LAURYSEN KITCHENS LTD.
2415 Carp Road,
Stittsville,
Ontario, K2S 1B3
TOXIC SUBSTANCE REDUCTION PLAN
INTRODUCTION:
Laurysen Kitchens Limited has been a manufacturer of custom kitchen
cabinetry since 1970. Since 1994, Laurysen Kitchens has experienced
strong growth not only in Ottawa but across the province of Ontario with
a Dealership Network that stretches across 27 different marketplaces.
The demands and trends of Ontario has led to positive changes to our
product, modes of operation and provided us with the ability to
purchase the most modern machines for manufacturing. This allows us
to maintain our commitment to quality as we increase our production
capacity. The Green Movement presented us with another opportunity to
move our production into the future and become a more
environmentally responsible manufacturer. In November of 2009, we
introduced a water based UV finishing system and we now offer NU
GREEN ZERO melamine which has zero added formaldehyde emissions.
As a consequence of this, the total emission of all VOCs was reduced by
more than 50% despite an increase in total production.
The Toxic Substance Reduction Act of 2009 identified that, in Phase 2,
that a reduction plan for total VOCs was required. These VOCs are
derived from the solvent-based and water-based coatings used to
protect and beautify the custom kitchen cabinets produced by Laurysen
Kitchens Limited.
FACILITY INFORMATION:
NPRI ID# 11159
Facility Name and address Laurysen Kitchens Limited
2415 Carp Road Stittsville, ON, K2S 1B3 Number of Full time employees 111
Two digit NAICS Code Four digit NAICS Code 33
3371
Six digit NAICS Code 337110– Wood Kitchen Cabinet and Countertop manufacturing 18T Easting 424034
Northing 5015420 102997632
UTM Spatial Coordinates Business Number COMPANY CONTACT INFORMATION:
Facility Public Contact Michael Laurysen, Plant Manager
Phone: (613) 836‐5353 Fax: (613) 836‐7511 E‐mail: [email protected] Mike Livermore, HSE Consultant
Phone: (613) 932‐5192 E‐mail: [email protected] Contact address : Same as the facility address TSR Plan Coordinator/ Preparer Mike Livermore, HSE Consultant Phone: (613) 932‐5192 E‐mail: [email protected] TSRP0136 Contact address : Highest Ranking Employee on site Caroline Castrucci, Vice President
Contact address : Phone: (613) 836‐5353 Same as the facility address Fax: (613) E‐mail: [email protected]
Facility Technical Contact Contact address : STATEMENT OF INTENT:
Laurysen Kitchens Limited is committed to the reduction of all VOCs as
part of our commitment to provide quality Laurysen Kitchens,
individually designed, to enhance our customers' home environment in a
professional and dependable manner at an affordable price.
OBJECTIVES:
A 10% reduction in total VOCs by 2018, based on 2012.
FACILITY DESCRIPTION:
Laurysen Kitchens is a family-owned and operated business with a rich
40-year history of manufacturing, design and customer service
expertise. The present site on Carp Road includes a 55,000 sq. ft.
manufacturing facility that specialises in custom kitchen cabinetry.
TOXIC SUBSTANCE REDUCTION PLAN FOR TOTAL VOCs:
INTRODUCTION:
Volatile Organic Compounds (VOCs) are components of the solventbased and water-based coatings used to protect and beautify our wood
kitchen cabinets.
Laurysen Kitchens is gradually moving more of its finishes to a waterbased system. These stains, lacquers, and topcoats have the same
luxurious finish as solvent-based products. The benefit of water-based
finishing system is it allows us to reduce our VOC emissions. The
topcoats are cured using UV light and have an added antimicrobial
protection to combat mold and other harmful bacteria.
Laurysen Kitchens have increased the use of water-based coatings from
6% to 34% of total coatings purchased since 2009. This trend will
continue for the next 5 years but is dependent on customer acceptance
and technological advances in the water-based coatings.
PROCESS STAGES:
MASS BALANCE:
Total VOCs received in 2012: 17.6 tonnes
Total VOCs shipped off-site as hazardous waste: 6.3 tonnes
Total VOC emissions from site: 11.3 tonnes
IDENTIFICATION OF OPTIONS:
(1)
(2)
(3)
(4)
(5)
(6)
(7)
MATERIAL OR FEEDSTOCK SUBSTITUTION: The primary source
of all VOCs are the solvent-based and water-based coatings
used to protect and beautify the wood kitchen cabinets.
Laurysen Kitchens Limited has been replacing, where possible,
solvent-based coatings with equivalent water-based coatings.
This has already resulted in a reduction of VOCs of more than
50%. Over the next 5 years it is anticipated that a further 10%
reduction can be achieved. This will dependent on further
advances in water-based coatings technology and customer
acceptance of these finishes.
PRODUCTION DESIGN OR REFORMULATION: There is no
anticipation that any redesign to the various lines of kitchen
cabinets would result in the use of less coatings per unit.
EQUIPMENT OR PROCESS MODIFICATION: Transfer efficiency
of spray applied coatings will be reviewed and testing will
determine if improvements can be made to the transfer
efficiency. This would include review of spray equipment used,
air pressure used and other variables.
SPILL AND LEAK DETECTION: There have been very few, minor
spills and no improvements are expected in this area.
ONSITE REUSE OR RECYCLING: None available
IMPROVED INVENTORY MANAGEMENT OR PURCHASING
TECHNIQUE: No reductions in total VOC would be expected.
TRAINING OR IMPROVED OPERATING PRACTICES: As
mentioned in paragraph (3) there will be work on whether
transfer efficiency can be improved. If this is possible then all
operators will be trained in any new procedures.
TECHNICAL FEASIBILITY:
(1)
(2)
(3)
(4)
(5)
(6)
(7)
MATERIAL OR FEEDSTOCK SUBSTITUTION: This project has
been on-going for the past 5 years and further progress would
be anticipated. Customer acceptance of the appearance of any
new water-based coatings would be the determining factor.
Improvements in the technology of water-based coatings would
be expected and this would include appearance.
PRODUCTION DESIGN OR REFORMULATION: Not feasible
EQUIPMENT OR PROCESS MODIFICATION: The present spray
equipment is very efficient and any improvements would be
small, but possible.
SPILL AND LEAK DETECTION: Not feasible
ONSITE REUSE OR RECYCLING: Not feasible
IMPROVED INVENTORY MANAGEMENT OR PURCHASING
TECHNIQUE: Not feasible
TRAINING OR IMPROVED OPERATING PRACTICES: As
mentioned in paragraph (3) there will be work on whether
transfer efficiency can be improved. If this is possible then all
operators will be trained in any new procedures.
ECONOMIC FEASIBILITY:
(1)
(2)
(3)
(4)
(5)
Minimal cost disadvantage in purchasing water-based coatings
and the equipment to use the coatings. Most of the equipment
requirements are already in place.
PRODUCTION DESIGN OR REFORMULATION:
EQUIPMENT OR PROCESS MODIFICATION: No extra costs
would be anticipated
SPILL AND LEAK DETECTION:
ONSITE REUSE OR RECYCLING:
COMPARISON OF 2015 DATA WITH 2014, 2013 AND 2012 FOR
TOXICS REDUCTION PLAN
CHANGE
FROM
PREVIOUS
YEAR(%)
CHANGE
(TONNES)
YEAR
SUBSTANCE
TOTAL
EMITTED
(TONNES)
2012
TOTAL VOCs
11.3
2013
TOTAL VOCs
22.3
+97%
+11
2014
TOTAL VOCS
13.8
-63%
-8.5
2015
TOTAL VOCS
10.9
-21%
-1.9
In 2013 there was a 25% increase in coatings use which was
reflective of the increase in total sales of kitchen cabinets. Also,
there was a reduction in water-based coatings usage from
50.3% of total coatings usage to 28.4% of total coatings usage.
This was due, primarily, to customer rejection of the quality of
some of the water-based finishes and subsequent replacement
with solvent-based alternatives.
In 2014 some of the quality problems were resolved and there
was an increase in the use of water-based coatings from 28.4%
of total coatings usage to 35.6%.
In 2015 most of the remaining quality problems with the waterbased coatings were resolved and the use of water-based
coatings increased to 68.1%
The five year plan to reduce total VOCs of 10% is believed to
be achievable, despite an increase to production over that time
period.