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NYS Governor's Awards for Pollution Prevention - Garden Way

Garden Way, Incorporated, Troy

Background

Garden Way Incorporated employs over 900 people in their Troy and East Greenbush locations. Manufacturing plants, located in Troy, New York, and Port Washington, Wisconsin, produce a variety of powered outdoor lawn and garden equipment under the brand names of TROYBILTTM, BOLENSTM, LazyboyTM, as well as CraftsmanTM. The Troy facility produces rototillers, mulching mowers, chipper-shredders and chipper-vacs.

Through implementation of powder coating technology, hazardous waste generation has been reduced by 99 percent and VOC air emissions have been eliminated.

Methodologies and Procedures

Prior to 1991, Garden Way used a xylene based lead paint for product finishing. Wastes included xylene solvents, lead paint residues and lead contaminated sodium hydroxide solutions used to clean paint from parts and paint hooks. The painting operation generated approximately 200 tons of hazardous wastes per year with an additional 40 to 60 tons of VOC emissions.

In mid 1991, the first in a series of finish coating upgrades took place which replaced liquid spray painting with powder coating technology. The powder coating uses a polyurethane powder electrostatically sprayed onto the parts. The part is then transported by conveyor through a 350°f degree bake oven to fluidize the powder into a high quality, high gloss finish. Parts are then cooled in a cooled tunnel and are ready for assembly.

The powder coating booths are full recycling booths with zero discharge. All powder not applied to parts is collected on pulse filters and recycled back to the main spray nozzles. Less than one pound of tramp powder is generated per month and this is simply baked into a polyurethane skin and landfilled. The dry powder contains no solvents and generates no VOCs.

Additionally, paint hook cleaning, previously accomplished via hot caustic stripping baths, was upgraded to use burn-off ovens with inherent after burners. Ash residues from this operation pass TCLP testing as non-hazardous waste.

Benefits

Aside from the environmental and liability benefits of a major elimination from regulated waste and emissions, a cost savings of over $25,000 per year was realized in reduced waste fees.

The new process also improved worker safety by eliminating potential exposures to lead, xylene solvents and hot sodium hydroxide solutions. Through the completion of this project, the finished product was improved with more durable, improved appearance coating.

The powder process also resulted in a faster, higher capacity line which increased plant efficiency. The new line and burn off ovens, coupled with the new washer systems, conveyors and a building addition doubled the capacity of the finishing line and allowed for further expansion of production while reducing chemical disposal by over 90 percent.

Any comments or questions?
Contact us at: 625 Broadway, Albany, NY 12233-1750;
518-402-9469 (phone); 518-402-9168 (fax)

This page was last modified March 8, 1999


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