New Paint Process Eliminates Source of VOC Emissions and Hazardous Waste at Kentucky Truck Plant

In 2007, Ford's Kentucky Truck Plant implemented an innovative new paint process that eliminates both a source of volatile organic compound (VOC) emissions and a hazardous waste stream from the facility. This process uses a new material to "purge" paint shop machinery. Purging is the process of cleaning out the lines and nozzles of automatic paint spray applicators between color changes or after downtime. In order to paint vehicles different colors, residual paint from the first color must be cleaned (or "purged") using a solvent or solvent-water blend so that the second color may be painted at a high quality. In the past, the material used in this purging process contained VOCs, which resulted in both VOC emissions from the plant and the creation of a hazardous liquid waste product.

Ford's paint engineers worked with Gage, a solvent supplier, to develop a new purge material that eliminates the VOC emissions from this process and converts the previously hazardous waste stream into a reusable non-hazardous waste. Since introduction, this new process has eliminated four tons of VOC emissions to the air and 74 tons of VOCs from the waste stream. It has also eliminated over 260,000 gallons of hazardous waste. The now non-hazardous waste stream is used by Waste Management, Inc., in a bioreactor to facilitate its landfill-gas-to-energy recovery process. Our waste stream is used to feed the bacteria used in the bioreactor, in order to accelerate the bacteria's conversion of landfill waste into a gas that is recovered and burnt to produce energy.

In addition to these environmental benefits, the new purging process has reduced per-unit painting costs and eliminated hazardous waste disposal costs. In total, the project resulted in a cost reduction of more than $330,000. All of these benefits have been achieved with no reduction in paint quality.

The Kentucky Truck Plant received an Environmental Leadership Award from Ford's Environmental Quality Office (EQO) for developing and implementing this process. These awards are given by EQO to recognize and promote ideas that are improving the environmental performance of Ford's manufacturing plants. Projects are judged on environmental leadership, environmental benefit and financial aspects. Special consideration is given to projects that have the potential to be replicated at other facilities for increased environmental benefits. The Kentucky Truck Plant's new purge process is being considered for replication at other paint shops.