In the past, office furniture manufacturing facilities, as well as many other industries such as painting and coating operations, were significant sources of air emissions. As part of their continuous improvement focus on the environment, KI manufacturing facilities have made considerable progress in reducing the amount and toxicity of air emissions that are generated in their manufacturing processes. These changes have positive impacts for KI and their customers by:
- Improving KI employee work environments
- Improving regional air quality in the areas in which the furniture manufacturing occurs
- Reducing potential for off-gassing and indoor air quality issues associated with the use of the final product lines, benefiting KI customers
- Reducing hazardous and toxic wastes generated at the manufacturing facilities, since solvent-based (i.e. volatile) materials commonly produce hazardous waste
- Focusing KI staff energy and efforts to productive activities rather than the strenuous and complicated tasks of air emissions permitting, record keeping, and monitoring required when a facility is a major source of air emissions.
The following table identifies some of the traditional methods for Kl's operations and how many KI facilities have reduced air emissions using these methods. Note that air emission reductions have also achieved other environmental benefits, such as water conservation and waste reduction.
| TRADITIONAL PROCESS |
PROCESS AT KI FACILITIES |
ENVIRONMENTAL BENEFITS |
| Using solvents to clean metal components prior to finishing |
Six-state phosphate cleaning systems for metal components (a water based cleaning system)
Counter-current water flow in wash systems |
Negligible VOC and HAP emissions with water-based cleaning
Counter-current water flow system achieves exemplary levels of cleaning, while limiting water usage and wastewater generation
Limited wastewater generated from system is treated and discharged to municipal wastewater treatment systems with negligible, if any, hazardous waste generation |
| Using solvent-based adhesives in chair and panel assembly |
Water-based adhesives
Solid or hot-melt adhesives |
Negligible VOC and HAP emmissions from water-based and hot-melt adhesives
Limited, if any, hazardous waste generation |
| Using solvent-based paints for metal component painting |
Electrostatic powder painting
Spray guns chosen for transfer efficiency
High solids paints |
Negligible VOC and HAP emissions from powder painting
Limited, if any, hazardous waste generation from powder painting since materials are not hazardous
Transfer efficiencies of the spray guns and the electrostatic process result in a greater percentage of paints being deposited on the intended part, thus reducing emissions and waste, and saving resources and money on raw materials |
| Achieving scratch and abrasion resistance through significant coating thickness |
Painting formulations are designed for superior coverage and resistance with minimum coating thickness |
Reduced air emissions since coating is accomplished with less paint |
| Uncontrolled decorative chromium electroplating |
Dual controls on decorative chromium electroplating including a surface tension reducing agent and a dry scrubber |
Per EPA's standards, a decorative chromium electroplating system needs to have one type of control device installed. KI's system has two control systems whose combined effect reduces air emissions of chromium to minimal amounts. |