Date of Site Visit: April 2024
Case study prepared by: PPRC, Seattle, Washington
This case study was developed under Assistant Agreement No. X9-02J19401 awarded by the U.S. Environmental Protection Agency (EPA). It has not been formally reviewed by EPA. The views expressed are solely those of PPRC. EPA and PPRC do not endorse any products or commercial services mentioned.
Introduction
Woodfold Manufacturing, Inc. in Forest Grove, Oregon, manufactures a line of finely finished wood products, including accordion doors, acoustic partitions, and other specialty wood products, often finished to custom specifications.
Woodfold is an employee-owned company and staff are proactive about continuous improvement and sustainability. For example,
Using waterborne paint.
Leading in continuous improvement in energy efficiency innovations. Since 2007, Woodfold has implemented measures that have reduced, 22,000 therms per year in natural gas consumption, and over 749,000 kwh annually in electricity consumption. Woodfold incorporates staff suggestions for energy efficiency, and utilizes Oregon state’s energy expertise resources such as Energy Trust, the Oregon State University Energy Efficiency Center, and Forest Grove Power & Light, for energy assistance.
Reinvigorating lean manufacturing efforts, which may result in reduction of inventory on site through better forecasting, reduction of scrap through yield studies and right-sizing stock, and more.
Quantifying and track carbon footprint and reductions in greenhouse gas emissions over time.
Reusing 55-gallon and 225-gallon raw material containers
Maximizing coolant life.
Regularly inspecting storm drains monthly and replacing catch basin filter annually.
The Pollution Prevention Resource Center (PPRC) partnered with Woodfold to conduct a p2 assessment and spray efficiency training. Funding for the project was provided by the EPA.
This case study provides a description of the activities, and estimated improvements and cost savings for Woodfold.
On-Site Walkthrough
Woodfold hosted PPRC for a walkthrough to add fresh eyes to assess pollution prevention opportunities in their operations. The assessment team prepared for the walkthrough with initial planning calls, and compilation of existing information and data. Then, in April, the team walked through the entire plant’s operations and facilities.
The team identified 16 recommendations. PPRC investigated all the opportunities and conducted some research and a preliminary feasibility review with the help of Woodfold staff. A report was then provided to Woodfold. Five opportunities bubbled up and were or will soon be implemented (including spray paint efficiency improvements from the training).
Spray Efficiency Training
After the walkthrough, the spray painters at Woodfold, and two managers participated in an on-site spray efficiency training delivered by PPRC.
The objectives of PPRC’s spray efficiency training are:
Improve transfer efficiency, which minimizes overspray
Improve build efficiency
Reduce the volume of paint mixed and sprayed
Reduce air emissions (reducing staff exposure and releases to the community)
Reduce generation of hazardous waste (air filters, overspray (if paints and coatings contain any hazardous ingredients)
(For more information about PPRC’s spray efficiency training and benefits, see our introductory video [English, Spanish], and our webpage PPRC.org/spray-efficiency.)
Results
PPRC and Woodfold identified 16 potential opportunities, and PPRC then compiled a recommendation report and conducted preliminary investigations to determine options, viability, benefit, and cost effectiveness.
Out of the 16 recommendations, five are currently being implemented, with an estimated $10,595 in annual savings, and others will continue to be evaluated and potentially implemented.
Table: Annual Cost, Time, Material, and Environmental Savings for Implemented Changes
Reductions | Source of Savings | Annual Cost Savings | Annual Time, Material, Resource Savings |
Spray Painting Operations | Improved transfer efficiency
| $3,700 | 62 pounds of paint (waterborne coating), reduced overspray, reduced air filter replacement |
Hazardous waste(1) | Bio-based cleaning system requires more frequent infusion of microbes | $0 | Increased use of bio-based infusion mats to eliminate waste stream, estimated at 10 gallons/year (less any metal fragments) |
Energy | Correct power factor(2) | $3,141 | 1,200 kVAR |
(Pending) Compressed air system optimization and leak check | TBD | TBD | |
Waste | Industrial plastic waste recycling | $500 | 5,000 pounds of acrylic and ABS, avoided disposal fees Note: Other plastic wastes are not recyclable resins |
Raw Material (excluding paint) | Stock length for extruded aluminum | $3,254 | 703 pounds |
(Pending) Adhesives study to consolidate to fewer
| TBD | Depends on functional performance of glues | |
Total Cost Savings of Current Implementations | $10,595 |
|
1Woodfold is a very small quantity generator so hazardous waste disposal is free.
2Opportunity identified by Oregon State University in partnership with Woodfold.
Conclusion
The collaboration between Woodfold Mfg., Inc. and PPRC demonstrates the value of ongoing pollution prevention efforts and continuous improvement in manufacturing practices. Through a detailed site assessment and spray efficiency training, Woodfold has successfully implemented key opportunities to reduce environmental impact, increase operational efficiency, and save costs. By adopting PPRC's recommendations, Woodfold has already achieved $7,341 in annual savings, reduced paint and energy consumption, and minimized hazardous waste. Additional opportunities remain under consideration, positioning Woodfold as a leader in sustainable manufacturing practices.
This case study highlights the importance of partnerships and proactive environmental stewardship, and it sets a strong example for other manufacturers looking to enhance their sustainability while maintaining cost-effective operations.
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