Sector Assessments

An Analysis of Pollution Prevention Opportunities and Impediments in the Wood Products Manufacturing Sector in Georgia

Pollution Prevention Assistance Needs of the Wood Products Manufacturing Sector

Organizational Needs

• Few Georgia wood products manufacturers have a formal method of identifying or evaluating waste reduction opportunities.

Several companies contacted indicated that their organization did actively identify waste reduction methods through evaluation of waste streams. These companies represent less than 10% of the total number. The existence of a program was most common among hazardous waste LQGs since a plan is required by Georgia environmental regulations. Most of the manufacturers contacted were interested in reducing waste and cost, but did not have an active pollution prevention program. Some primary needs of wood product manufacturers are to implement a pollution prevention program and to be educated on the benefits of such a program.

• Few Georgia wood products manufacturers have an engineering or technical staff.

The majority of Georgia wood products manufacturers are small businesses that are primarily focused on production of a particular product. Companies with engineering resources are primarily those with more than 100 employees, or build complex designs such as prefabricated and trailer mounted housing. New technologies that benefit the businesses from an engineering perspective are discovered by the small businesses through vendors. Trade shows where vendors show and demonstrate new products were mentioned by several wood products manufacturers as a primary resource for finding new technologies. Access to engineering resources is a primary need of small wood products manufacturers to better evaluate and identify beneficial technologies.

• Most Georgia wood products manufacturers are unaware of the various state, federal, and university technical assistance programs that can aid in waste reduction.

Fewer than 12% of the businesses that responded to the survey had used either university or government programs to assist in minimizing waste. Most companies contacted were unaware of the existence of such programs. Most federal, state, and university programs can provide information at no cost to the business. Wood product manufacturers need to be informed of the existence of technical assistance programs.

• Few Georgia wood products manufacturers are active with trade associations.

There are a number of trade associations available to wood products manufacturers. There are 73 wood product associations listed in the National Trade and Professional Associations 1995 directory. Manufactured housing businesses are involved with the Georgia Manufactured Housing Association. Large particleboard, plywood, and veneer manufacturers tend to be members of various trade organizations. In general, the small manufacturer is not a member of any trade organization. There are only 4 companies in Georgia that are member of the National Furniture Manufacturers Association. The Hardwood Plywood and Veneer Association has approximately 8 members in Georgia. Several companies contacted indicated that they were active with the local Chamber of Commerce. Wood products manufacturers could benefit from becoming active members of trade organizations by taking advantage of the technical, educational, and regulatory programs offered by the associations.

Technical Needs

• Waste reduction could be realized in solvent emissions by some relatively simple methods that would result in significant cost reduction.

There is an overall lack of awareness of new technologies in the Georgia wood products industry. This is caused by several factors such as a lack of engineering resources, little or no activity within trade organizations, and the lack of either formal or informal waste reduction programs. Some simple solutions to these technology gaps are listed below.

• Training of employees who spray apply coatings.
• Education on various spray application technologies such as HVLP, airless, electrostatic, etc.
• Education on alternative coatings - UV cure, high-solids, water-based.
• Education on alternative low-VOC glues and adhesives.
• Education on how to use existing waste recyclers.
• Education on environmental compliance including Title V.
• Education on automation of assembly and coating processes.
• Education on alternative engineering materials

Technology Research Needs

The previous pages addressed common technologies that have potential waste reduction opportunities encountered in the wood products industry. The information presented provides a statement of the type of technology used, the level of expertise at which it is used, and ways to reduce waste. Not all processes and technologies used by wood product manufacturers are discussed. Some of the common processes are universally done well and have very few health or environmental concerns. Research may be needed to reduce emissions from urea and phenol resins, and to further industrialize water-based coatings for wood products.

• Alternatives to Urea and Phenol Formaldehyde Resins

Urea formaldehyde resins are used to manufacture particleboard and similar materials by bonding wood fibers together. Urea formaldehyde resins will make up less than 5% of the weight of the finished wood; the majority of the finished board consists of wood. These resins do release formaldehyde from processing. Phenol formaldehyde resins are used to manufacture strandboard and plywood. The 1993 TRI reported releases from these industries in Georgia of 167,078 pounds of formaldehyde and 154,780 pounds of methanol. Methanol is also a component of urea formaldehyde resins. Phenol emissions in Georgia from these industries were 20,396. Phenol formaldehyde resins seem to contain less methanol, but are dark in color. The dark color of phenol formaldehyde is unsuitable for most particle board due to appearance, but is used internally in plywood manufacture.

There are some companies using various isocyanate resins as an alternative to either urea or phenol formaldehyde. Isocyanate resins are an alternative, but typically have a cost disadvantage when compared to urea or phenol formaldehyde. Isocyanates are also considered a worker exposure hazard and are reportable on the TRI.

• Alternatives to Solvent-based Coatings

Water-based clearcoats do exist that can replace solvent-based materials for high-quality furniture finishing. Current feedback from industries using water-based clear-coats indicate that they are slightly less durable. Companies that have switched to water-based clear-coats have had to absorb large costs associated with research and equipment investment. Additional research is needed to further industrialize water-based and other low VOC coatings that have the high durability of current solvent-based materials. These materials may exist in other industries. Basic research and or demonstration projects are needed to make low VOC technologies available to the small wood products manufacturer. Some of the water-based coatings in current use also contain isocyanates.

Meeting the Pollution Prevention Needs of the Wood Products Manufacturing Sector

Meeting Organizational Needs

• Provide Pollution Prevention Training

Small and large wood products manufacturers will benefit from education and training of plant management and production staff on pollution prevention techniques. The ultimate goal is to have each company conduct pollution prevention assessments, evaluate results, and implement cost effective solutions.

Due to the large number of manufacturers, one-on-on training with each company is not practical. Training could be partially accomplished by conducting workshops in the Atlanta area, and one or more workshops in each of the other Georgia regions. Participation of the Chamber of Commerce and various trade organizations in training activities would enhance the process. Fact sheets will also be developed for wood products manufacturers. P²AD will develop fact sheets and design workshop programs as part of existing conferences or as stand alone presentations. Education and training of vendors that work with the wood products industry on pollution prevention and assistance resources are other ways of reaching wood products manufacturers with beneficial information.

• Identify Engineering Resources for Process Design and Environmental Services

Engineering resources are available for small businesses through EDI's network of regional offices. Georgia Tech Research Institute (GTRI) also provides engineering services though regional offices. Services may include information on equipment selection, manufacturing, and environmental compliance. In order to take advantage of these services, P²AD will provide descriptions of these and other services available to wood products manufacturers.

• Identify Educational Resources to Provide Environmental Regulatory Training

• Identify and Encourage Development of Wood Products Trade Organizations

The above items will require additional research to identify resources and design programs to meet these needs.

Meeting Technical Needs

• Provide training on new and standard coating technologies and equipment
• Provide training resources for coating and adhesive application
• Provide education on alternative coatings and adhesives

This information can be distributed in booklet form and through workshops. P²AD will first develop written information for distribution to wood products manufacturers. There are several good documents previously published that can serve as models or that can be distributed without further editing. Any workshops developed for wood products manufacturers will include this information.

Meeting Research Needs

• Several trade organizations are active with particleboard and plywood manufacturers. These organizations may be interesting in supporting research in alternative resins and application systems. Applied research projects may be necessary to take advantage of previously completed research. P²AD should seek industrial partners in developing research programs.

• Applied research or demonstration projects will be identified to help bring new coating technologies to wood products manufacturers. P²AD should seek industrial partners for completion of demonstration projects. Information gained will be distributed through fact sheets and workshops