CASE STUDY: Crown Cork and Seal Company

Location: Industry: Pollution Prevention Application: Annual Savings: Payback Period: Contact: Background Arden, NC (Buncombe County) Can Manufacturing (SIC: 3411) Solvent Substitution, Recycling and Reuse Programs, Energy Conservation, VOC Reduction $175,131 Immediate N/A

Crown Cork and Seal Company was a three-piece can manufacturing plant with seven lines producing a variety of different can sizes for several food processing customers. The company's waste reduction programs focused on material modifications and recovery/reuse/recycling of solid waste materials. Elimination of 1,1,1-Trichloroethane By replacing 1,1,1-trichloroethane vapor degreasers with aqueous-based cleaners, Crown Cork and Seal eliminated a source of air emissions and spent halogenated waste, saving the cost of disposal (RCRA F003). VOC Reduction After welding sheets of tinplate into cylinders, a spray coating material was used to coat the welding seam and protect it from the product packed in the can. In 1997, the facility changed the side stripe spray used to a lower volatile spray. Additionally, a solvent-based product may be applied to the side of the cans with a thermal spot gun. In 1997, the gun was changed to produce a smaller spot, thus reducing solvent usage and VOC emissions. Metal Recycling Crown Cork and Seal not only recycles scrap tin plate generated from the cutting process, but has also implemented source reduction techniques during the manufacturing process to reduce spoilage of the tin plate material. A continuous strand of copper wire is used as a heat conductor during the welding process to form the can. As the copper wire is utilized, it is cut into short pieces, collected, and shipped to a recycling facility. Material Reuse/Recycling Programs Crown Cork and Seal recycles office paper, aluminum cans, chipboard, and cardboard, and rebuilds and reuses wooden pallets and top frames. Energy Conservation By implementing more efficient lighting, replacing existing generators with reduced capacitors, and installing more efficient motors, Crown Cork and Seal has significantly reduced electrical consumption.

Waste Reduction Activities

1997 Case Study

SIC 3400 - p. _1_

Waste Reduced and Annual Savings

The table below shows the wastes reduced and cost savings for each waste reduction program implemented at the facility. Savings for metal and other material reuse and recycling activities includes revenue generated by sale of the waste and avoided landfill tipping fees. Savings calculated for recycling (repairing) of wooden pallets and frames also includes the cost savings from having pallets and frames repaired versus purchasing new ones.
Waste Reduction Process Waste Reduced Annual Savings

Elimination of 1,1,1trichloroethane VOC Reduction Metal Use Efficiency and Recycling

110 gallons/year

$400

7.66 tons/year N/A Tinplate spoilage reduced 25% $82,255 over 1996 $30,685 652,219 lbs. steel scrap recycled in 1997 283,844 lbs. Wood 107 tons solid waste 15% energy use reduction over 1996 $48,786 $3,507 $4,292 $36,983 $206,908

Material Reuse/Recycling: - Pallets - Top frames - Other wastes Energy Conservation

Total Savings

Other Activities

Crown Cork and Seal was recognized for Significant Achievement in the Small Business Category of the 1995 Governors Award for Excellence in Waste Reduction competition. The facility is no longer in operation.

1997 Case Study

SIC 3400 - p. _2_