Office of Technical Assistance Executive Office of Environmental Affairs Commonwealth of Massachusetts

Summary

Galileo Electro-Optics Corporation of Sturbridge, Massachusetts, implemented chemical substitution in its production and quality inspection areas to reduce volatile organic compound (VOC) emissions. The changes which cost less than $ 1,000 have reduced trichloroethylene (TCE) purchases, usage and emissions in the production operation by more than 95%. A Galileo-designed reclamation system recycles Freon in-process. This has reduced Freon purchases by 72% and cut emissions by nearly 60% from 1988 levels. In quality inspections, the annual use and emission of 560 pounds of Freon has been eliminated, saving the firm $2,700 each year.

Background

The Galileo Electro-Optics Corporation, which employs 250 people, manufactures fiber optic plates. In the typical production sequence, plates are mounted to fixtures using wax prior to cutting, polishing or grinding. TCE was then used to remove the wax.

In a quality control inspection operation, a Freon-based aerosol was used to blow dust and debris off the part. (It is necessary to thoroughly remove the contaminants in order to obtain accuracy in inspection.) As part of the manufacturing process, glass fibers are placed in molds to form fused blocks of fibers. These blocks act to transfer images with a high degree of clarity, such as in photocopier machines. Prior to molding, the fibers are cleaned in a two-part vapor degreaser which uses Freon. First, a Freon-based soap solution washes the fibers. Following the wash, the fibers are rinsed in a Freon-based solvent then dried and assembled into the molds. It is vital that the fibers be free of contamination, which creates cracks in the fibers, spoiling the resolution of the image. Also, the cleaning solvent itself must readily evaporate from the fibers; otherwise, the blocks explode when subjected to high temperatures in a further processing step. Currently, only Freon meets the evaporation and cleaning needs of Galileo.

Toxic Use Reduction

After attending seminars given by OTA and DEP on toxics use reduction, Galileo formed a Toxics Use Reduction Task Force to investigate the potential for removing highly toxic chemicals from the work area. In addition to purchase and disposal costs the use of such chemicals impacts on the cost of ventilation needed to insure worker safety.

As part of the planning process, all employees were requested to submit ideas and suggestions to the task force. These ideas were incorporated into reduction plans submitted by the task force. Vendors were consulted concerning waxes and alloys which could be removed without the use of TCE. Galileo's long-term plan is to eliminate Freon use in cleaning. In the meantime, Galileo is focusing on eliminating the cleaning steps in the manufacture of their product. Parts will be manufactured clean rather than cleaned after being made.

Toxics Use Reduction Modifications

The substitutions required no new equipment modifications or worker training. TCE substitution required approximately 20 hours of in-house testing by production engineers and product scientists. The new wax and alloy have low melting temperatures. These new materials hold the piece during machining, yet can be melted for easy removal. This allows Galileo to use water heated to 175 F to remove the material. Some material requires acetone for removal (Galileo is researching aqueous alternatives.)

By installing prefiltered air hoses and nozzles, Galileo has been able to substitute dry pure nitrogen for the Freon used in quality inspections. The nitrogen is supplied by cylinders in another area of the facility. Each 1000 pound cylinder lasts approximately 30 days.

Galileo designed and installed an integral pumping system, still and holding tanks to reclaim and permit re-use of the Freon used in cleaning. A pilot system was tested, using small quantities of material to prove that the reclamation method did not affect product quality. The material within the degreaser is tested regularly before being removed for reclamation. Galileo actively maintains the Freon so that the material lasts longer and changes can be made less frequently.

Results

Reductions Achieved: TCE use was cut from 1849 pounds per year to 100 pounds per year in the small and large glass mounting area. In quality inspection, Freon use has been eliminated. Overall, Freon emissions have been reduced from 157,591 pounds in 1988 to 33,673 pounds in 1992.

Economics: The TCE substitution took 4 hours to research and 20 hours to test. The switch cost less than $1000 to implement. The substitution eliminated the need for improved safety and ventilation equipment, which would have cost a minimum of $10,000. Galileo's use of TCE is now well below reporting thresholds for the federal and state governments. By disposing of less contaminated TCE, Galileo saves $10,600 yearly.

The substitution of nitrogen for Freon took 5 hours of planning and design, and 26 hours of installation time. The project cost a total of $3,000 and has saved $2,700 yearly. This change has permitted Galileo to eliminate the use and emission of more than 560 pounds of Freon each year. In light of the fact that the price of Freon and TCE rise every year, the savings are likely to increase over time.

Galileo spent about half a year with a model unit making alterations on a trial unit. An additional year was spent automating the unit and phasing it in facility-wide. Approximately 200 hours were spent on installation and set-up of the production unit. Labor costs were approximately $3,000 and equipment costs were $12,000. The 110 drums of Freon saved led to cost reductions of $110,000 yearly. Galileo then learned that Freon will increase to $2000 per drum further increasing purchase savings.