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Leggett and Platt Incorporated, Masterack Division, eliminated the use of volatile organic solvents at their Atlanta, Georgia facility. This was accomplished while experiencing constant business growth and achieving greater product durability. An advanced powder coating process was installed to replace an existing wet paint system. The powder coating provided improved product performance and reduced volatile organic compound (VOC) emissions to near zero.

Background

Leggett and Platt, Masterack Division, is a manufacturer of high quality metal shelves, racks, and institutional furniture. The manufacturing process involves fabrication and assembly of metal components. Components and assemblies are washed and degreased in an aqueous spray wash system. Prior to modifications, components were coated using a wet paint system. In 1985, VOC emissions from the paint line exceeded 100 tons per year.

Process Modifications

In order to reduce VOC emissions, a small, self-contained powder coating booth was purchased. In addition, the facility was upgraded with the construction of a new spray washer, coater oven, material handling system, and powder line. The powder coating system works by spraying electrostatically charged powder resin onto parts using oil-free compressed air. After deposition of the coating, the part is placed in an oven where the coating melts and bonds to the surface. The facility began full operation in January 1994 and the wet paint line was discontinued at that time.

Results

Paint sludge, solvent from wash up, and VOC emissions were virtually eliminated. Other benefits include improved product quality at a comparable price, a safer working environment, and reduced paper work and reporting. The cost of the booth was approximately $15,000, and the total cost of the technology and facility upgrades approached $4,000,000. A comparison of wet painting and powder coating is given on the back.