coatings. The company determined that a hybrid system comprising conventional stains and wash coats and waterborne glazes, sealers, and topcoats would be most suitable. The conventional stains and washes control excessive grain disruption and provide a sealed base adequate for the subsequent waterborne finish. Henredon initiated this conversion on the occasional production line, through which it eventually fed 25 percent of the plant’ production. Concurrently, Henredon is developing waterborne s versions for 90 percent of the facility’ finishes. s
Waste Reduction
Compared to conventional spray equipment, the HVLP/air-assisted airless conversion resulted in a 13- to 20percent reduction in materials usage for stains, lacquers, glazes, and sealers. Complete implementation of the two initiatives will result in an overall reduction in emissions of 73 percent. Because the metal baffle-type filters have a 10-year service life compared to the service life of one week for the paper/cardboard filters, the switch to metal filters has nearly eliminated the facility’ paper/cardboard filter waste stream. s
Annual Savings/Payback
With capital investment of $12,380 and $70,806, respectively, annual savings for the two phases amount to $84,450 with a payback of 1.2 to 2 months. Annual purchase and disposal costs to fit a single booth with paper filters was $5,594 while purchase and installation costs for the new metal filters is $687 per booth. The cleaning cost per metal filter is $2 per month. The payback period of 8.14 weeks for the metal filters does not include labor savings. Below is a summary of the Phase I and Phase II programs.
SIC 2500 Case Studies -3August 1995
Pollution Prevention Activities: Henredon Furniture Industries
Activity HVLP and AirAssisted Airless Conversion (Phase I Hybrid Waterborne Conversion
Capital Investment, $ 12,380
Material Use, lbs Before 175,673 After 139,984
VOC Emissions, lbs Before 933,240 After 811,291
Savings Realized, $/yr 84,450
Payback Period 1.2-2 months
70,806
175,653
139,984
811,291
253,920
NA
NA
SIC 2500 Case Studies
-4-
August 1995