POLLUTION PREVENTION AT SOUTHWIRE MACHINERY DIVISION

SUMMARY

An Environmental Committee at Southwire Machinery Division (SMD) continually evaluates and implements pollution prevention and waste minimization opportunities throughout the facility. Measures implemented by the committee have resulted in cost savings through reduced solid and hazardous waste, and toxic chemical use.

BACKGROUND

SMD, located in Carrollton, GA, is a 160,000 square foot, large capacity machine and fabrication shop. The production activities at SMD primarily consist of welding and cutting operations, machine shop operations, heat treating, shot blasting, spray painting, and millwright assembly of machinery.

An Environmental Committee made up of individuals from all areas of the shop is responsible for implementing SMD’s waste minimization program. The committee, supported by the division manager, has the authority to find solutions, implement changes, and purchase equipment necessary to carry out pollution prevention options.

The committee convenes twice a month to discuss current issues and make assignments for the implementation of pollution prevention strategies. The committee also works to educate other employees about pollution prevention and encourages them to make suggestions through the quarterly and yearly environmental STAR (Suggestions, Thoughts, and Recommendations) awards.

POLLUTION PREVENTION MODIFICATIONS AND RESULTS

Toxics Use Reduction

• Installed a distillery unit to recycle spent lacquer thinner from paint booths. This system reduced raw material costs and the amount of hazardous waste generated. Over 140 gallons of thinner was recycled in one year and the payback period was estimated to be less than 1.5 years.

• Replaced the oil used in an electrical discharge machine with one that is less toxic, replaced chlorinated solvents used for cleaning with less toxic substitutes, and substituted a lower VOC paint for a large quantity stock paint.

Solid Waste Reduction

• In 1996, reduced the amount of solid waste disposed 35 percent over 1991.

• Implemented procedures for the handling and storage of partial spools of welding wire to ensure they are used up instead of discarded, saving on disposal and purchasing costs.

• Established a policy to paint all shotblasted parts within 36 hours of shotblasting to prevent rusting and the need for re-blasting, reducing the amount of blasting material used. Also, moisture is added to spent shot blast dust causing it to rust into a solid form and making it more marketable to recyclers.

• Sawdust from the shipping department is reused as an oil absorbent in other departments, and shredded paper from the accounting department is used as a packing material in the shipping department.

• Tyvek suits are reused until dirty instead of discarding them at the end of the day.

• Replaced masking tape with reusable magnetized rubber pads for masking parts during paint application, and began sending spent paint filters for fuels blending instead of disposing of them in a landfill.

• Began recycling fluorescent bulbs, used oil, and coolants.

• In 1996 recycled 58,126 pounds of cardboard, 26,333 pounds of paper, 1,026 pounds of aluminum cans, 125,808 pounds of wood waste, and 1,626,841 pounds of scrap metal.

Stormwater Pollution Prevention

• Bi-monthly inspections are conducted of all outfalls, and spill and leak prevention measures were implemented throughout the facility to prevent stormwater pollution.