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Facility ID: 75006THGLD1900J
Facility Name and Address: PPG ARCHITECTURAL COATINGS 1900 N JOSEY LN CARROLLTON, TX 75006 Parent Company: PPG INDUSTRIES INC Industry: Paint and Coating Manufacturing (325510) Chemical: Zinc compounds Reports: View TRI Facility profile report for this facility View TRI Form R submissions by this facility |
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Production Related Waste Management for Selected Chemical
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Waste Management Comparison -
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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* |
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2022 |
Source Reduction:: S43: Introduced in-line product quality monitoring or other process analysis system[-15-24%]
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Methods to Identify SR Opportunities: T01: Internal pollution prevention opportunity audit(s)
Methods to Identify SR Opportunities: T04: Participative team management |
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2021 |
Source Reduction:: S43: Introduced in-line product quality monitoring or other process analysis system[-15-24%]
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Methods to Identify SR Opportunities: T01: Internal pollution prevention opportunity audit(s)
Methods to Identify SR Opportunities: T04: Participative team management |
Source Reduction: Source Reduction - Active pollution prevention team participation resulting in reduced environmental impact |
2020 |
Source Reduction:: W43: Substituted a feedstock or reagent chemical with a different chemical[-5-14%]
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Methods to Identify SR Opportunities: T01: Internal pollution prevention opportunity audit(s)
Methods to Identify SR Opportunities: T04: Participative team management |
W43: Research and Development department identified potential for improved delivery of chemical into product formulations by switching from a particulate solid form to a liquid form. Source Reduction - Research and Development department transferred technology to manufacturing site and incorporated in product formulations using constituents. Source Reduction - Research and Development department identified opportunity for chemical delivery in product formulation in liquid form. This method increases material delivery efficiency and reduces chemical loss indiscarded raw material packaging |
2019 |
Source Reduction:: W43: Substituted a feedstock or reagent chemical with a different chemical[-15-24%]
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Methods to Identify SR Opportunities: T01: Internal pollution prevention opportunity audit(s)
Methods to Identify SR Opportunities: T04: Participative team management |
W43: Chemical of concern has been exchanged from a raw material in solid form to one in liquid form. Handling of chemical in liquid form increases efficiency of chemical delivery into product formulation. Source Reduction - Research and Development department identified opportunity for chemical delivery in product formulation in liquid form. This method increases material delivery efficiency and reduces chemical loss in discarded raw material packaging Source Reduction - Research and Development department transferred technology to manufacturing site and incorporated in product formulations using constituents. Source Reduction: Ways P2 Was Incorporated in Original Process Design - Research and Development department identified potential for improved delivery of chemical into product formulations by switching from a particulate solid form to a liquid form. |
2018 |
Source Reduction:: W21: Instituted procedures to ensure that materials do not stay in inventory beyond[-15-24%]
Source Reduction:: W51: Instituted recirculation within a process[-25-49%] |
Methods to Identify SR Opportunities: T01: Internal pollution prevention opportunity audit(s)
Methods to Identify SR Opportunities: T03: Materials balance audits Methods to Identify SR Opportunities: T04: Participative team management Methods to Identify SR Opportunities: T01: Internal pollution prevention opportunity audit(s) Methods to Identify SR Opportunities: T03: Materials balance audits Methods to Identify SR Opportunities: T04: Participative team management Barriers: B3-Barriers to P2 B3 - Concern that product quality may decline as a result of source reduction. |
W21: Re-circulation of obsolete finished paint streams back into manufacturing process W51: Re-circulation of paint wash waters and/or dust collector solids back into manufacturing process Source Reduction - Review of wash water and/or dust collector solids composition for utilization into specific product formulations Source Reduction - Review of obsolete paint streams composition for utilization into specific product formulations Source Reduction - Identification of suitable accumulation and reuse systems for return back to the process Source Reduction - Identification of available inventories for material re-processing Source Reduction - Members of facility, product technology and business unit team members coordinating activities to address consolidation and reuse challenges Other Environmental Practices - Additional reduction efforts are continuously being sought out by product science and technology department. These consist in substitution of raw materials with reportable constituents with others free of reportable constituents Barriers to P2: B3 - Concern that product quality may decline as a result of source reduction. - New products added during RY2018 that had not been reviewed previously. New reuse opportunities are being implemented for RY2019. Other Environmental Practices: Recycling - PPG Carrollton uses recycling of streams back into the manufacturing process as a method to reduce waste streams from its operations. First, any particulates contained in our dust collection systems are accumulated into drums. These drums are later returned back into the site, and are added back into the product formulation for new products, depending on the product composition. Second, the facility tries to reduce paint waste streams by limiting the amount of water used to clean paint manufacturing vessels during certain product manufacturing campaigns. The wash waters that are generated whenever these are generated are consolidated inside tanks and are reused in similar composition product batches as needed. Finally, any obsolete paint streams that are identified at our warehouse operations are brought back into the manufacturing site for re-processing. The materials are paired with suitable production batches, and these are subsequently poured into the process vessels as part of the manufacturing batch instructions. All of these recycling additions are coordinated with the Quality Control Department to assure consistency |
2017 |
Source Reduction:: W21: Instituted procedures to ensure that materials do not stay in inventory beyond[-5-14%]
Source Reduction:: W51: Instituted recirculation within a process[-5-14%] |
Methods to Identify SR Opportunities: T01: Internal pollution prevention opportunity audit(s)
Methods to Identify SR Opportunities: T04: Participative team management Methods to Identify SR Opportunities: T01: Internal pollution prevention opportunity audit(s) Methods to Identify SR Opportunities: T04: Participative team management |
W21: The Carrollton Plant and Distribution Center have teamed up and stepped up to the challenge of reworking, repacking, and relabeling of slow and obsolete (SLOB) materials. With an extensive SLOB inventory list to go after, the team realized that they were going to have to get organized quickly in order to meet their goals and objectives. The team developed goals and delegated tasks to each other, which resulted in the initial workflow process. This workflow process is constantly being honed and refined. The SLOB workflow process starts with the Plant Manager evaluating the SLOB Inventory List and choosing the materials that he wants sent to Carrollton. The Plant Manager then communicates his selections off to the site Quality Control Manager to see if his selections can indeed be reworked at the Carrollton facility. Once the Plant Manager and Quality Control Manager agree on the selection of materials, the list is handed off to Fulfillment Planning for approval. If what was selected from the SLOB inventory List makes sense to deliver from storage to the plant, Fulfillment Planning approves and sets up an order for the selected products. Once shipped, the Distribution Centers receive and transfer the materials, physically and systemically, to the Carrollton plant. Several floor bays have been specifically selected to handling incoming SLOB materials. Production management works with fulfillment to get the SLOB materials placed into orders. Fulfillment helps determine which SLOB materials will be relabeled, reworked, or repacked. Once orders are cut, while Production Management see that the orders are executed and processed properly. Quality Control keeps track of all reprocessed materials with all accomplishments and status changes. Carrollton will continue using this process moving forward and work through new SLOB opportunities, as they arise. W51: Water conservation is a very important parameter in the operations of a water-based manufacturing site, considering our geographical location that has limited water resources. Through focus on specific activities that result in significant consumption of potable water, such as the use of water for cleaning process tanks, wash water reuse, area water use for cleaning and other improvements, the PPGAC Carrollton TX site has been able to reduce its water consumption intensity during RY 2017.. Water use is monitored on a monthly basis, and water use practices are reviewed periodically to minimize its total quantity. Water use reductions in product manufacturing has yielded positive results in the level of wash water sent to the facility wastewater treatment system for processing and discharge. The Carrollton site has made it possible by scheduling products of similar composition on specific tanks, and by limiting the amount of water used to prepare a tanks between product batches Source Reduction - Verification of materials suitable for recovery and recycle Source Reduction - Review of compatibility of washwaters with other paint formulations Source Reduction - Coordination between production and quality departments for SLOB products for reuse optimization Source Reduction - Coordination between production and quality departments for washwater reuse optimization |
2016 |
Source Reduction:: W21: Instituted procedures to ensure that materials do not stay in inventory beyond[-25-49%]
Source Reduction:: W51: Instituted recirculation within a process[-25-49%] |
Methods to Identify SR Opportunities: T01: Internal pollution prevention opportunity audit(s)
Methods to Identify SR Opportunities: T04: Participative team management Methods to Identify SR Opportunities: T01: Internal pollution prevention opportunity audit(s) Methods to Identify SR Opportunities: T04: Participative team management |
W21: The Carrollton Plant and Distribution Center have teamed up and stepped up to the challenge of reworking, repacking, and relabeling of slow and obsolete (SLOB) materials. With an extensive SLOB inventory list to go after, the team realized that they were going to have to get organized quickly in order to meet their goals and objectives. The team developed goals and delegated tasks to each other, which resulted in the initial workflow process. This workflow process is constantly being honed and refined. The SLOB workflow process starts with the Plant Manager evaluating the SLOB Inventory List and choosing the materials that he wants sent to Carrollton. The Plant Manager then communicates his selections off to the site Quality Control Manager to see if his selections can indeed be reworked at the Carrollton facility. Once the Plant Manager and Quality Control Manager agree on the selection of materials, the list is handed off to Fulfillment Planning for approval. If what was selected from the SLOB inventory List makes sense to deliver from storage to the plant, Fulfillment Planning approves and sets up an order for the selected products. Once shipped, the Distribution Centers receive and transfer the materials, physically and systemically, to the Carrollton plant. Several floor bays have been specifically selected to handling incoming SLOB materials. Production management works with fulfillment to get the SLOB materials placed into orders. Fulfillment helps determine which SLOB materials will be relabeled, reworked, or repacked. Once orders are cut, while Production Management see that the orders are executed and processed properly. Quality Control keeps track of all reprocessed materials with all accomplishments and status changes. Carrollton will continue using this process moving forward and work through new SLOB opportunities, as they arise. W51: Water conservation is a very important parameter in the operations of a water-based manufacturing site, considering our geographical location that has limited water resources. Through focus on specific activities that result in significant consumption of potable water, such as the use of water for cleaning process tanks, wash water reuse, area water use for cleaning and other improvements, the PPGAC Carrollton TX site has been able to reduce its water consumption intensity, as expressed in gallons of water per gallon of product during Year 2016 by 15.3% when compared to the same value during the previous year. Water use is monitored on a monthly basis, and water use practices are reviewed periodically to minimize its total quantity. Water use reductions in product manufacturing has yielded positive results in the level of wash water sent to the facility wastewater treatment system for processing and discharge. The Carrollton site has made it possible by scheduling products of similar composition on specific tanks, and by limiting the amount of water used to prepare a tanks between product batches Source Reduction - Verification of materials suitable for recovery and recycle. Source Reduction - Business unit wide initiative. Source Reduction - Plant internal sustainability initiative Source Reduction - Reduction of wastewater discharge by consolidation of washwaters for reuse in manufacturing batches. Other Barriers to Source Reduction - Test |
2015 |
Source Reduction:: W21: Instituted procedures to ensure that materials do not stay in inventory beyond[-50-99%]
Source Reduction:: W51: Instituted recirculation within a process[-50-99%] Source Reduction:: W58: Other process modifications[-50-99%] |
Methods to Identify SR Opportunities: T01: Internal pollution prevention opportunity audit(s)
Methods to Identify SR Opportunities: T04: Participative team management Methods to Identify SR Opportunities: T05: Employee recommendation (independent of a formal company program) Methods to Identify SR Opportunities: T01: Internal pollution prevention opportunity audit(s) Methods to Identify SR Opportunities: T04: Participative team management Methods to Identify SR Opportunities: T05: Employee recommendation (independent of a formal company program) Methods to Identify SR Opportunities: T01: Internal pollution prevention opportunity audit(s) Methods to Identify SR Opportunities: T04: Participative team management Methods to Identify SR Opportunities: T05: Employee recommendation (independent of a formal company program) |
W21: Identification of inventoried slow moving and obsolete materials for reprocessing. W51: Recovery of washwaters from paint dispersion and formulation operations, as well as solids from dust collector recovery drums to return back to paint manufacturing process. W58: Preparation of similar or compatible paint formulations using no-scrape/no-wash method to reduce washwater generation and water consumption. Source Reduction - Review of paint formulation residues recovery options within process vessels. Source Reduction - Discussion with feedback from production, engineering, maintenance and quality control personnel to develop strategy. Source Reduction - Method review by field level personnel to determine methods for returning valuable materials back to process for reuse. Source Reduction - Evaluation of obsolete formulas and integration for reprocessing into new formulas. Other Environmental Practices: Recycling - Reuse of dust collector solids and latex washwaters within process as part of paint formulation process. Pigments and filler materials are recovered and returned to finished product Other Environmental Practices: Methods for Identifying Pollution Prevention Opportunities - Evaluation for process and identification of opportunities for recovery |
2014 |
Other Environmental Practices: Recycling - PPG recycles wash water through on-site waste water treatment facility. Facility extracts solids from waste water for disposal at landfill and keeps pollutants from entering city waste water treatment. |
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2013 |
Source Reduction:: W13: Improved maintenance scheduling, recordkeeping, or procedures
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Methods to Identify SR Opportunities: T01: Internal pollution prevention opportunity audit(s)
Methods to Identify SR Opportunities: T02: External pollution prevention opportunity audit(s) |
W13: Procedures are being revised and better maintenance scheduling Source Reduction - Out side vendors have been contracted to assis in auditing Source Reduction - There has been a team formed to monitor and evaluate the effectiveness of Pollution Prevention Opportunities |
2004 |
Source Reduction:: W13: Improved maintenance scheduling, recordkeeping, or procedures
Source Reduction:: W52: Modified equipment, layout, or piping |
Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T11: Other |
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2003 |
Source Reduction:: W19: Other changes in operating practices
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Methods to Identify SR Opportunities: T04: Participative team management
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1994 |
Source Reduction:: W71: Other cleaning and degreasing modifications
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Methods to Identify SR Opportunities: T04: Participative team management
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