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Clean Manufacturing Technology and Safe Materials Institute (CMTI) and the Coating Applications Research Laboratory (CARL) Center for the Environment

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Clean Manufacturing Technology and Safe Materials Institute (CMTI) and the Coating Applications Research Laboratory (CARL) Center for the Environment Discovery Park Purdue University. Lynn A. Corson, Ph. D., Director James R. Noonan, Assistant Director. Phone: 765-463-4749

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slide1

Clean Manufacturing

Technology and Safe

Materials Institute

(CMTI)

and the

Coating Applications

Research Laboratory

(CARL)

Center for the Environment

Discovery Park

Purdue University

Lynn A. Corson, Ph. D., Director

James R. Noonan, Assistant Director

Phone: 765-463-4749

Website: engineering.purdue.edu/CMTI/

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CMTI Technical Assistance Benefits to the Companies and the State of Indiana

$1.27 is estimated to be generated as state tax revenue for every one dollar appropriated to the Institute. This does not consider any multiplier effect from increased employment/employee income tax and/or sales tax from the income/purchases of any additional employees the savings may have produced.

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Established January 1, 1994

Pursuant to 1990 State Statute

CARL Lab: Emission Factor Testing and Development

Mission:

To provide Technical assistance, research, and education services to Indiana manufacturers to reduce their use of toxic raw materials and the generation of environmental wastes.

CMTI/CARL Electrostatic

Paint Testing

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Funding:

  • Biennial state appropriation supports 40% – 50% of the Institute operation.
  • Balance of support is from state and federal grants and contracts and other sponsored programs (private sector contracts for services).

CARL lab powder coating on wood

Personnel:

  • Six employees: 2 process engineers, 1 outreach coordinator, 2 technical support and 1 administrator.
  • Process Engineers have an average of 22 years of manufacturing and consulting experience.

CARL lab environmental chamber

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Fibrils, magnified 200,000 times; a carbon nanotube, mixed into plastic resins make the material electrically conductive. The plastics

then can be painted using an electrostatic process that reduces waste. CMTI initiated the interaction of Hyperion with UTA/GE Plastics and assisted in testing that culminated in a “Governor’s Award” winning project. Saved $2 million & 40% pollution reduction.

Services:

  • EPA designated Local Resource Center: One of eleven in the nation to provide technical assistance to public entities in the development of an ISO 14001 Environmental Management System (EMS).
  • Small Manufacturers Assistance Program: Contracted to Indiana Department of Environmental Management to provide technical assistance to small manufacturers (< 100 employees) pursuant to Section 507(c) of the Clean Air Act.
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Services:

Enhancing Economic Development

  • Full range of ISO 14001/EMS services: gap analysis, internal auditor training, lead auditor training, pre-registration and registration audits, as well as EMS document preparation.
    • All engineers are Registration Accreditation Board (RAB) Certified Lead Auditors.
    • Other staff members are RAB-certified Environmental Auditors.
    • CMTI has trained 1000 professionals in ISO 14001 certification programs
    • CMTI EMS “Rescue” Program – Assist dozens of “Tier One” companies achieve ISO Registration saving hundreds of Indiana jobs
    • CMTI EMS staff has performed over 100 EMS audits for nearly 100 companies
  • Air permit application assistance services – Title V,
  • FESOP, MSOP
  • Environmental/Hazardous Waste Audits
  • Phase One Environmental Assessments
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Services:

  • EPA Sustainable Futures Initiative: Prime contractor to EPA (headquarters) to promote its program with the chemical manufacturing sector, nation wide. Initiative includes seminars, conferences, regulatory incentives and the use of web-based tools.
  • Indiana Department of Transportation: Provide environmental regulatory compliance and program development services with funding from the Joint Transportation Research Program (Federal Highway Administration).
  • Clean manufacturing (process engineering): technical assistance to manufacturers usually focuses on replacing toxic raw material inputs with less or non-toxic alternatives and/or modification of the process to reduce hazardous waste generation, air emissions and/or wastewater discharges.

CARL Lab

Indiana Water Craft Mfg.

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Industry Assistance Initiatives

Wood Furniture Industry Initiative:

EPA issued wood furniture NESHAP affecting Indiana’s furniture manufacturers: CMTI organized 34 Indiana furniture companies into CMTI/Wood Furniture Consortium to address the industry’s compliance with the EPA rule and reduce its economic impact.

Indiana Furniture

Spray Training

CMTI developed complete compliance program for the industry as well as a furniture coating spray operators training program. CMTI trained over 1,300 spray operators.

Powder Paint on Wood Desks

  • Results:
  • Industry savings of $1.3 million annually
  • 50% reduction in pollutant air emissions (2.5 million pounds)
  • Initiative is estimated to have saved scores of Indiana jobs.
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Industry Assistance Initiatives

Fiber Reinforced Plastics/RV Industry Initiative:

The industry generates $6 billion in sales per year, an estimated 37,000 jobs and 4 million pounds of air pollutants for Indiana. CMTI organized an industry consortium in 1997 (on going) to address its pollution issues and to enhance its economic viability.

CARL lab EPA Emission Factor Development for FRP industry

CARL is the CFA Certified FRP Emissions Testing Laboratory

Emissions testing and application method research lead to a CMTI FRP spray training program

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Fiber Reinforced Plastics/RV Industry Initiative:

(Continued)

  • Results:
  • Training of over 400 employees
  • Industry savings of $3.8 million annually
  • Reduced air pollutant emissions by over 2.5 million pounds
  • Initiative is estimated to have saved scores of Indiana jobs.
  • EPA MACT standard – implementation is slated for 2006 – nearly all Indiana FRP companies are already in compliance – in part due to the emissions reductions achieved by the consortium’s initiative – strategically enhancing Indiana’s economic performance
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Industry Assistance Initiatives

Light-Resin Transfer Molding Project (L-RTM)

Continuing technical assistance to the $6 billon industry

CARL lab will research and optimize an innovative alternative to the classic open mold method of FRP production – L-RTM.

The project will investigate vacuum infusion of resin material into light mold tooling as an alternate method to open mold fabrication.

Master Mold for RV Rear Cap

Indiana Built Class A RV

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Light-Resin Transfer Molding Project

(Continued)

Example: Open Mold FRP Spray Process

Example: L-RTM schematic

  • Results:
  • Independent, non-biased analysis of innovative technology
  • Pollutant air emissions reduction estimated at over 70%;
  • very important technology to address future EPA concerns
  • Initiative is designed to help keep Indiana companies
  • competitive in today’s global market
  • If the EPA were to impose stricter emission controls this technology will be vital to Indiana’s FRP industry
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