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Last updated:
May 03, 2001
Aviat Aircraft, Inc.
Address - PO Box 1240, Afton, WY 83110
Phone: (307) 886-3151, E-mail: AVIAT@sisna.com
Contact - Dan Hiner
Product or Service
Aviat Aircraft, Inc., manufactures two lines of single engine, FAA certified aircraft, the
Husky A-1 utility airplane and the Pitts Special aerobatic airplane. The company
also manufactures the kit for a home built, single-engine aerobatic biplane–the Eagle
II.
Number of Employees
70 employees operating five days per week, one shift per day
Waste Stream Targeted:Polyurethane paint and dopes
Summary
- Aviat Aircraft, Inc. is in the process of evaluating the painting procedures for their aircraft. Conventional high pressure paint systems currently used are being evaluated against the high volume, low pressure (HVLP) methods using water-based paints with the goal being to reduce the hazardous waste stream as well as improving production efficiency.
Waste Reduction Activities
- The existing painting operation consists of conventional high-pressure application of polyurethane paints and dopes. Water based paints are not considered an option as their current state of technology does not provide the necessary surface finish required. However, Aviat will continue to experiment with water-based paints. A low VOC polyurethane paint is most appropriate for this high-performance application. Aviat continues to experiment with high volume/low pressure (HVLP) paint sprayers as compared to their existing high pressure atomization system to determine suitability.
Major Benefits
- Reduced VOC emissions in proportion to the amount of coating sprayed
- Reduced solid waste by one-half, associated with over spray of solids clogging filters
- Alleviated concerns associated with plugged paint room filters
- Reduced potential health hazards for employees
- Positive business and environmental image
Cost Savings
- Projected savings would be approximately $23,000 per year based on the current amount of paint used. This does not include the savings associated with thinner use, dope use, paint filters, clean-up, waste disposal or time. The payback period for this process improvement would be less than one month.
Obstacles
- Surface finish requirements not met quite yet (Aviat is continuing testing with different types of sprayers to find the best application)
- Water-based paint requires additional drying time
Key to Success in Implementing Pollution Prevention Modification
- Finishing requirements must be met
Waste Stream Targeted: Paint solid wastes
Summary
- Aviat Aircraft discovered by changing a paint mixing system they can reduce the amount of paint wasted thus reducing the hazardous waste stream and saving money.
Waste Reduction Activities
- Existing pot life of the two-component polyurethane paint is short because the amount needed is not always calculated correctly based on current production amounts and methods. A new paint mixing system has been purchased which will allow paint to be mixed on an as-needed basis and will meet production specifications on a much more consistent basis.
Major Benefits
- Cost savings
- Reduced hazardous waste stream
- Improved process efficiency
- Improved working conditions for employees
- Positive business and environmental image
Cost Savings
- Estimated annual savings: $11,000 per year based on a 25% savings in the urethane paints. The estimated $2,500 cost of the paint mixing will be recovered in the first three months of operation.
Obstacles
- Employee training
Key to Success in Implementing Pollution Prevention Modification
- Production staff support for change in process methodology
Waste Stream Targeted: Solvents
Summary
- Aviat Aircraft, Inc. evaluated their management and production practices associated with solvent cleaners and determined that by instituting a schedule, they could save significantly on solvents.
Waste Reduction Activities
- Solvents are currently used for cleaning and maintaining paint equipment. Current solvent cleaner system is not operated on a set schedule–it is done sporadically. In order to minimize the volume of in-process acetone and butyrate thinner, the MAMTC engineer recommended that the existing solvent cleaners be operated on a set schedule with records maintained to track efficiency. This will allow for additional recycling of acetone and butyrate thinner on a more consistent basis.
Major Benefits
- Savings on overall solvent purchases
- Reduced hazardous waste stream
- >Improved process efficiency
- Improved working conditions for employees
- Positive business and environmental image
Cost Savings
- Projected savings associated with recycling the acetone: 600 gallons at a savings of $2,200
Obstacles
- None
Keys to Success in Implementing Pollution Prevention Modification
- Consistency in management and production practices