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Facility ID: 03055HTCHNOLDWI

Facility Name and Address:
 HITCHINER COUNTERGRAVITY CAST OPERATIONS (VCO/DCO/MCT)
594 ELM ST
MILFORD, NH 03055

Parent Company: HITCHINER MANUFACTURING CO INC

Industry: Steel Investment Foundries (331512)
Chemical: Ammonia

Reports:
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Production Related Waste Management for Selected Chemical


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lchemid=0007664417
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Pollution Prevention Activities for Selected Chemical

Reporting Year Section 8.10: Newly Implemented Source Reduction Activity Section 8.10: Methods to Identify Activity Section 8.11: Optional Pollution Prevention Information*
2014 Source Reduction:: W53: Use of a differant process catalyst[-100%]
Methods to Identify SR Opportunities: T11: Other
Source Reduction - We have transitioned from an alcohol-based slurry material, to a water-based slurry material that no longer uses ammonia as part of the shell-building process. This process change went into effect in September 2014.
2013 Source Reduction:: W13: Improved maintenance scheduling, recordkeeping, or procedures

Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T10: Vendor assistance
Source Reduction - Additional source reduction activities include switching our shell process from alcohol-based to water-based which will eliminate the need for ammonia. Estimated completion: 2014.
2012 Source Reduction:: W58: Other process modifications

Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T10: Vendor assistance
W58: W58 - Moving to a water based shell building method which would eliminate the need for ammonia in the process. Have installed necessary equipment and currently testing materials.
2011 Source Reduction:: W58: Other process modifications
Methods to Identify SR Opportunities: T04: Participative team management
Other Environmental Practices - Hitchiner experienced moderate growth for this division in 2011. Ammonia is a material used to gel slurry used in the investment casting process. We expect to better control the use of this material with improved engineering practices and delivery systems being considered for late CY2011 - early CY2012. These improvements should reduce the amount of ammonia utilized.
2010 Source Reduction:: W58: Other process modifications
Methods to Identify SR Opportunities: T04: Participative team management
Other Environmental Practices - Hitchiner experienced moderate growth for this division in 2010. Production output increased and is expected to increase in the coming years 10% or more. Ammonia is a material used to gel the slurry used in the investment casting process. We expect to better control the use of this with improved engineering / delivery system in 2011 - with benefits realized in 2012. The shell building process is expected to change in the 4th quarter of 2011 - which should reduce ammonia usage as a percentage of output.
2009 Source Reduction:: W58: Other process modifications
Methods to Identify SR Opportunities: T04: Participative team management
Other Environmental Practices - Production was down in 2009 in the second half of the year. We expect to see an increase in production in 2010 - and Hitchiner is reviewing plans to modify the shell room where ammonia is used in the process to accomondate the increases in production expected over the next few years. Capital improvement projects will take into consideration the ammonia delivery equipment - which should optimize it's usage. The current system doesn't allow for adequate regulation of volumes based on production - the new system will take this into account.
2008 Source Reduction:: W58: Other process modifications
Methods to Identify SR Opportunities: T04: Participative team management
2007 Source Reduction:: W58: Other process modifications
Methods to Identify SR Opportunities: T04: Participative team management
Source Reduction - In 2007, hitchiner engineers looked at ways of better controlling the ammonia usage by studying alternative approaches to exposing in-Process parts to this material. Although no substantial changes were made with respect to the current process, much was learned and ammonia usage is down slightly from 2006. It was determined through the studies that the flow of ammonia could be reduced and still maintain the tolerances needed for the process. Studies continue in 2008 and i'D expect progress to be made with respect to reducing this materials usage going forward.
2006 Source Reduction:: W58: Other process modifications
Methods to Identify SR Opportunities: T04: Participative team management
Source Reduction - In 2006 Hitchiner demolished one of the larger plants within this Elm Street complex. Prior to demolition, many of the processes in this plant were eliminated in 2005 and the few remaining processes in 2006 were discontinued in November of 2006. Source reduction/pollution control activities include transferring a portion of that production to a newer, more efficient plant that uses a water based manufacturing process. Other environmental benefits obtained as a result of the plant elimination included a considerable reduction in basic utilities usage (gas, water, sewer, electricity), and more efficient use of equipment that was ultimately consolidated in other plants.
2005 Source Reduction:: W54: Instituted better controls on operating bulk containers to minimize discarding
Methods to Identify SR Opportunities: T01: Internal pollution prevention opportunity audit(s)
2003 Source Reduction:: W42: Substituted raw materials
Source Reduction:: W58: Other process modifications
Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T04: Participative team management
2002 Source Reduction:: W42: Substituted raw materials
Source Reduction:: W58: Other process modifications
Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T04: Participative team management
2001 Source Reduction:: W42: Substituted raw materials
Source Reduction:: W58: Other process modifications
Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T04: Participative team management
2000 Source Reduction:: W42: Substituted raw materials
Methods to Identify SR Opportunities: T04: Participative team management
1991 Source Reduction:: W19: Other changes in operating practices
Source Reduction:: W58: Other process modifications
Source Reduction:: W81: Changed product specifications
Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T04: Participative team management
*Classifications of Optional Pollution Prevention Information shown in brackets are provided by EPA.