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Formica Corporation is an environmentally responsible company that has active programs under way in all areas of environmental management. The following information summarizes the efforts of Formica Corporation in the areas of raw material management, solid waste management and air pollution control.
Raw Material Management:
Formica Corporation uses stainless steel plates to impart surface on the majority of laminates it produces. This process replaced a paper release system, thereby saving thousands of trees per year and conserving the energy resources required to convert the trees into paper. In addition, by not using release paper, Formica Corporation has reduced the amount of scrap paper it sends to landfill by as much as 80,000 cubic yards per year. Formica Corporation uses water-based phenolic and melamine resins in the manufacturing process. The wood used in the manufacturing of Formica® brand laminate filler paper comes from non- rainforest timber. Formica Corporation has eliminated the use of heavy metals in its decorative papers.
Waste Management:
Laminate residues generated during the manufacturing process are burned in Formica Corporation power boilers. This significantly reduces the amount of solid waste sent to landfills and reduces the use of non- renewable fuels such as natural gas and coal. Formica Corporation composts 80% of the solid waste generated at its Ohio facility. Sample chips are recycled by Formica Corporation corporate and distributor sales representatives. All current items are re-collated into new sample sets.
Air Pollution Controls:
Formica Corporation controls particulate emissions at all of its manufacturing facilities with control devices that operate at 99% efficiency. Formica Corporation has installed state-of-the-art equipment to control Volatile Organic Compound (VOC) emissions at the Ohio and California facilities. Because of this equipment and ongoing projects, VOC emissions have steadily decreased over the last few years. In recent years, Formica Corporation has replaced solvent-based phenolic resins with water-based phenolic resins, thereby greatly reducing VOC emissions. In summary, the management of Formica Corporation believes it is our responsibility to help preserve the environment. We will continue to make changes in all areas of our operation.
Formica Recycling: Sander Dust Recycling
The backside of our laminate sheets are sanded to create fine grooves in the material, thus increasing the surface area to make the laminate easier to adhere to substrates. The sanding dust generated during this process is collected in bag filters and is incinerated. The heat from incineration is used to create steam that heats our laminate presses. The natural gas consumption is reduced by 30 to 40 % by this effort.
Laminate Sheets
Usable portions of otherwise damaged laminate sheets are salvaged at the cut down saw.
Protective Barrier
Portions of damaged sheets of non-decorative laminate are used as protective barriers on top of stacks of laminate ready to be shipped. The barrier protects laminate from scratches.
Samples
Damaged sheets that would have been disposed of are salvaged and used for samples.
Kraft Paper
Rolls of Kraft paper are unwound and saturated with phenolic resin, dried, and are cut to a uniform length in preparing this paper to become the underlying core of our laminate. This paper contains 40% recovered material (byproducts from lumber operations).
Corrugated Core
The corrugated core on which our papers arrive are recycled into other cardboard products.
Paper
Unusable Kraft paper, wrappers from the outside of the paper rolls, and Kraft paper, which has been used as padding during the pressing of laminate is collected and recycled.
Steam
The burning of our own scrap generates 40% of the steam that is used at the manufacturing facility.
Banding Straps
Metal Banding Straps are being phased out and replaced with plastic straps that can easily reused and after reuse can be recycled.
Water Based Glues
Formica is offering water-based glues for all of their products, which will replace solvent-based glues. These glued are used to install the product and are low in volatile organic compound (VOC) content.
Solid Surface Dust
Dust generated in the manufacturing process of the solid surface is reused by another manufacturer as a raw material in their product. (40,000 lbs. / month.)
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