NJTAP Pollution Prevention Case Study -- Union Ink

Wilson Imperial Uses Bradley Grant to Reduce Solvent Emissions

Wilson Imperial is a maker of deglossers, brush cleaners, paint and graffiti removers, and specialty products. The company has operated at its location in Newark, New Jersey since 1918. With the aid of a Bradley Grant for $2,750, administered by the New Jersey Technical Assistance Program for Industrial Pollution Prevention (NJTAP), Wilson Imperial installed hinged steel covers on its mixing tanks. By doing so, the company saves a projected $8,200 per year, and reduces VOC emissions by 32,800 annually.

The Old System

Wilson Imperial manufactures solutions and blends of hydrocarbon solvents prior to filling on a semi-automated line. Several of these products are processed or blended in mobile floor tanks. In these formulations, mild heat is generated, and loss of volatile ketones, alcohols, and aromatic hydrocarbons has exceeded eight percent of total batch weight.

The New System

Experimentation revealed that adding properly fitting covers to the mixing tanks would significantly decrease losses due to solvent evaporation. Consequently, Wilson Imperial installed seven hinged, stainless steel covers on its mixing tanks, to reduce solvent loss. Installation of the new covers was completed in September 1997.

The Bradley Grant

The Bradley Grant Program, formally known as the New Jersey Pollution Prevention Implementation Incentive Grant Program, was enacted to encourage the installation of pollution prevention technology. The program, sponsored by former Senator Bill Bradley, is intended to show the usefulness of offering pollution prevention grants. The Bradley Grants, funded by the USEPA and administered by NJTAP, provide financial assistance to small manufacturers in New Jersey, in order to implement pollution prevention programs at their facilities.

Wilson Imperial was awarded a Bradley Grant for $2,750, approximately half the estimated project cost of installation for the tank covers.

Financial Benefits

The total cost for the project was $6,504, which includes cover manufacture and fabrication, as well as modifications to the existing tanks allowing them to accept the covers. The pollution prevention grant paid $2,750 of implementation costs.

Because installation of the tank covers has decreased solvent evaporation, less solvents are now needed in the production process. The estimated annual savings are $8,200. The payback period for this project is 5.5 months, and the five-year internal rate of return (IRR) is 218%. Had grant funds not been available, the payback and IRR would have been 9.5 months and 124%, respectively.

Environmental Benefits

With an average production of 1,250 pounds per week, 656 pounds of hazardous air pollutants are expected to be eliminated. This translates to a decrease in fugitive air emissions of 32,800 lb annually.

The air emissions reduced, are primarily methylene chloride, toluene and ethanol. Prior to installation of the tank covers, the company typically lost 8% of total product weight to evaporation. After installation, the evaporation rate is estimated to have dropped to 1% of the total product weight.

Table 1: Environmental Benefits

Conclusion

By adding fitted steel covers to their mixing tanks, Wilson Imperial has been able to reduce annual fugitive VOC emissions by 32,000 lb. In doing so, the company realizes an annual savings of $8,200 on solvent purchases. As an added benefit, the smell of solvent vapors in the work area has noticeably decreased. Implementation of this project has benefited the environment by decreasing pollution while also decreasing Wilson Imperial's operating expenses, demonstrating that environmental projects can be economically profitable for small companies.