2015 Sustainability Report

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Project Highlights

Separating paint remnants reduces landfilled waste, costs

The simple step of separating solvent-based and water-based paint remnants from the filling lines at our Architectural Coatings plant in Amsterdam has reduced the facility’s paint waste stream by more than 75 percent, or 53 metric tons, per year.
 
Historically, the facility combined the two paint remnants and incinerated the resulting sludge. Collecting the remnants separately allows the paint to be recycled after it passes color, drying and viscosity testing.
 
In addition to reducing waste, the change saves more than $22,000 annually.

PPG Barberton turns scrap into raw material

A $6.3 million investment in a trim recycling system at PPG Barberton in Ohio eliminated more than 426 metric tons of non-hazardous landfilled waste and saved $1.6 million in raw material costs during 2015.
 
The system, which came online full-time in September 2014, converts scrap material from the production of TESLIN® Synthetic Printing Sheets into pellets that are reintroduced into the manufacturing process as a raw material. The scrap waste stream has been cut by 51 percent, with additional reductions expected. 


 

New technology, pipelines reduce sludge at PPG Comex facility

Recycling solvent materials and reconfiguring filling pipelines eliminated more than 276 metric tons of waste and saved $91,000 in disposal and raw material costs in 2015 at the PPG Comex facility in Tepexpan, Mexico.
 
The facility previously incinerated the materials that resulted from distilling waste solvent. Today, new technology developed by our researchers allows these them to be used as a raw material in two new primer products. These primers contain 67 percent to 69 percent reused materials.
 
In the plant’s packaging department, approximately 16 gallons (60 liters) of paint remained in the pipelines when a batch’s filling process was completed. This required 32 gallons (120 liters) of cleaning solvent to flush out the lines between each batch. By reconfiguring the pipelines, the plant now saves 13 gallons (50 liters) of paint per batch and uses 50 percent less cleaning solvent. 

Mojave site demonstrates excellent waste management practices

Building 4A at PPG’s aerospace facility in Mojave, California, is a model waste handling site.

Two Mojave team members, Ed Lightfoot and Bryan Covell, are responsible for managing the plant’s 250 waste profiles and work continuously to improve the waste handling process. Both have gone through multiple federal and California hazardous waste training programs, helping the Mojave hazardous waste management system achieve zero violations between 2010 and 2015.

In 2015, the Mojave plant took in 653 metric tons of waste and then packaged, classified and shipped it out for proper disposal. The site also reduced its landfilled waste more than 58 percent between 2012 and 2015 by recycling used pails as scrap metal, saving roughly $27,000 annually. In addition, a new process to recycle waste solvents back into the cleaning processes that was introduced in 2015 saved almost $110,000 in hazardous waste disposal costs and raw materials.

Waste minimization project reduces hazardous waste by 70 percent

After a new waterborne production process increased its rate of hazardous waste generation, our automotive coatings facility in Cheonan, Korea, formed a waste-minimization team to address the issue. Improvements included:
  • Reusing the final water rinse as the initial rinse of the next batch;
  • Reusing filtered resin in the next batch; and
  • Eliminating the need for intermediate storage in the filling department.
 
These and other improvements reduced the hazardous waste generated from the new process by more than 70 percent, saving the facility approximately $150,000 per year.
 

 
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