13. LAYMAN S REPORT. Timber industry switches to water-based paints

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1 13. LAYMAN S REPORT Timber industry switches to water-based paints The application of synthetic paints on wooden elements for outdoor uses (such as frames, windows and doors) causes considerable environmental damage in Europe through the release of poisonous substances, waste and the use of non-renewable resources such as tropical wood. From an environmental perspective the switch to a large-scale use of water-based paints for outdoor uses is a desirable solution. However, there are a number of disadvantages connected with using this type of paint regarding economic, technical and labour factors. Up until 1999, the timber company Stam & Landman in Heerhugowaard also sprayed the frames they produced with paint on a solvent basis such as turpentine. It was expected then that within a few years there would be a ban on the use of synthetic paints. The spray system that was currently in use was not suitable for spraying water-based paints. The timber company needed to consider investing in a modern, yet expensive automatic sprayer. So rather than putting off the inevitable, it was decided to start the WATER project, a pilot project partly funded by the European Commission. In doing so the Netherlands would be familiarizing itself with the conscientious process of spraying with water-based paints. The WATER-project (Water-based coating Technique for Environmental damage Reduction) is aimed at demonstrating an innovative technical system that enables the European timber industry to switch from synthetic paints to water-based paints. The project was carried out at Stam & Landman between February 1999 and February It needed to show that the new spraying process would dampen all existing economic, technical and labour barriers with regard to the use of water-based paints for outdoor uses on all wood types, including the environmentally friendly pinewood. It was precisely pine that had presented problems in the past, on account of improper application of water-based paints hampering vapour inhibitors, which ultimately could lead to wood rot. This was also one of the reasons that the SGT (joinery industry foundation guarantee fund) would not allow a large-scale introduction of water-based paint sprayers.

2 Problems overcome by modern sprayers In order to prevent these problems, an innovative concept was called for that would make it possible to introduce the large-scale use of water-based paints in the timber industry. After careful research Stam & Landman selected a creative concept that would combine both existing and new technologies from different parties. An automatic transport system for the frames, a paint shower stall with paint recovery, a spray robot that gets its information from scanning the parts to be sprayed, a cooling wall for recovering the paint and a drying station all see to it that water-based paints can be applied on softwood (pine) without any problems. Problems are now a thing of the past on account of the sensors scanning information from the frames and then directing the spraying robot with this information in order to give an even coat of paint. The spraying is done electro-statically which sees to it that the paint evenly coats the frame in all spots. Finally during the drying process the temperature is gradually increased and the humidity is regulated. These factors together ensure an optimal vapour inhibition. The results were quite satisfactory. The quality of the spraying turned out to be good on all the wood types used, including pine. Furthermore the spray system led to the prevention of excess paint use. This is primarily due to regulating the amount of paint in the spraying process by scanning the frames. Secondly using a spray robot ensures that the maximum amount of paint used actually lands on the frame. The paint that misses the frame is collected and recycled. This led to a sharp reduction in the amount of waste compared to the old situation. Based on the fact that the spraying takes place in a conditioned area and the results were positive, the SKH (wood inspection foundation) issued the certificate necessary for a warranty for spraying with water-based paints. This solves the problem of using water-based paints on non-tropical wood types, because the SGT (joinery industry foundation guarantee fund) accepts this certificate. On account of this it is now possible to supply all frames with a warranty, regardless of wood type. However one of the most important advantages for both the environment and the labourtechnical field is that the emission level of hazardous substances has been reduced to zero. Worldwide this means that the use of water-based paints presents a significantly smaller threat to the OZONE layer. Closer to home this means that the personnel are no longer exposed to substances that may cause the Organic Psycho Syndrome (OPS), also cynically known as the mad painter disease. A nasty disease that not only can affect painters, but also other occupations such as printers if they frequently work with thinners. The initial symptoms are vague complaints of fatigue or irritability. However the disease can ultimately lead to premature dementia.

3 Major positive environmental impact possible Prior to starting the project an estimate was made as to the environmental impact of using such a spray system. For instance it would have to be possible to reduce emissions of hazardous substances by 96%. This was only possible if synthetic paints were no longer used. Water-based paints still contain a small amount of thinner, but are made up mostly of water. Since the introduction of the spray system frames have been sprayed exclusively with waterbased paint. It was expected that recycling paint would reduce the percentage of waste by 80%. In actual practice this was not possible due to a variety of problems related to the precision of a number of components on the sprayer. As a result some of the paint landed next to the collecting trays. This paint could not be recycled and ended up as waste. During the project the reduction of paint waste stagnated at 71%. Nevertheless this is being studied further, because it is certainly possible to further reduce the amount of paint waste. Unfortunately, one of the objectives to decrease the use of tropical hardwood is not up to the timber companies. In the best scenario the timber companies play an advisory role, because it is the client, often a city council or a project developer, who determines the wood type chosen. This project was not able to show that the use of hardwood was reduced, but it clearly showed the possibility of making pine a good alternative. It is possible based on the information from Stam & Landman to get an impression of the environmental impact that such systems would have if they were used in similar factories throughout the Netherlands and Europe. See the table below. Figure: National and European dimension Environmentalaspect Environmentaleffect Timber company Stam & Landman Production VOC Production solid waste Wood use National dimension European dimension Old situation (kg) 18,242 1,672,748 3,330,999 Situation ,182 99,930 Profit (%) Old situation (kg) ,227,837 2,445,034 Situation , ,060 Profit (%) Old situation (kg) Situation 2000 Profit (%) Profit or loss is dependent on client

4 Are the environmental advantages economically feasible? The environmental advantages are a very important part of this project, but the economical aspect must also not be overlooked. The system, as it is set up at Stam & Landman, is extremely suited for spraying frames with water-based paint. It guarantees a constant quality of spraying, which is of vital commercial importance. However it is still uncertain if the spray system is economically feasible as it was run during the project. The costs were not passed on to the customer, because he/she would choose the cheapest supplier, which would most probably be a timber company that does not yet use water-based paint. A portion of the costs is earned back from recycling the paint, but the spray system did not function optimally during the project so there is still potential to gain more. Recycling paint also has the advantage that less waste is produced, which also lowers the cost for the processing. The expectation is that the system will also have a positive impact on the personnel. The workers will no longer be exposed to solvents and as a result run less risk of suffering from Organic Psycho Syndrome. Since the spray robot does the active spraying, the sprayer no longer has to be the one to coat every nook and cranny with paint. This should ultimately affect the health statistics. It is not possible to give an exact answer as to whether or not this spray system was the best move economically, because the appropriate figures are not available. A study from the accountant does show that the investment for the spray system did not have a negative influence on the company s results. The investment was needed sooner or later, since it will be required to switch from synthetic to water-based paints in the near future. The financial aid that was available from the WATER-project was the last bit of persuasion needed for the management to invest in the spray system. There were different investment possibilities, including a system in which two employees would spray manually. In the end the system with the robot spray was chosen, which reduced the number of man-hours and gave a consistent spray quality. A consistent quality is of particular importance with softwoods. Also with an eye on the future, when the final coat is applied in the factory it is important that the spraying is done with a consistently high quality.

5 Positive results for industries The main question put forward by the European Commission regarding the WATER-project was: Is it possible to apply water-based paints on softwood (pine) frames without any problems?. Now that the project is completed everyone can see that the answer is a wholehearted YES. So, there is no reason for a negative advice to apply a similar concept throughout the Dutch and European construction and timber industry, as long as a comparable system is used to apply paint to wood. It may be also very possible to make variations in the components that were combined in this project to make a modern, well-functioning spray system. However, Stam & Landman did not explore these possibilities. It is also possible to apply this concept in other sectors, where spraying and/or coating activities are part of the production process, for example in the furniture branch. These industries too emit solvents into the atmosphere and will need to meet increasingly more stringent emission norms as does the timber industry.