United States Air and Radiation EPA/430/R-92/1 10

Environmental Protection (ANR-445) October 1992

Agency

i-.►EPA Vacuum Panel and Thick Wall Foam

Insulation for Refrigerators:

Cost Estimates for

Manufacturing and Installation

Printed on Recycled Paper

 EE-RM-93-801 COMMENT OR5

&EPA 

United States 

Environmental Protection 

Agency 

Air and Radiation 

(ANR-445) 

EP A/430/R-92/11 0 

October 1992 

Vacuum Panel and Thick Wall Foam 

Insulation for Refrigerators: 

Cost Estimates for 

Manufacturing and Installation 

@ Printed on Recycled Paper 

&EPA 

United States 

Environmental Protection 

Agency 

Air and Radiation 

(ANR-445) 

EP A/430/R-92/11 0 

October 1992 

Vacuum Panel and Thick Wall Foam 

Insulation for Refrigerators: 

Cost Estimates for 

Manufacturing and Installation 

@ Printed on Recycled Paper 
United States Air and Radiation EPA/430/R-92/1 10

Environmental Protection (ANR-445) October 1992

Agency

2 EPA Vacuum Panel and Thick Wall Foam

Insulation for Refrigerators:

Cost Estimates for

Manufacturing and Installation

 EE-RM-93-801 COMMENT OR5

v &EPA 

= 

United States 

Environmental Protection 

. Agency 

Air and Radiation 

(ANR-445) 

EPAl4301R-92/110 

October 1992 

Vacuum Panel and Thick Wall Foam 

Insulation for· Refrigerators: 

Cost Estimates for 

Manufacturing and Installation 

v &EPA 

= 

United States 

Environmental Protection 

. Agency 

Air and Radiation 

(ANR-445) 

EPAl4301R-92/110 

October 1992 

Vacuum Panel and Thick Wall Foam 

Insulation for· Refrigerators: 

Cost Estimates for 

Manufacturing and Installation 
VACUUM PANEL AND THICK WALL FOAM

INSULATION FOR REFRIGERATORS:

Cost Estimates for Manufacturing and Installation

prepared for

US Environmental Protection Agency

Global Change Division

Office of Atmospheric and Indoor Air Programs

Office of Air and Radiation

U. S. EPA Project No. X818749-01-0

by

James M. Waldron

Center for Robotics and Manufacturing Systems

University of Kentucky College of Engineering

Lexington, Kentucky 40506-0108

October 1992

 EE-RM-93-801 COMMENT OR5

VACUUM PANEL AND THICK WALL FOAM 

-INSULATION FOR REFRIGERATORS: 

Cost Estimates for Manufacturing and Installation 

prepared for 

US Environmental Protection Agency 

Global Change Division 

Office of Atmospheric and Indoor Air Programs 

Office of Air and Radiation 

U. S. EPA Project No. X818749-01-O 

by 

James M. Waldron 

Center for Robotics and Manufacturing Systems _ University of Kentucky College of Engineering 

Lexington, Kentucky 40506-0108 

October 1992 

VACUUM PANEL AND THICK WALL FOAM 

-INSULATION FOR REFRIGERATORS: 

Cost Estimates for Manufacturing and Installation 

prepared for 

US Environmental Protection Agency 

Global Change Division 

Office of Atmospheric and Indoor Air Programs 

Office of Air and Radiation 

U. S. EPA Project No. X818749-01-O 

by 

James M. Waldron 

Center for Robotics and Manufacturing Systems _ University of Kentucky College of Engineering 

Lexington, Kentucky 40506-0108 

October 1992 
VACUUM PANEL AND THICK WALL FOAM

INSULATION FOR REFRIGERATORS:

Cost Estimates for Manufacturing and Installation

ABSTRACT

Improved insulation between the outer case and the inner liner is among the technologies

available to refrigerator manufacturers to achieve significant reductions in energy consumption and the pollution associated with its generation. One approach is to add more

insulation to the refrigerator cabinet. A second, "super insulation", is a developing technology which would allow refrigerator manufacturers to significantly improve energy efficiency without compromising the internal to external volume ratio of the refrigerator. One

approach to super insulation is the use of vacuum insulation panels (VIPs).

The fixed and variable costs for these two cabinet insulation technologies are evaluated in

this study. The manufacturing costs for VIPs are examined by developing the material,

process and equipment requirements for producing and transporting VIPs on a mass production basis. VIP installation costs are established by developing a generic refrigerator assembly line and then the material, epuipment and process modifications required. for receiving, storing, delivering, and installing VIPs into refrigerators. Plant and component

modifications are also developed for the added foam approach.

Raw material bulk densities suggest that the VIP plant be located adjacent to the silica plant

to minimize transportation cost. Silica processing must be optimized between the silica

plant and the VIP plant to minimize the required investment in plant and equipment.

Trade-offs between VIP plant efficiency and refrigerator energy efficiency must be made

during development to determine the best mix of panel dimensions.

Existing refrigerator assembly plants can be retrofit to receive and install VIPs, but some

-ii-

 EE-RM-93-801 COMMENT OR5

VACUUM PANEL AND THICK WALL FOAM 

INSULATION FOR REFRIGERATORS: 

Cost Estimates for Manufacturing and Installation 

ABSTRACT 

~proved insulation between the outer case and the inner liner is among the technologies . 

. available to refrigerator manufacturers to achieve significant reductions in energy consumption and the pollution associated with its generation. One approach is to add more 

insulation to the refrigerator cabinet. A second, "super insulation", is a developing technology which would allow refrigerator manufacturers to significantly improve energy efficiency without compromising the internal to external volume ratio of the :efrigerator. One 

approach to super insulation is the use of vacuum insulation panels (VIPs). 

The fixed and variable costs for these two cabinet insulation technologies are evaluated in 

this study. The manufacturing costs for VIPs are examined by developing the material, 

process and equipment requirements for producing and transporting VIPs on a mass production basis. VIP installation costs are established by developing a generic refrigerator assembly line and then the material, epuipment and process modifications required for receiving, storing, delivering, and installing VIPs into refrigerators. Plant and component 

modifications are also developed for the added foam approach. 

Raw material bulk densities suggest that the VIP plant be located adjacent to the silica plant 

to minimize transportation cost. Silica processing must be optimized between the silica· 

plant and the VIP plant to minimize the required investment in plant and equipment. 

Trade-offs between VIP plant efficiency and refrigerator energy efficiency must be made 

during development to determine the best mix of panel dimensions. 

Existing refrigerator assembly plants can be retrofit to receive and install VIPs, but some 

-iiVACUUM PANEL AND THICK WALL FOAM 

INSULATION FOR REFRIGERATORS: 

Cost Estimates for Manufacturing and Installation 

ABSTRACT 

~proved insulation between the outer case and the inner liner is among the technologies . 

. available to refrigerator manufacturers to achieve significant reductions in energy consumption and the pollution associated with its generation. One approach is to add more 

insulation to the refrigerator cabinet. A second, "super insulation", is a developing technology which would allow refrigerator manufacturers to significantly improve energy efficiency without compromising the internal to external volume ratio of the :efrigerator. One 

approach to super insulation is the use of vacuum insulation panels (VIPs). 

The fixed and variable costs for these two cabinet insulation technologies are evaluated in 

this study. The manufacturing costs for VIPs are examined by developing the material, 

process and equipment requirements for producing and transporting VIPs on a mass production basis. VIP installation costs are established by developing a generic refrigerator assembly line and then the material, epuipment and process modifications required for receiving, storing, delivering, and installing VIPs into refrigerators. Plant and component 

modifications are also developed for the added foam approach. 

Raw material bulk densities suggest that the VIP plant be located adjacent to the silica plant 

to minimize transportation cost. Silica processing must be optimized between the silica· 

plant and the VIP plant to minimize the required investment in plant and equipment. 

Trade-offs between VIP plant efficiency and refrigerator energy efficiency must be made 

during development to determine the best mix of panel dimensions. 

Existing refrigerator assembly plants can be retrofit to receive and install VIPs, but some 

-ii-
may require significant rearrangement. The technology to install VIPs into refrigerator

cases and doors exists now in some plants:

Thickening the foam insulation may be more cost effective on smaller refrigerators (<20')

where kitchen dimensions are less limiting and where internal/external volume ratios are

less important.

 EE-RM-93-801 COMMENT OR5

may require significant rearrangement. The technology to install VIPs into refrigerator 

cases and doors exists now in some plants: 

Thickening the foam insulation may be more cost effective on smaller refrigerators «20') 

where kitchen dimensions are less limiting and where internal/external volume ratios are 

less important. 

-iiimay require significant rearrangement. The technology to install VIPs into refrigerator 

cases and doors exists now in some plants: 

Thickening the foam insulation may be more cost effective on smaller refrigerators «20') 

where kitchen dimensions are less limiting and where internal/external volume ratios are 

less important. 

-iii-
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 EE-RM-93-801 COMMENT OR5

CONTENTS 

Abstr~ct .......... ; ............................................................................................................................... ii 

Figures ............................................................................................................................................ v 

Tables ............................................................................................................................................ vi 

Abbreviations ............................................. ~ ............................................................................... vii 

Acknowledgements .................................................................................................................. viii 

Introd.uction ................................................................................................................................... 1 

Fin.dings ......................................................................................................................................... 4 

Recommendations ........................................................................................................................ 5 

Generic refrigerator assembly lin.e ............................................................................................. 6 

Vacuum insulation panel requirements .......................................................................... : ......... 9 

Vacuum insulation panel manufacturing ............................................................................... 14 

J:anel installation into refrigerators ......................................................................................... 43 

Total program and product cost for VIP production and installation ................................ 54 

Thick wall alternative ............................................................................................................. ; .. 62 

Energy analysis ...................................................................................................... , ..................... 73, 

References .................................................................................................................................... 75 

Appendices .................................................................................................................................. 77 

-ivCONTENTS 

Abstr~ct .......... ; ............................................................................................................................... ii 

Figures ............................................................................................................................................ v 

Tables ............................................................................................................................................ vi 

Abbreviations ............................................. ~ ............................................................................... vii 

Acknowledgements .................................................................................................................. viii 

Introd.uction ................................................................................................................................... 1 

Fin.dings ......................................................................................................................................... 4 

Recommendations ........................................................................................................................ 5 

Generic refrigerator assembly lin.e ............................................................................................. 6 

Vacuum insulation panel requirements .......................................................................... : ......... 9 

Vacuum insulation panel manufacturing ............................................................................... 14 

J:anel installation into refrigerators ......................................................................................... 43 

Total program and product cost for VIP production and installation ................................ 54 

Thick wall alternative ............................................................................................................. ; .. 62 

Energy analysis ...................................................................................................... , ..................... 73, 

References .................................................................................................................................... 75 

Appendices .................................................................................................................................. 77 

-iv-
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 EE-RM-93-801 COMMENT OR5

FIGURES 

Number Page· 

1 Equivalent Insulations ..................................................................................................... 3 

2 Case and Liner Pre-foam Areas ...................................................................................... 7 

:3 Door Pre-foam Area ......................................................................................................... 8 

4 Refrigerator Panell..c>cations ........................................................................................ 10 

5 Panel Plant Layout ......................................................................................................... 17 

6 Panel Plant Organization .................................................................................. ~ ........... 19 

7 Silica Processing Flow Chart ......................................................................................... 22 

8 Jet-O-Drier Flash Drier ................................. : ............................................................... 26 

9 .Vacupress Densifier ........................................................................................................ 30 

10 Vacupress Installation .................................................................................................... 31 

11 Process Specifications _ Form, Fill, and Seal Line ..................................................... 33 

12 Form, Fill, and Seal Line ................................................................................................ 35 

13 VIP Receiving Area - Refrigerator Plant ..................................................................... 44 

14 Case and Liner Pre-foam Areas with VIPs ................................................................. 48 

15 Door Pre-foam Area with VIPs ............................................................................. : ....... 50 

16 VIP Project Schedule ...................................................................................................... 59 

17 Start~up Curve - VIP Plant .................................................................................... : ...... 61 

-vFIGURES 

Number Page· 

1 Equivalent Insulations ..................................................................................................... 3 

2 Case and Liner Pre-foam Areas ...................................................................................... 7 

:3 Door Pre-foam Area ......................................................................................................... 8 

4 Refrigerator Panell..c>cations ........................................................................................ 10 

5 Panel Plant Layout ......................................................................................................... 17 

6 Panel Plant Organization .................................................................................. ~ ........... 19 

7 Silica Processing Flow Chart ......................................................................................... 22 

8 Jet-O-Drier Flash Drier ................................. : ............................................................... 26 

9 .Vacupress Densifier ........................................................................................................ 30 

10 Vacupress Installation .................................................................................................... 31 

11 Process Specifications _ Form, Fill, and Seal Line ..................................................... 33 

12 Form, Fill, and Seal Line ................................................................................................ 35 

13 VIP Receiving Area - Refrigerator Plant ..................................................................... 44 

14 Case and Liner Pre-foam Areas with VIPs ................................................................. 48 

15 Door Pre-foam Area with VIPs ............................................................................. : ....... 50 

16 VIP Project Schedule ...................................................................................................... 59 

17 Start~up Curve - VIP Plant .................................................................................... : ...... 61 

-v-
TABLES

Number Page

1 Vacuum Panels for 21' & 24' Refrigerators ..................................................................12

2 Vacuum Panels for 21' & 24' Refrigerators-Material Size .......................................13

3 Panel Plant Equipment ...................................................................................................18

4 Annual Panel Plant Operating Cost .............................................................................20

5 Average Silica Use Per 8 Hour Shift .............................................................................24

6 . Silica Silo Inventory ........................................................................................................27

7 Form, Fill, and Seal Line Changeovers and Scheduling ............................................28

8 Average Daily Panel Requirements for Refrigerator Assembly line ......................40

9 48 Foot Trailer Loading ..................................................................................................42

10 Flow Thru Rack Requirements ......................................................................................45

11 Refrigerate Plant Equipment .......................................................................................52

12 Additional Operating Cost-Refrigerator Plant .........................................................53

13 Vacuum Insulated Panel Manufacturing Program Cost ........................................:..55

14 Product Cost for VIP Manufacturing and Installation ..............................................57

15 VIP Product Cost Sensitivity Analysis .........................................................................58

16 Thick Insulation Alternatives External Dimensions ..................................................64

17 Carton Sizes for 18' Refrigerators with Thicker Insulation .......................................66

18 Thick Foam Alternatives Retooling Requirements ....................................................68

19 Cost to Increase Insulation Thickness on 18' Refrigerators ......................................69

20 Thick Wall Product Cost Sensitivity Analysis .............................................................70

21 Cost to Increase Insulation Thickness on 18' Refrigerator Doors Only ..................71

22 Baseline 1991 Refrigerator ..............................................................................................74

23 Energy Consumption Analysis Results ........................................................................74

 EE-RM-93-801 COMMENT OR5

TABLES 

Number Page 

1 Vacuum Panels for 21' & 24' Refrigerators .................................................................. 12 

2 Vacuum Panels for 21' & 24' Refrigerators-Material Size ....................................... 13 

3 Panel Plant Equipment .................. ; ................................................................................ 18 

4 Annual Panel Plant Operating Cost ............................................................................. 20 

5 Average Silica Use Per 8 Hour Shift ............................................................................. 24 

6 . Silica Silo Inventory ........................................................................................................ 27 

7 Form, Fill, and Seal line Changeovers and Scheduling ....................... : .................... 28 

8 Average Daily Panel Requirements for Refrigerator Assembly line ..................... .40 

9 48 Foot Trailer Loading .................................................................................................. 42 

10 Flow Thru Rack Requirements ...................................................................................... 45 

11 Refrigeratc~' Plant Equipment ....................................................................................... 52 

12 Additional Operating Cost-Refrigerator Plant ........................................................ :53 

13 Vacuum Insulated Panel Manufacturing Program Cost ........................................ : .. 55 

14 Product Cost for VIP Manufacturing and Installation ........................ ~ ..................... 57 

15 VIP Product Cost Sensitivity Analysis ..................... : ................................................... 58 

16 Thick Insulation Alternatives External Dimensions .................................................. 64 

17 Carton Sizes for 18' Refrigerators with Thicker Insulation .............. : .............. : ......... 66 ' 

18 Thick Foam Alternatives Retooling Requirements .................................................... 68 

19 Cost to Increase Insulation Thickness on 18' Refrigerators ...................................... 69 

20 Thick Wall Product Cost Sensitivity Analysis ............................................................. 70 

21 Cost to Increase Insulation Thickness on 18' Refrigerator Doors Only ....... ~ .......... 71 

22 Baseline 1991 Refrigerator .............................................................................................. 74 

23 Energy Consumption Analysis Results ........................................................................ 74 

-viTABLES 

Number Page 

1 Vacuum Panels for 21' & 24' Refrigerators .................................................................. 12 

2 Vacuum Panels for 21' & 24' Refrigerators-Material Size ....................................... 13 

3 Panel Plant Equipment .................. ; ................................................................................ 18 

4 Annual Panel Plant Operating Cost ............................................................................. 20 

5 Average Silica Use Per 8 Hour Shift ............................................................................. 24 

6 . Silica Silo Inventory ........................................................................................................ 27 

7 Form, Fill, and Seal line Changeovers and Scheduling ....................... : .................... 28 

8 Average Daily Panel Requirements for Refrigerator Assembly line ..................... .40 

9 48 Foot Trailer Loading .................................................................................................. 42 

10 Flow Thru Rack Requirements ...................................................................................... 45 

11 Refrigeratc~' Plant Equipment ....................................................................................... 52 

12 Additional Operating Cost-Refrigerator Plant ........................................................ :53 

13 Vacuum Insulated Panel Manufacturing Program Cost ........................................ : .. 55 

14 Product Cost for VIP Manufacturing and Installation ........................ ~ ..................... 57 

15 VIP Product Cost Sensitivity Analysis ..................... : ................................................... 58 

16 Thick Insulation Alternatives External Dimensions .................................................. 64 

17 Carton Sizes for 18' Refrigerators with Thicker Insulation .............. : .............. : ......... 66 ' 

18 Thick Foam Alternatives Retooling Requirements .................................................... 68 

19 Cost to Increase Insulation Thickness on 18' Refrigerators ...................................... 69 

20 Thick Wall Product Cost Sensitivity Analysis ............................................................. 70 

21 Cost to Increase Insulation Thickness on 18' Refrigerator Doors Only ....... ~ .......... 71 

22 Baseline 1991 Refrigerator .............................................................................................. 74 

23 Energy Consumption Analysis Results ........................................................................ 74 

-vi-
ABBREVIATIONS

AGV-Automatic Guided Vehicle

Board Foot-A volume element V x V x 1"

CFC-Chlorofluorocarbons

DOE-Department of Energy

K-A specific property of a conducting material defined as the quantity of heat conducted

across a unit area normal to the flow path in unit time and for unit temperature gradient

along the flow. Expressed as Btu-IN/HR-SQFI DEG F

NAECA-National Appliance Energy Conservation Act

ORNL--Oak Ridge National Laboratory

Torr-pressure equal to a column of mercury one millimeter high.

VIP-Vacuum insulation panel

 EE-RM-93-801 COMMENT OR5

ABBREVIATIONS 

AGV-Automatic Guided Vehicle 

Board Foot-A volume element l' x l' x 1" 

CFC-Chlorofluorocarbons 

[x)E-DepartmentofEnergy 

K-A specific property of a conducting material defined as the quantity of heat conducted 

across a unit area normal to the flow path in unit time and for unit temperature gradient 

along the flow. Expressed as Btu-IN /HR-SQFT-DEG F 

NAECA-National Appliance Energy Conservation Act 

ORNL-Dak Ridge National Laboratory 

Torr-pressure equal to a column of mercury one millimeter high. 

VIP-Vacuum insulation panel 

-viiABBREVIATIONS 

AGV-Automatic Guided Vehicle 

Board Foot-A volume element l' x l' x 1" 

CFC-Chlorofluorocarbons 

[x)E-DepartmentofEnergy 

K-A specific property of a conducting material defined as the quantity of heat conducted 

across a unit area normal to the flow path in unit time and for unit temperature gradient 

along the flow. Expressed as Btu-IN /HR-SQFT-DEG F 

NAECA-National Appliance Energy Conservation Act 

ORNL-Dak Ridge National Laboratory 

Torr-pressure equal to a column of mercury one millimeter high. 

VIP-Vacuum insulation panel 

-vii-
ACKNOWLEDGEMENTS

This study was completed with the assistance of a technical consultant, Louis W. Dawson,

who has more than 30 years of experience in major appliances-primarily in refrigerator

manufacturing.

General Electric Appliances (GEA) provided samples of 18 cubic foot refrigerator cabinets

and liners and samples of prototype VIPs. Refrigerator specifications and cost information

were made available, through a non-disclosure agreement, to support the study. Ken

Downs, GEA, assisted in the development of VIP sizes and served as a sounding board as

the VIP manufacturing and installation processes were developed. GEA also assisted in developing tooling costs for thick wall alternatives.

T -&7o engineers, W Robert Keelen .nd Richard Muse, from the University of Kentucky (UK)

Center for Robotics and Manufacturing Systems, and with combined manufacturing experience exceeding 60 years, provided valuable assistance and input.

Stephen Poulter, a senior in the mechanical engineering department at UK, provided capable CAD assistance in preparing figures and tables.

Also, considerable technical and cost information on raw materials and manufacturing

equipment was provided by many companies which are listed as references on page 75.

Two companies in particular; Fres-Co System USA, Inc. (Larry Restivo) and Degussa Corporation (Roger Caffier & Nick Ludovic) were especially helpful in providing key inputs.

- viii -

 EE-RM-93-801 COMMENT OR5

ACKNOWLEDGEMENTS 

This study was .completed with the assistance of a technical consultant, Louis W. Dawson, 

who has more than 30 years of experience in major appliances-primarily in refrigerator 

manufacturing. 

General Electric Appliances (GEA) provided samples of 18 cubic foot refrigerator cabinets 

and liners and samples of prototype VIPs. Refrigerator specifications and cost information 

were made available, through a non-disclosure agreement, to support the study. Ken 

Downs, GEA, assisted in the development of VIP sizes and served as a sounding board as 

the VIP manufacturing and installation processes were developed. GEA also assisted in developing tooling costs for thick wall alternatives. 

Two engineers, W. Robert Keelen '3nd Richard Muse, from the University of Kentucky (UK) 

Center for Robotics and Manufacturing Systems, and with combined manufacturing experience exceeding 60 years, provided valuable assistance and input. 

Stephen Poulter, a senior in the mechanical engineering department at UK, provided capable CAD assistance in preparing figures and tables. 

Also, con"siderable technical and cost information on raw materials and manufacturing 

equipment was provided by many companies which are listed as references on page 75. 

Two companies in particular; Fres-Co System USA, Inc. (Larry Restivo) and Degussa Corporation (Roger Caffier & Nick Ludovic) were especially helpful in providing key inputs. 

-viiiACKNOWLEDGEMENTS 

This study was .completed with the assistance of a technical consultant, Louis W. Dawson, 

who has more than 30 years of experience in major appliances-primarily in refrigerator 

manufacturing. 

General Electric Appliances (GEA) provided samples of 18 cubic foot refrigerator cabinets 

and liners and samples of prototype VIPs. Refrigerator specifications and cost information 

were made available, through a non-disclosure agreement, to support the study. Ken 

Downs, GEA, assisted in the development of VIP sizes and served as a sounding board as 

the VIP manufacturing and installation processes were developed. GEA also assisted in developing tooling costs for thick wall alternatives. 

Two engineers, W. Robert Keelen '3nd Richard Muse, from the University of Kentucky (UK) 

Center for Robotics and Manufacturing Systems, and with combined manufacturing experience exceeding 60 years, provided valuable assistance and input. 

Stephen Poulter, a senior in the mechanical engineering department at UK, provided capable CAD assistance in preparing figures and tables. 

Also, con"siderable technical and cost information on raw materials and manufacturing 

equipment was provided by many companies which are listed as references on page 75. 

Two companies in particular; Fres-Co System USA, Inc. (Larry Restivo) and Degussa Corporation (Roger Caffier & Nick Ludovic) were especially helpful in providing key inputs. 

-viii-
INTRODUCTION

The construction of a typical U. S. refrigerator consists of a thermoformed plastic inner liner

and a steel outer case with CFC blown polyurethane foam insulation in between. The doors

usually are of similar construction. Two technologies, vacuum insulation panels (VIPs) and

thicker foam insulation, have been proposed to reduce the thermal load through the refrigerator cabinet wall and the resulting power requirement.

The current design evolved from the use of fiberglass insulation during the sixties and

brought significant energy efficiency improvements. The use of foam insulation allowed

refrigerator manufacturers to increase the food storage capacity of a given refrigerator

while maintaining the same external dimensions. This "thin wall" concept has been a key

in refrigerator design. Increasing the thickness of the walls could require consumer compromises in food storage capacity for available kitchen space for consumers of larger (> 18')

refrigerators.

CFCs used in the foam insulation have been banned by the Montreal Protocol and the

Clean Air Act Amendments of 1990. Furthermore, President Bush has mandated that their

use be completely eliminated after 1995.

The Department of Energy (DOE), authorized by the National Appliance Energy Conservation Act (NAECA) of 1987, has issued stringent refrigerator energy standards to be met for

1993 production. These standards require, on the average, a 30 percent additional efficiency increase over 1990 requirements; and possible further efficiency increases for 1998._

Many technologies can be used to reduce the energy consumption of refrigerators. Improvements can be made to the hermetic system, control systems, such as the defrost system, and components, such as fans, or to the cabinet enclosure. Improvements to the cabinet are limited to increases in thermal resistance through better gaskets, increased insulation, or lower thermal conductivity insulation. Insulation like VIPs would enhance thermal

resistance without adversely affecting the internal volume to external dimension ratio.

-1-

 EE-RM-93-801 COMMENT OR5

INTRODUCTION 

The construction of a typical U. S. refrigerator consists of a thermoformed plastic inner liner 

and a steel outer case with CFC blown polyurethane foam insulation in between. The doors 

usually are of similar construction. Two technologies, vacuum insulation panels (VIPs) and 

thicker foam insulation, have been proposed to reduce the thermal load through the refrigerator cabinet wall and the resulting power requirement. 

The current design evolved from the use of fiberglass insulation during the sixties and . 

brought significant energy efficiency improvements. The use of foam insulation allowed 

refrigerator manufacturers to increase the food storage capacity of a given refrigerator 

while maintaining the same external dimensions. This "thin wall" concept has been a key 

in refrigerator design. Increasing the thickness of the walls could require consumer compromises in food storage capacity for available kitchen space for consumers of larger (> 18') 

refrigerators. 

CFCs used in the foam insulation have been banned by the Montreal Protocol and the 

Clean Air Act Amendments of 1990. Furthermore, President Bush has mandated that their 

use be completely eliminated after 1995. 

The Department of Energy (DOE), authorized by the National Appliance Energy Conservation Act (NAECA) of 1987, has issued stringent refrigerator energy standards to be met for 

1993 production. These standards require, on the average, a 30 percent additional effici~ncy increase over 1990 requirements; and possible further efficiency increases for 1998 .. 

Many tedmologies can be used to reduce the energy consumption of refrigerators. Jrn- . 

provements can be made to the hermetic system, control systems, such as the defrost system, and components, such as fans, or to the cabinet enclosure. Improvements to the cabinet are limited to increases in thermal resistance through better gaskets, increased insulation, or lower thermal conductivity insulation. Insulation like VIPs would enhance thermal 

resistance without adversely affecting the internal volume to external dimension ratio. 

-1-

INTRODUCTION 

The construction of a typical U. S. refrigerator consists of a thermoformed plastic inner liner 

and a steel outer case with CFC blown polyurethane foam insulation in between. The doors 

usually are of similar construction. Two technologies, vacuum insulation panels (VIPs) and 

thicker foam insulation, have been proposed to reduce the thermal load through the refrigerator cabinet wall and the resulting power requirement. 

The current design evolved from the use of fiberglass insulation during the sixties and . 

brought significant energy efficiency improvements. The use of foam insulation allowed 

refrigerator manufacturers to increase the food storage capacity of a given refrigerator 

while maintaining the same external dimensions. This "thin wall" concept has been a key 

in refrigerator design. Increasing the thickness of the walls could require consumer compromises in food storage capacity for available kitchen space for consumers of larger (> 18') 

refrigerators. 

CFCs used in the foam insulation have been banned by the Montreal Protocol and the 

Clean Air Act Amendments of 1990. Furthermore, President Bush has mandated that their 

use be completely eliminated after 1995. 

The Department of Energy (DOE), authorized by the National Appliance Energy Conservation Act (NAECA) of 1987, has issued stringent refrigerator energy standards to be met for 

1993 production. These standards require, on the average, a 30 percent additional effici~ncy increase over 1990 requirements; and possible further efficiency increases for 1998 .. 

Many tedmologies can be used to reduce the energy consumption of refrigerators. Jrn- . 

provements can be made to the hermetic system, control systems, such as the defrost system, and components, such as fans, or to the cabinet enclosure. Improvements to the cabinet are limited to increases in thermal resistance through better gaskets, increased insulation, or lower thermal conductivity insulation. Insulation like VIPs would enhance thermal 

resistance without adversely affecting the internal volume to external dimension ratio. 

-1-
While buyers of smaller capacity units (<21') may be willing to accept some compromises

to avoid additional cost, buyers of larger units are more likely to pay a premium to preserve food storage capacity. The need to maintain this "thin wall" concept while meeting

new, regulatory, refrigerator energy efficiency standards and other future requirements for

energy efficiency improvements without CFCs may necessitate the use of new thermal

insulation technologies.

One approach to improved thermal insulation is the use of vacuum insulation panels in

conjunction with a non-CFC blown foam. These panels may be manufactured by filling a

porous.bag with a micro-grained powder, placing the bag into an envelope impervious to

water and gases, and evacuating and sealing the envelope. The evacuated space provides a

barrier to the transfer of heat which is more effective than any modern day insulation.

These panels have about 67% lower thermal conductivity than CFC blown foam (Figure ).

Research and development on vacuum panels has gone on for several years but the feasibility and cost for actual production and application continues to be debated. Ot',.er important issues such as the long term degradation of the vacuum and the impact of CFC substitutes, are being addressed elsewhere.

This study evaluates the manufacturing feasibility and estimates cost to produce and install

vacuum insulation panels into refrigerators. It also estimates the manufacturing and product costs of adding more foam to thicken the urethane foam insulation.

 EE-RM-93-801 COMMENT OR5

While buyers of smaller capacity units «21') may be willing to accept some compromises 

.to avoid additional cost, buyers of larger units are more likely to pay a premium to preserve food storage capacity. The need to maintain this "thin wall" concept while meeting 

new, regulatory, refrigerator energy efficiency standards and other future requirements for 

energy efficiency improvements without CFCs may necessitate the use of new thermal 

insulation technologies. 

One approach to improved thermal insulation is the use of vacuum insulation panels in 

conjunction with a non-CFC blown foam. These panels may be manufactured by filling a 

porous. bag with a micro-grained powder, placing the bag into an envelope impervious to 

water and gases, and evacuating and sealing the envelope. The evacuated space provides a 

barrier to the transfer of heat which is more effective than any modern day insulation. 

These panels have about 67% lower thermal conductivity than CFC blown foam (Figure 1). 

Research and development on vacuum panels has gone on for several years but the feasibilityand cost for actual production and applicauon continues to be debated. Ot~ler Important issues such as the long term degradation of the vacuum and the impact of CFC substitutes, are being addressed elsewhere. 

This study evaluates the manufacturing feasibility and estimates cost to produce and install 

vacuum insulation panels into refrigerators. It also estimates the manufacturing and PFoduct costs of adding more foam to thicken the urethane foam insulation. 

-2-

While buyers of smaller capacity units «21') may be willing to accept some compromises 

.to avoid additional cost, buyers of larger units are more likely to pay a premium to preserve food storage capacity. The need to maintain this "thin wall" concept while meeting 

new, regulatory, refrigerator energy efficiency standards and other future requirements for 

energy efficiency improvements without CFCs may necessitate the use of new thermal 

insulation technologies. 

One approach to improved thermal insulation is the use of vacuum insulation panels in 

conjunction with a non-CFC blown foam. These panels may be manufactured by filling a 

porous. bag with a micro-grained powder, placing the bag into an envelope impervious to 

water and gases, and evacuating and sealing the envelope. The evacuated space provides a 

barrier to the transfer of heat which is more effective than any modern day insulation. 

These panels have about 67% lower thermal conductivity than CFC blown foam (Figure 1). 

Research and development on vacuum panels has gone on for several years but the feasibilityand cost for actual production and applicauon continues to be debated. Ot~ler Important issues such as the long term degradation of the vacuum and the impact of CFC substitutes, are being addressed elsewhere. 

This study evaluates the manufacturing feasibility and estimates cost to produce and install 

vacuum insulation panels into refrigerators. It also estimates the manufacturing and PFoduct costs of adding more foam to thicken the urethane foam insulation. 

-2-
Figure 1

Equivalent Insulations

K=BTU - IN/HR-FT2-°F

0.240

6" Fiberglass

K-0.120

3" Urethane Foam

K-0,040

1" Vacuum Insulated Panel

 EE-RM-93-801 COMMENT OR5

Figure 1 

Equivalent Insulations 

K=BTU-IN/HR-FT2_oF 

6

11 Fiberglass 

]8 Urethane FoaM 

VZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZd 

In VaCUUM Insulated Panel 

-3-

K = 0,240 

K = 0,120 

K = 0,040 

Figure 1 

Equivalent Insulations 

K=BTU-IN/HR-FT2_oF 

6

11 Fiberglass 

]8 Urethane FoaM 

VZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZd 

In VaCUUM Insulated Panel 

-3-

K = 0,240 

K = 0,120 

K = 0,040 
FINDINGS

• It is feasible, with existing technology, to manufacture vacuum insulation panels

(VIPs) in sufficient volume and with sufficient quality for installation into household

refrigerators.

• Existing refrigerator plants can be retrofit to install VIPs- but may require significant

rearrangement and cost.

• This technology will allow significant reduction in refrigerator energy usage without

increasing the external dimensions of the refrigerator.

• Replacing urethane foam with VIPs will significantly increase the variable manufacturing cost and thus the retail price of refrigerators. The increase in variable manufacturing cost of the refrigerator is estimated to be $1.39 per board foot of VIPs or about

$40 for a 21 cubic foot refrigerator. This would translate to about $120 higher retail

cost. This cost can probably be reduced through optimization of silica processing

steps between silica manufacturing and VIP manufacturing. Also, other filler materials, such as aluminum silicate, in place of or in combination with precipitated silica

may prove more cost effective. A goal of $1.00 per board foot is probably attainable

within three to five years of initial production.

• Investment and expense required to implement the production and application of

VIPs for three hundred thousand 21 or 24 cubic foot refrigerators per year is estimated

to be about $24 million. This cost can probably be reduced by optimization of the flash

drying and densification processes between the VIP plant and the silica plant. Increased costs to the consumer will be minimized if the total systems cost, from the

manufacture of silica to the final panel installation, is optimized.

• As the cost of urethane foam increases, the cost difference between foam and VIPs

will decrease by about $0.02/board foot for every 10% increase in foam cost. This

 EE-RM-93-801 COMMENT OR5

FINDINGS 

• It is feasible, with existing technology, to manufacture vacuum insulation panels 

(VIPs) in sufficient volume and with sufficient quality for installation into household 

refrigerators. 

CD Existing refrigerator plants can be retrofit to install VIPs- but may require significant 

rearrangement and cost. 

• This technology will allow significant reduction in refrigerator energy usage without 

increasing the external dimensions of the refrigerator. 

• Replacing urethane foam with VIPs will significantly increase the variable manufacturing cost and thus the retail price of refrigerators. The increase in variable manufacturing cost of the refrigerator is estimated to be $1.39 per board foot of VIPs or about 

$40 for a 21 cuQic foot refrigerator. This would translate to about $120 higher retail 

cost. This cost can probably be reduced through optimization of silica processing 

steps between silica manufacturing and VIP manufacturing. Also, other filler materials, such as aluminum silicate, in place of or in combination with precipitated silica 

may prove more cost effective. A goal of $1.00 per board foot is probably attainable 

within three to five years of initial production. 

• Investment and expense required to implement the production and application of _ 

VIPs for three hundred thousand 21 or 24 cubic foot refrigerators per year is estimated 

to be about $24 million. This cost can probably be reduced by optimization of the flash 

drying and densification processes between the VIP plant and the silica ~lant. Increased costs to the consumer will be minimized if the total systems cost, from the 

manufacture of silica to the final panel installation, is optimized. 

• As the cost of urethane foam increases, the cost difference between foam and VIPs 

~l decrease by about $O.02/board foot for every 10% increase in foam cost. This 

-4-

FINDINGS 

• It is feasible, with existing technology, to manufacture vacuum insulation panels 

(VIPs) in sufficient volume and with sufficient quality for installation into household 

refrigerators. 

CD Existing refrigerator plants can be retrofit to install VIPs- but may require significant 

rearrangement and cost. 

• This technology will allow significant reduction in refrigerator energy usage without 

increasing the external dimensions of the refrigerator. 

• Replacing urethane foam with VIPs will significantly increase the variable manufacturing cost and thus the retail price of refrigerators. The increase in variable manufacturing cost of the refrigerator is estimated to be $1.39 per board foot of VIPs or about 

$40 for a 21 cuQic foot refrigerator. This would translate to about $120 higher retail 

cost. This cost can probably be reduced through optimization of silica processing 

steps between silica manufacturing and VIP manufacturing. Also, other filler materials, such as aluminum silicate, in place of or in combination with precipitated silica 

may prove more cost effective. A goal of $1.00 per board foot is probably attainable 

within three to five years of initial production. 

• Investment and expense required to implement the production and application of _ 

VIPs for three hundred thousand 21 or 24 cubic foot refrigerators per year is estimated 

to be about $24 million. This cost can probably be reduced by optimization of the flash 

drying and densification processes between the VIP plant and the silica ~lant. Increased costs to the consumer will be minimized if the total systems cost, from the 

manufacture of silica to the final panel installation, is optimized. 

• As the cost of urethane foam increases, the cost difference between foam and VIPs 

~l decrease by about $O.02/board foot for every 10% increase in foam cost. This 

-4-
assumes that VIP cost will remain the same although a decrease is likely as the manufacturing process is optimized.

• Thicker foam insulation is a viable alternative on smaller models (<18') where kitchen

installation dimensions are less limiting. Maintaining the same approximate height

width: depth ratios will be necessary to avoid significant kitchen fit problems (reduced market) when adding more insulation.

• Adding VIPs will not increase refrigerator shipping cost because even with the added

weight of VIPs, the weight of a 48 foot trailer remains less than one half the gross

weight limit. Shipping cost will increase for thicker insulation, even with a one half

inch increase in insulation thickness, because the number of refrigerators per trailer

will be reduced.

• The product and transportation cost increase to add one inch of foam to an 18' cabinet

will be about 50% of the cost of adding vacuum insulation panels to a 21' cabinet and

will give comparable energy improvement.

RECOMMENDATIONS

1. A prototype facility should be built by an appliance manufacturer or an independent

company to develop and optimize VIP manufacturing. A joint venture with either a

silica manufacturer or a form, fill, and seal equipment manufacturer is an alternative.

2. Long term vacuum and insulation degradation should be evaluated via accelerated life

tests and field trials, so that refrigerator life cycle benefits and liabilities (in warranty

and out of warranty costs) are better understood.

 EE-RM-93-801 COMMENT OR5

assumes that VIP cost will remain the. same although a decrease is likely as the mari~­

facturing process is optimized. 

• Thicker foam insulation is a viable alternative on smaller models «18') where kitchen 

installation dimensions are less limiting. Maintaining the same approximate height: 

width: depth ratios will be necessary to avoid significant kitchen fit problems (reduced market) when adding more insulation. 

• Adding VIPs will not increase refrigerator shipping cost because even with the added 

weight of VIPs, the weight of a 48 foot trailer remains less than one half the gross 

weight limit. Shipping cost will increase for thicker insulation, even with a one half 

inch increase in insulation thickness, because the number of refrigerators per trailer 

will be reduced. 

• The product and transportation cost increase to add one inch of foam to an 18' cabinet 

will be about 50% of the cost of adding vacuum insulation panels to a 21' cabinet and 

will give comparable energy improvement. 

RECOMMENDATIONS 

1. A prototype facility should be built by an appliance manufacturer or an independent 

company to develop and optimize VIP manufacturing. A joint venture with either a 

silica manufacturer or a form, fill, and seal equipment manufacturer is an alternative. 

2. Long term vacuum and insulation degradation should be evaluated via accelerated life 

tests and field trials, so that refrigerator life cycle benefits and liabilities (in warranty 

and out of warranty costs) are better understood. 

-5-

assumes that VIP cost will remain the. same although a decrease is likely as the mari~­

facturing process is optimized. 

• Thicker foam insulation is a viable alternative on smaller models «18') where kitchen 

installation dimensions are less limiting. Maintaining the same approximate height: 

width: depth ratios will be necessary to avoid significant kitchen fit problems (reduced market) when adding more insulation. 

• Adding VIPs will not increase refrigerator shipping cost because even with the added 

weight of VIPs, the weight of a 48 foot trailer remains less than one half the gross 

weight limit. Shipping cost will increase for thicker insulation, even with a one half 

inch increase in insulation thickness, because the number of refrigerators per trailer 

will be reduced. 

• The product and transportation cost increase to add one inch of foam to an 18' cabinet 

will be about 50% of the cost of adding vacuum insulation panels to a 21' cabinet and 

will give comparable energy improvement. 

RECOMMENDATIONS 

1. A prototype facility should be built by an appliance manufacturer or an independent 

company to develop and optimize VIP manufacturing. A joint venture with either a 

silica manufacturer or a form, fill, and seal equipment manufacturer is an alternative. 

2. Long term vacuum and insulation degradation should be evaluated via accelerated life 

tests and field trials, so that refrigerator life cycle benefits and liabilities (in warranty 

and out of warranty costs) are better understood. 

-5-
GENERIC REFRIGERATOR ASSEMBLY LINE

As a basis for this study a generic refrigerator line and factory has been defined. Product

assumptions for this line are:

1. Three cabinet sizes may be produced: 18 cubic foot, 21 cubic foot and 24 cubic foot.

2. Steel case and plastic liner construction. Steel doors also have plastic inner liners.

3. Urethane foam insulation in both the cabinet and door.

4. Foam blowing agent will be R-li or a suitable substitute. Foam, in conjunction with

vacuum insulation panels, will provide a mechanical structure equivalent to the

current design.

5. Product redesign changes to accommodate VIPs will be minimal.

Process assumptions are:

1. The fabrication and assembly line will operate two 7.6 hour shifts, five days/week,

220 days/year.

2. The line will produce onc unit every 20 seconds.

3. At 85% efficiency the line will have a capacity of about 500,000 units per year. (180

units/hour x 7.6 hours/shift x 2 shifts/day x 220 days/year x .85)

4. Output will average 1,163 units per 7.6 hour shift.

The areas of the plant which are examined in this study are case and liner pre-foam and

door pre-foam. The case and liner pre-foam area is shown in Figure 2. The door pre-foam

area is shown in Figure 3.

The layouts of the affected areas will be different in each refrigerator plant and the actual

rearrangement and costs required to install VIPs will vary from this study and from one

manufacturer to another.

 EE-RM-93-801 COMMENT OR5

GENERIC REFRIGERATOR ASSEMBLY LINE 

As a basis for this study a generic refrigerato~ line and factory has been defined. Product 

assumptions for this line are: 

1. ~ee cabinet sizes may be produced: 18 cubic foot, 21 cubic foot and 24 cubic foot. 

2. Steel case and plastic liner construction. Steel doors also have plastic inner liners. 

3. Urethane foam insulation in both the 'cabinet and door. 

4. Foam blowing agent will be R-ll or a suitable substitute. Foam, in conjunction with 

vacuum insulation panels, will provide a mechanical structure equivalent to the 

current design. 

5. Product redesign changes to accommodate VIPs will be minimal . 

. Process assumptions are: 

1. The fabrication and assembly line will operate two 7.6 hour shifts, five days/week, 

220 days/year. 

2. lhe line will produce one. unit every 20 seconds. 

3. At 85% efficiency the line will have a capacity of about 500,000 units per year. (180 

units/hour x 7.6 hours/shift x 2 shifts/day x 220 days/year x .85) 

4. Output will average 1,163 units per 7.6 hour shift. 

The areas of the plant which are examined in this study are case and liner pre-foam and 

door pre-foam. The case and liner pre-foam area is shown in Figure 2. The door pr~foam 

area is shown in Figure 3. 

The layouts of the affected areas will be different in each refrigerator plant and the actual 

rearrangement and costs required to install VIPs will vary from this study and from one 

manufacturer to another. 

-6-

GENERIC REFRIGERATOR ASSEMBLY LINE 

As a basis for this study a generic refrigerato~ line and factory has been defined. Product 

assumptions for this line are: 

1. ~ee cabinet sizes may be produced: 18 cubic foot, 21 cubic foot and 24 cubic foot. 

2. Steel case and plastic liner construction. Steel doors also have plastic inner liners. 

3. Urethane foam insulation in both the 'cabinet and door. 

4. Foam blowing agent will be R-ll or a suitable substitute. Foam, in conjunction with 

vacuum insulation panels, will provide a mechanical structure equivalent to the 

current design. 

5. Product redesign changes to accommodate VIPs will be minimal . 

. Process assumptions are: 

1. The fabrication and assembly line will operate two 7.6 hour shifts, five days/week, 

220 days/year. 

2. lhe line will produce one. unit every 20 seconds. 

3. At 85% efficiency the line will have a capacity of about 500,000 units per year. (180 

units/hour x 7.6 hours/shift x 2 shifts/day x 220 days/year x .85) 

4. Output will average 1,163 units per 7.6 hour shift. 

The areas of the plant which are examined in this study are case and liner pre-foam and 

door pre-foam. The case and liner pre-foam area is shown in Figure 2. The door pr~foam 

area is shown in Figure 3. 

The layouts of the affected areas will be different in each refrigerator plant and the actual 

rearrangement and costs required to install VIPs will vary from this study and from one 

manufacturer to another. 

-6-
Figure 2

Case and Liner Pre-foam Areas

Liners From

Vacuum Form 3

To Foam

Stations

H

4 I

N

1. Seal Case

2. Apply Foam Release

3. Foam Release Cure Ovens

4, Liner Insert Station

(X) Manual Operators

Cases From

I Fabrication

 EE-RM-93-801 COMMENT OR5

I 

-..J 

I 

liners FroM 

V o.eUUM ForM 

C 

Figure 2 . , 

ase and L-Iner Pre-foam A reas ' 

3 

1. Seal Cnse 

2. Apply F 00.1'1 Relense 

1---

I 

~2 ~ I I Cnses FrOM 

I ~ ~ I ~nbficntion 

I~ I 

I 2~~1 L ___ ~ 

3. F onM Release Cure Ovens 

4. Liner Insert Sto.tloo 

<X) Manual [Jpera tors ' 

I 

-..J 

I 

liners FroM 

V o.eUUM ForM 

C 

Figure 2 . , 

ase and L-Iner Pre-foam A reas ' 

3 

1. Seal Cnse 

2. Apply F 00.1'1 Relense 

1---

I 

~2 ~ I I Cnses FrOM 

I ~ ~ I ~nbficntion 

I~ I 

I 2~~1 L ___ ~ 

3. F onM Release Cure Ovens 

4. Liner Insert Sto.tloo 

<X) Manual [Jpera tors ' 
Figure 3

Door Pre-Foam Area

Door

De i i very

fron Point

To Inner Door

Assenb I y

I

Door Foan

Systen

1. Freezer Door

2. Fresh Food Door.

3. Load Foan Conveyor

4. Unload Foon Conveyor

QX Manual Operators

 EE-RM-93-801 COMMENT OR5

Door 

Del ivery 

fron Paint 

Figure 3 

Door Pre-Foam Area 

To Inner Door II Ass~ly ..... _ 

~DDR{CD[=1===::: 

-8-

---------... 

-------, 

'1 1 

Door Foan 

Systen 

, 

I I 

I I 

I I 

I I 

I I 

I I 

J J 

-------/ 

I. Freezer Door 

2. Fresh Food Door. 

3. Load Foan Conveyor 

4. Unload Foan Conveyor 

CX) Manual Operators 

Door 

Del ivery 

fron Paint 

Figure 3 

Door Pre-Foam Area 

To Inner Door II Ass~ly ..... _ 

~DDR{CD[=1===::: 

-8-

---------... 

-------, 

'1 1 

Door Foan 

Systen 

, 

I I 

I I 

I I 

I I 

I I 

I I 

J J 

-------/ 

I. Freezer Door 

2. Fresh Food Door. 

3. Load Foan Conveyor 

4. Unload Foan Conveyor 

CX) Manual Operators 
. VACUUM INSULATION PANEL REQUIREMENTS

This study assumes that all 21 and 24 cubic foot refrigerators made on this generic line will

receive vacuum insulation panels and the total annual volume of these models is 300,000

per year. Eighteen cubic foot models are not included since this size is more price sensitive

and would be less likely to use VIPs. A thicker insulation alternative for smaller, more price

sensitive models is discussed in "Thick Wall Alternatives".

All of the 21 and 24 cubic foot models will be produced on the line with an annual capacity

of 500,000, thus using 60% of that line's capacity. The other 40% would be used for 18'

models. When running models with vacuum insulation panels, the 20 second cycle time

will still be maintained.

It is assumed that the refrigerator line will schedule the models which will receive VIPs an

equivalent of three days or six shifts each week, or a maximum of 6,978 refrigerators with

VIPs per week. These models normally wi`: be 60% of each day's production or 1,396 per

day on two shifts, but sufficient in-process storage is provided to support a continual two

shift run.

Both cabinet sizes use the same set of panels, giving slightly less coverage'for the 24 foot as

a trade off for increased manufacturing efficiency in the panel plant. The 18 foot model also

could use these same panels. As the volume of models with VIPs increases, justifying a

second panel line, panel sizes could be further tailored to specific models to attain greater

energy improvement.

Through analysis of an actual 18 cubic foot cabinet, optimum panel locations and sizes

were developed. All of these panels would, of course, fit into a 21 cubic foot and a 24 cubic

foot cabinet since all of the dimensions are the same or slightly larger. A 21 cubic foot

refrigerator with VIP locations is shown in Figure 4.

 EE-RM-93-801 COMMENT OR5

· VACUUM INSULATION PANEL REQUIREMENTS 

This study assumes that all 21 and 24 cubic foot refrigerators made on this generic line will 

receiv·e vacuum insulation panels and the total annual volume of these models is 300,000 

per year. Eighteen cubic foot models are not included since this size is more Pri:ce sensitive 

and would be less likely to use VIPs. A thicker insulation alternative for smaller, more price 

sensitive models is discussed in "Thick Wall Alternatives". 

All of the 21 and 24 cubic foot models will be produced on the line with an annual capacity 

of 500,000, thus using 60% of that line's capacity. The other 40% would be used for 18' 

models. When running models with vacuum insulation panels, the 20 second cycle time 

will still be maintained. 

It is assumed that the refrigerator line will schedule the models which will receive VIPs an 

equivalent of three days or six shifts each week, or a maximum of 6,978 refrigerators with 

VIPs per week. These models normally wr: be 60% of each day's production or 1,396 per 

day on two shifts, but sufficient in-process storage is provided to support a continual two 

shift run. 

Both cabinet sizes use the same set of panels, giving slightly less coverage 'for the 24 foot as 

a trade off for increased manufacturing efficiency in the panel plant. The 18 foot model also 

could use these same panels. As the volume of models with VIPs increas.es, justifying a 

second panel line, panel sizes could be further tailored to specific models to attain greater 

energy improvement. 

Through analysis of an actual 18 cubic foot cabinet, optimum panellocatio~s and sizes 

were developed. All of these panels would, of course, fit into a 21 cubic foot and a 24 cubic 

foot cabinet since all of the dimensions are the same or slightly larger. A 21 cubic foot 

refrigerator with VIP locations is shown in Figure 4. 

-9-

· VACUUM INSULATION PANEL REQUIREMENTS 

This study assumes that all 21 and 24 cubic foot refrigerators made on this generic line will 

receiv·e vacuum insulation panels and the total annual volume of these models is 300,000 

per year. Eighteen cubic foot models are not included since this size is more Pri:ce sensitive 

and would be less likely to use VIPs. A thicker insulation alternative for smaller, more price 

sensitive models is discussed in "Thick Wall Alternatives". 

All of the 21 and 24 cubic foot models will be produced on the line with an annual capacity 

of 500,000, thus using 60% of that line's capacity. The other 40% would be used for 18' 

models. When running models with vacuum insulation panels, the 20 second cycle time 

will still be maintained. 

It is assumed that the refrigerator line will schedule the models which will receive VIPs an 

equivalent of three days or six shifts each week, or a maximum of 6,978 refrigerators with 

VIPs per week. These models normally wr: be 60% of each day's production or 1,396 per 

day on two shifts, but sufficient in-process storage is provided to support a continual two 

shift run. 

Both cabinet sizes use the same set of panels, giving slightly less coverage 'for the 24 foot as 

a trade off for increased manufacturing efficiency in the panel plant. The 18 foot model also 

could use these same panels. As the volume of models with VIPs increas.es, justifying a 

second panel line, panel sizes could be further tailored to specific models to attain greater 

energy improvement. 

Through analysis of an actual 18 cubic foot cabinet, optimum panellocatio~s and sizes 

were developed. All of these panels would, of course, fit into a 21 cubic foot and a 24 cubic 

foot cabinet since all of the dimensions are the same or slightly larger. A 21 cubic foot 

refrigerator with VIP locations is shown in Figure 4. 

-9-
Figure 4

Refrigerator Panel Locations

21ft3 Refrigerator with 10 Panels

 EE-RM-93-801 COMMENT OR5

Figure 4 

Refrigerator Panel Locations 

21 ft3 Refrigerator with 10 Panels 

-10-

Figure 4 

Refrigerator Panel Locations 

21 ft3 Refrigerator with 10 Panels 

-10-
There are ten panels in each refrigerator. The panels will be produced in five sizes with two

thicknesses (1/2" & 1") and two lengths (21" & 28"). Table 1 shows the panel dimensions for

each location and the installation area where they would be attached. Table 2 shows the

sizes for the barrier and porous pouch material required to produce the five panel sizes in

the panel plant.

A panel was not planned in the freezer back because interference with the suction line, ice.

maker fill tube, and air flow duct necessitated a small panel which was deemed ineffective.

A product redesign to relocate some of these could allow a freezer back panel to be large

enough to be justified.

 EE-RM-93-801 COMMENT OR5

There are ten panels in each refrigerator. The panels will be produced in five sizes with two 

thicknesses (lli" & 1 ") and two lengths (21 II & 28"). Table 1 shows the panel dimensions for 

each location and the installation area where they would be attached. Table 2 shows the 

sizes for the baIJ'ier and porous pouch material required to produce the five panel sizes in 

the panel plant. 

A panel was not planned in the freezer back because interf~rence with the suction line, ice. 

. maker fill tube, and air flow duct necessitated a small panel which was deemed ineffective. 

A product redesign to relocate some of these could allow a freezer back panel to be large 

enough to be justified. 

-11-

There are ten panels in each refrigerator. The panels will be produced in five sizes with two 

thicknesses (lli" & 1 ") and two lengths (21 II & 28"). Table 1 shows the panel dimensions for 

each location and the installation area where they would be attached. Table 2 shows the 

sizes for the baIJ'ier and porous pouch material required to produce the five panel sizes in 

the panel plant. 

A panel was not planned in the freezer back because interf~rence with the suction line, ice. 

. maker fill tube, and air flow duct necessitated a small panel which was deemed ineffective. 

A product redesign to relocate some of these could allow a freezer back panel to be large 

enough to be justified. 

-11-
Table 1

Vacuum Panels for 21' & 24' Refrigerators

PANEL # SIZE (INCHES) LOCATION INSTALLATION AREA

1 1 x 2l x 28 Freezer Top Case Pre-Foam

2&3 1 x 21 x 19 Freezer Sides Case Pre-Foam

4&6 1 x 21 x 30 Fresh Food Sides Case Pre-Foam

5 1 x 21 x 28 Fresh Food Back Liner Pre-Foam

7 0.5 x 28 x 10 Fresh Food Bottom Case Pre-Foam

8 0.5 x 28 x 19 Freezer Door Door Pre-Foam

9&10 0.5 x 28 x 19 Fresh Food Door Door Pre-Foam

Total area of panels = 35.5 square feet

Total weight of panels = 29 pounds

Total board feet = 29

 EE-RM-93-801 COMMENT OR5

I 

.... 

N 

I 

Table 1 

Vacuum Panels for 21' & 24' Refrigerators 

PANEL # SIZE (INCHES) 

1 1 x21 x28 

2&3 1 x 21 x 19 

4&6 1 x 21 x 30 

5 1 x21 x28 

7 0.5 x 28 x 10 

8 0.5x28 x 19 

9&10 0.5 x 28 x 19 

Total area of panels = 35.5 square feet 

Total weight of panels = 29 pounds 

Total board feet = 29 

LOCATION INSTALLATION AREA 

Freezer Top Case Pre-Foam 

Freezer Sides Case Pre-Foam 

F':'E:'sh Food Sides Case Pre-Foam 

Fresh Food Back Liner Pre-Foam 

Fresh Food Bottom Case Pre-Foam 

Freezer Door Door Pre-Foam 

Fresh Food Door Door Pre-Foam 

I 

.... 

N 

I 

Table 1 

Vacuum Panels for 21' & 24' Refrigerators 

PANEL # SIZE (INCHES) 

1 1 x21 x28 

2&3 1 x 21 x 19 

4&6 1 x 21 x 30 

5 1 x21 x28 

7 0.5 x 28 x 10 

8 0.5x28 x 19 

9&10 0.5 x 28 x 19 

Total area of panels = 35.5 square feet 

Total weight of panels = 29 pounds 

Total board feet = 29 

LOCATION INSTALLATION AREA 

Freezer Top Case Pre-Foam 

Freezer Sides Case Pre-Foam 

F':'E:'sh Food Sides Case Pre-Foam 

Fresh Food Back Liner Pre-Foam 

Fresh Food Bottom Case Pre-Foam 

Freezer Door Door Pre-Foam 

Fresh Food Door Door Pre-Foam 
Table 2 '

Vacuum Panels for 21' & 24' Refrigerators

MATERIAL SIZE (Inches)

PANEL #

SIZE

(Inches)

MATERIAL SIZE WITH FLANGES

POROUS POUCH BARRIER

(+1.5") (+2.0")

1&5 1x21x28 22.5x29.5 23x30

2&3 1x21x19 22.5x20.5 23x21

4&6 1 x21 x30 22.5x31.5 23x32

(+1.0") (+1.5")

7 .5x,28x10 29x11 29.5x11.5

8,9&10 .5x28x19 29x20 29.5x20.5

Total square inches 5726.5 5971.5

Total square feet x .2 (top & bottom) 79.5 82.9

 EE-RM-93-801 COMMENT OR5

I 

.... 

Co) 

I 

Table 2 

Vacuum Panels for 21' & 24' Refrigerators 

MATERIAL SIZE (Inches) 

MATERIAL SIZE WITH FLANGES 

SIZE 

PANEL # (Inches) POROUS POUCH BARRIER 

(+1.5") (+2.0") 

1&5 1 x 21 x 28 22.5 x 29.5 23)(30 

2&3 1 x 21 x 19 22.5 x 20.5 23 x 21 

4&6 1 x 21 x 30 22.5 x 31.5 23x32 

(+1.0") (+1.5") 

7 .5 x.28 x 10 29 x 11 29.5 x 11.5 

8,9 & 10 .5 x 28 x 19 29 x20 29.5 x 20.5 

Total square inches 5726.5 5971.5 

Total square feet x -2 (top & bottom) 79.5 82.9 

I 

.... 

Co) 

I 

Table 2 

Vacuum Panels for 21' & 24' Refrigerators 

MATERIAL SIZE (Inches) 

MATERIAL SIZE WITH FLANGES 

SIZE 

PANEL # (Inches) POROUS POUCH BARRIER 

(+1.5") (+2.0") 

1&5 1 x 21 x 28 22.5 x 29.5 23)(30 

2&3 1 x 21 x 19 22.5 x 20.5 23 x 21 

4&6 1 x 21 x 30 22.5 x 31.5 23x32 

(+1.0") (+1.5") 

7 .5 x.28 x 10 29 x 11 29.5 x 11.5 

8,9 & 10 .5 x 28 x 19 29 x20 29.5 x 20.5 

Total square inches 5726.5 5971.5 

Total square feet x -2 (top & bottom) 79.5 82.9 
VACUU M INSULATION PANEL MANUFACTURING

This section describes the facility, organization, materials, and equipment required to

produce three million VIPs per year for three hundred thousand 21 or 24 cubic foot refrigerators.

When selecting the location for the facility with regard to the appliance assembly plant,

several elements must be considered. Raw material sources and transportation, the possible

requirement to make VIPs for multiple assembly plants, and the trend away from vertical

integration and toward "assembly only" plants are all items which must be factored into

this decision.

Materials for VIPs were selected from those currently being used for R & D, and costs were

obtained from the materials manufacturers or their representatives.

The VIP manufacturing process was defined and the equipment selected after numerous

discussions with several parties yvl-.3 have produced VIPs for R & D; manufacturers of

form, fill, and seal equipment who incorporate vacuum packaging in their equipment;

users of form, fill, and seal equipment for vacuum packed products such as coffee; manufacturers of silica and bag materials; and many equipment manufacturers who supply

equipment which has the capability to perform portions of the VIP manufacturing process.

Some equipment manufacturers whose equipment was considered but not included in the

final design are included in the references.

VIP manufacturing is discussed in the following sections.

A. Facility and equipment

B. Panel plant organization and operation

C. Silica material

D. Bag materials

E. Silica material handling

 EE-RM-93-801 COMMENT OR5

VACUUM INSULATION PANEL MANUFACTURING 

This section describes the facility, organization, materials, and equipment required to 

produ~ three million VIPs per year for three hundred thousand 21 or 24 cubic foot refrigerators. 

When selecting the location for the facility ~th regard to the appliance assembly plant, 

several elements must be considered. Raw material sources and transportation, the possible 

requirement to make VIPs for multiple assembly plants, and the trend away from vertical 

integration and toward "assembly only" plants are all items which must be factored into 

this decision. 

M9.terials for VIPs were selected from those currently being used for R&D, and costs were 

obtained from the materials manufacturers or their representatives. 

The VIP manufacturing process was defined and the equipment selected after numerous 

discussions with several partie~ 'N'h.J have produced VIPs for R&D; manufacturers of 

form, fill, and seal equipment who incorporate vacuum packaging in their equipment; 

users of form, fill, and seal equipment for vacuum packed products such as coffee; manufacturers of silica and bag materials; and many equipment manufacturers who supply 

equipment which has the capability to perform portions of the VIP manufacturing process. 

Some equipment manufacturers whose equipment was considered but not included in the 

final design are included in the references. 

VIP manufa~ing is discussed in the following sections. 

A. Facility and equipment 

B. Panel plant organization and operation 

C. Silica material 

D. Bag materials 

E. Silica material handling 

-14-

VACUUM INSULATION PANEL MANUFACTURING 

This section describes the facility, organization, materials, and equipment required to 

produ~ three million VIPs per year for three hundred thousand 21 or 24 cubic foot refrigerators. 

When selecting the location for the facility ~th regard to the appliance assembly plant, 

several elements must be considered. Raw material sources and transportation, the possible 

requirement to make VIPs for multiple assembly plants, and the trend away from vertical 

integration and toward "assembly only" plants are all items which must be factored into 

this decision. 

M9.terials for VIPs were selected from those currently being used for R&D, and costs were 

obtained from the materials manufacturers or their representatives. 

The VIP manufacturing process was defined and the equipment selected after numerous 

discussions with several partie~ 'N'h.J have produced VIPs for R&D; manufacturers of 

form, fill, and seal equipment who incorporate vacuum packaging in their equipment; 

users of form, fill, and seal equipment for vacuum packed products such as coffee; manufacturers of silica and bag materials; and many equipment manufacturers who supply 

equipment which has the capability to perform portions of the VIP manufacturing process. 

Some equipment manufacturers whose equipment was considered but not included in the 

final design are included in the references. 

VIP manufa~ing is discussed in the following sections. 

A. Facility and equipment 

B. Panel plant organization and operation 

C. Silica material 

D. Bag materials 

E. Silica material handling 

-14-
F. Flash drying

G. - Silo storage

H. Densifying

I. Bag filling

J. Panel manufacturing line

K. Quality control

L. Packaging

M. Bar coding

N. Shipping and transportation

0. Safety and environmental considerations

A. Facility and Equipment

It was assumed that the panel plant would be built 100 miles from the refrigerator plant

and next to the silica plant, and that the silica plant would be next to the silicate plant.

Sodium silicate and sulfuric acid are the raw materials for the production of precipitated

silica. A major consideration for the location of the complex would be transportation means

and routes for sand and soda ash, which are the raw materials for sodium silicate.

About three pounds of sodium silicate are required to produce one pound of silica: Silica is

transferred to the VIP plant at about four pounds per cubic foot and completed VIPs are

about 12 pounds per cubic foot. These ratios suggest that shipping VJPs may be less expensive than shipping silica or its raw materials.

The building would be sized to accommodate three panel lines for future expansion to ten

million panels (one million refrigerators) per year. Cost for only one panel line and supporting equipment is included in this study. Building cost was estimated based on actual

cost of a recent plant and includes normal power distribution, lighting, offices, heating and

air conditioning, and other utility equipment plus truck docks, parking lot, landscaping,

roads, etc.

 EE-RM-93-801 COMMENT OR5

F. Flash drying 

G. - Silo storage 

H. Densifying 

1. Bag filling 

J. Panel manufacturing line 

K. Quality control 

L. Packaging 

M. Bar coding 

N. Shipping and transportation 

O. -Safety and environmental considerations 

-A. Facility and Equipment 

It was assumed that the panel plant would be built 100 miles from the refrigerator plant 

and next to the silica plant, and that the silica plant would be next to the silicate plant. 

Sodium silicate and sulfuric acid are the raw materials for the production of precipitated 

silica. A major consideration for the location of the complex would be transportation means 

and routes for sand and soda ash, which are the raw materials for sodium silicate. 

About three pounds of sodium silicate are required to produce one pound of silica; Silica is 

transferred to the VIP plant at about four pounds per cubic foot and completed VIPs are 

about 12 pounds per cubic foot. These ratios suggest that shipping VIPs may be less expensive than shipping silica or its raw materials. 

The building would be sized to accommodate three panel lines for future expansion to ten 

million panels (one million refrigerators) per year. Cost for only one panel fine and supporting equipment is included in this study. Building cost was estimated based on actual 

cost of a recent plant and includes normal power distribution, lighting, offices, heating and 

air conditioning, and other utility equipment plus truck docks, parking lot, landscaping, 

roads, etc. 

-15-

F. Flash drying 

G. - Silo storage 

H. Densifying 

1. Bag filling 

J. Panel manufacturing line 

K. Quality control 

L. Packaging 

M. Bar coding 

N. Shipping and transportation 

O. -Safety and environmental considerations 

-A. Facility and Equipment 

It was assumed that the panel plant would be built 100 miles from the refrigerator plant 

and next to the silica plant, and that the silica plant would be next to the silicate plant. 

Sodium silicate and sulfuric acid are the raw materials for the production of precipitated 

silica. A major consideration for the location of the complex would be transportation means 

and routes for sand and soda ash, which are the raw materials for sodium silicate. 

About three pounds of sodium silicate are required to produce one pound of silica; Silica is 

transferred to the VIP plant at about four pounds per cubic foot and completed VIPs are 

about 12 pounds per cubic foot. These ratios suggest that shipping VIPs may be less expensive than shipping silica or its raw materials. 

The building would be sized to accommodate three panel lines for future expansion to ten 

million panels (one million refrigerators) per year. Cost for only one panel fine and supporting equipment is included in this study. Building cost was estimated based on actual 

cost of a recent plant and includes normal power distribution, lighting, offices, heating and 

air conditioning, and other utility equipment plus truck docks, parking lot, landscaping, 

roads, etc. 

-15-
The building would be air conditioned to provide the required humidity control as well as

employee comfort. There would be one sheltered, two trailer receiving dock and one sheltered, two trailer shipping dock. A layout of the panel plant is shown in Figure 5.

The panel plant equipment, which will be discussed in detail later, is summarized in Table

3, along with the estimated costs. A 25% contingency, commonly used by manufacturers

for feasibility study estimates, has been included.

B. Plant organization and operation

The plant will have nine salaried and 22 hourly personnel, as shown on the organization

chart in Figure 6. Hourly personnel will be paid on a day work plan. Position descriptions

for all personnel will allow them to do any job which they are capable of performing. Cross

training and job flexibility will be rewarded with higher hourly rates.

Quality control personnel will be responsible for inspection work as well as quality engineering and process cor irol. Foremen will be responsible for process control and have

dotted line responsibility to the quality control manager. The quality control manager will

also be responsible for safety and OSHA compliance.

Machine control personnel will be responsible for set-up, machine control, process control,

loading material on and off equipment, minor maintenance and unjamming, preventive

maintenance, and housekeeping in their area.

Shipping material handlers will be responsible for loading trailers and keeping the line

stocked with material, which will be done primarily during changeovers. Three operators

are planned on each shift so that adequate relief to trailer loaders can be provided by assignment rotation. Panel plant operating personnel and costs are summarized in Table 4.

 EE-RM-93-801 COMMENT OR5

-

The building wo~d be air conditioned to provide the required humidity control as well as . 

employee comfort. There would be one sheltered, two trailer receiving dock and one sheltered, two trailer shipping dock. A layout of the panel plant is shown in Figure 5. 

The panel plant equipment, which will be discussed in detail later, is summarized in Table 

3, along with the estimated costs. A 25% contingency, commonly used by manufacturers 

for feasibility study estimates, has been included. 

B. Plant organization and operation 

The plant will have nine salaried and 22 hourly personnel, as shown on the organization 

chart in Figure 6. Hourly personnel will be paid on a day work plan. Position descriptions 

f~r all personnel will allow them to do any job which they are capable of performing. Cross 

training and job flexibility will be rewarded with higher hourly rates. 

Quality control personnel will be responsible for inspection work as well as qualityengineering and process cor 'rol. Foremen will be responsible for process control and have 

dotted line responsibility to the quality control manager. The quality control manager will 

also be responsible for safety and OSHA compliance. 

Machine control personnel will be responsible for set-up, machine control, process control, 

loading material on and off equipment, minor maintenance and unjamming, preventive 

maintenance, and housekeeping in their area. 

Shipping material handlers will be responsible for loading trailers and keeping the line 

stocked with material, which will be done primarily during changeovers. Three oPerators 

are planned on each shift so that adequate relief to trailer loaders can be provided by assigtUl}ent rotation. Panel plant operating personnel and costs are summarized in Table 4. 

-16-

-

The building wo~d be air conditioned to provide the required humidity control as well as . 

employee comfort. There would be one sheltered, two trailer receiving dock and one sheltered, two trailer shipping dock. A layout of the panel plant is shown in Figure 5. 

The panel plant equipment, which will be discussed in detail later, is summarized in Table 

3, along with the estimated costs. A 25% contingency, commonly used by manufacturers 

for feasibility study estimates, has been included. 

B. Plant organization and operation 

The plant will have nine salaried and 22 hourly personnel, as shown on the organization 

chart in Figure 6. Hourly personnel will be paid on a day work plan. Position descriptions 

f~r all personnel will allow them to do any job which they are capable of performing. Cross 

training and job flexibility will be rewarded with higher hourly rates. 

Quality control personnel will be responsible for inspection work as well as qualityengineering and process cor 'rol. Foremen will be responsible for process control and have 

dotted line responsibility to the quality control manager. The quality control manager will 

also be responsible for safety and OSHA compliance. 

Machine control personnel will be responsible for set-up, machine control, process control, 

loading material on and off equipment, minor maintenance and unjamming, preventive 

maintenance, and housekeeping in their area. 

Shipping material handlers will be responsible for loading trailers and keeping the line 

stocked with material, which will be done primarily during changeovers. Three oPerators 

are planned on each shift so that adequate relief to trailer loaders can be provided by assigtUl}ent rotation. Panel plant operating personnel and costs are summarized in Table 4. 

-16-
Figure 5

Panel Plant Layout

(44,400 square feet)

290'

I

Utilities

Rest

Room Stock Room

KDO

11

Erptoyee

Area

Receiving

Truck Dock

Future

Truck Dock

Future

Truck Dock

Shipping

Truck Dock

1. Incoming Silica from

Silica Plant

2, Flash Dryers

3. Silica Silos

4, Future Silos

5. Densif iers

6. Foal, Fill, & Seat Line

7, Reseal Stations

8, Stack & Bundle Station

9. Bar Code Applicator

10, Ad justoveyor

11; Future Panel Lines

 EE-RM-93-801 COMMENT OR5

IRest 

Utilities ROOM 

I 

.... 

....... 

I 

100' 

t 

MOintenonce Q C 

lI' Lob' 

~Ilr~ 

U 

11 

6 

FigureS 

Panel Plant Layout 

(44

1400 square feet) 

240' 

Stock ROOM 

10 

Mo.ln Offices Erployee OOM AreQ 

-\ 

Receiving 

Truck Dock 1. IncOMhg Silicll fro", 

SllCll Plllnt 

Future 2, nQsh Dryers 

Truck Dock 3, SticQ S«os 

Future 4, r utt.re Silos 

Truck Dock 5, Denslflers 

Shipping 6, rorl\ rll~ & SeQt L~ 

Truck Dock 7, ReseQt StQtlons 

8, StQck & BuMle StQtlon 

9, Bar Code AwticQtor 

10. Ad}JStoveyor 

11; r uve PQnel lines 

IRest 

Utilities ROOM 

I 

.... 

....... 

I 

100' 

t Q C 

lI' MOintenonce Lob' 

~Ilr~ 

U 

11 

6 

FigureS 

Panel Plant Layout 

(44

1400 square feet) 

240' 

Stock ROOM 

10 

est 

Mo.ln Offices Erployee OOM AreQ 

-\ 

Receiving 

Truck Dock 1. IncOMhg Silicll fro", 

SllCll Plllnt 

Future 2, nQsh Dryers 

Truck Dock 3, SticQ S«os 

Future 4, r utt.re Silos 

Truck Dock 5, Denslflers 

Shipping 6, rorl\ rll~ & SeQt L~ 

Truck Dock 7, ReseQt StQtlons 

8, StQck & BuMle StQtlon 

9, Bar Code AwticQtor 

10. Ad}JStoveyor 

11; r uve PQnel lines 
Table 3

Panel Plant Equipment

EQUIPMENT NUMBER VENDOR CQ"'/UNIT TOTAL SHIPPING INSTALLATION TOTAL COST

Silos 2 Peabody $50,000 $100,000 $3,000 $8,000 $111,000

Pneumatic system Roessler 210,000 2,500 21,000 233,500

Flash dryer 1 Aljet 440,000 440,000 8,800 44,000 492,800

Densifier 1 Aljet 200,000 200,000 4,000 20,000 224,000

Auger filler 1 Mateer-Burt , 15,000 15,000 450 3,000 18,450

Form, fill, and seal 1 Fres-Co 5,000,000 5,000,000 150,000 11000,000 6,150,000

Hot bar reseal 1 Fres-Co 50,000 50,000 50,000

Vacuum check 1 Taptone 25,000 25,000 250 5,000 30,250

Bundle stacking 1 Zellerbach 50,000 50,000 1,000 5,000 56,000

Auto pack 1 Zellerbach 13,000 13,000 100 1,300 14,400

Bar code 1 Zellerbach 21,000 21,000 500 1,000 22,500

Adjustoveyor 1 Stewart Glapat 50,000 50,000 $2,000 $2,000 54,000

Tractors 2 Kenworth 60,000 120,000 N/A N/A 120,000

Trailers 6 Dorsey 16,000 96,000 N/A N/A 96,000

QC lab equipment 1 Various 100,000 100,000

Maintenance equipment Various 50,000 50,000

Fork/coil truck 1 Clark 40,000 40,000 40,000

Spare parts 5% of selected eq. 250,000 250,000

Building 1 44,400 sq. ft. $85/sq. ft. 3,774,000 3,774,000

band 100,000 100,000

Office equipment $25,000 $25,000

Total equipment cost

Contingency 25%

$12,011,900

3,002,975

Total with contingency $15,014,875'

 EE-RM-93-801 COMMENT OR5

I 

... 

Q) 

I 

EQUIPMENT 

Silos 

Pneumatic system 

Flash dryer 

Densifier 

Auger filler 

Fonn, fill, and seal 

Hot bar reseal 

Vacuum check 

Bundle stacking 

Auto pack 

Barcode 

Adjustoveyor 

Tractors 

Trailers 

QC lab equipment 

Maintenance equipment 

Fork/ coil truck 

Spare parts 

Building 

Land 

Office equipment 

Total equipment cost 

Contingency 25% 

Total with contingency 

NUMBER 

2 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

2 

6 

1 

1 

1 

Table 3 

Panel Plant Equipment 

VENOOR CO':'/UNIT TOTAL 

Peabody $50,000 $100,000 

Roessler 210,000 

Aljet 440,000 440,000 

Aljet 200,000 200,000 

Mateer-Burt J 15,000 15,000 

Fres-Co 5,000,000 5,000,000 

Fres-Co 50,000 50,000 

Taptone 25,000 25,000 

Zellerbach 50,000 50,000 

Zellerbach . 13,000 13,000 

Zellerbach 21,000 21,000 

Stewart Glapat 50,000 SO,OOO 

Kenworth 60,000 120,000 

Dorsey 16,000 96,000 

Various 100,000 

Various SO,Ooo 

Clark 40,000 40,000 

5% of selected eq. 250,000 

44,400 sq. ft. $85/sq. ft. 3,774,000 

100,000 

$25,000 

SI-llPPING INSTALLA nON 

$3,000 $8,000 

2,500 21,000 

8,800 44,000 

4,000 20,000 

450 3,000 

150,000 1,000,000 

250 5,000 

1,000 5,000 

100 1,300 

500 1,000 

$2,000 $2,000 

N/A N/A 

N/A N/A 

TOTAL COST 

$111,000 

233,500 

492,800 

224,000 

18,450 

6,150,000 

50,000 

30,250 

56~000 

14,400 

22,500 

54,000 

120,000 

96,000 

100,000 

SO,OOO 

40,000 

250,000 

3,774,000 

100,000 

$25,000 

$12,011,900 

3,002,975 

$15,014,875 ' 

I 

... 

Q) 

I 

EQUIPMENT 

Silos 

Pneumatic system 

Flash dryer 

Densifier 

Auger filler 

Fonn, fill, and seal 

Hot bar reseal 

Vacuum check 

Bundle stacking 

Auto pack 

Barcode 

Adjustoveyor 

Tractors 

Trailers 

QC lab equipment 

Maintenance equipment 

Fork/ coil truck 

Spare parts 

Building 

Land 

Office equipment 

Total equipment cost 

Contingency 25% 

Total with contingency 

NUMBER 

2 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

2 

6 

1 

1 

1 

Table 3 

Panel Plant Equipment 

VENOOR CO':'/UNIT TOTAL 

Peabody $50,000 $100,000 

Roessler 210,000 

Aljet 440,000 440,000 

Aljet 200,000 200,000 

Mateer-Burt J 15,000 15,000 

Fres-Co 5,000,000 5,000,000 

Fres-Co 50,000 50,000 

Taptone 25,000 25,000 

Zellerbach 50,000 50,000 

Zellerbach . 13,000 13,000 

Zellerbach 21,000 21,000 

Stewart Glapat 50,000 SO,OOO 

Kenworth 60,000 120,000 

Dorsey 16,000 96,000 

Various 100,000 

Various SO,Ooo 

Clark 40,000 40,000 

5% of selected eq. 250,000 

44,400 sq. ft. $85/sq. ft. 3,774,000 

100,000 

$25,000 

SI-llPPING INSTALLA nON 

$3,000 $8,000 

2,500 21,000 

8,800 44,000 

4,000 20,000 

450 3,000 

150,000 1,000,000 

250 5,000 

1,000 5,000 

100 1,300 

500 1,000 

$2,000 $2,000 

N/A N/A 

N/A N/A 

TOTAL COST 

$111,000 

233,500 

492,800 

224,000 

18,450 

6,150,000 

50,000 

30,250 

56~000 

14,400 

22,500 

54,000 

120,000 

96,000 

100,000 

SO,OOO 

40,000 

250,000 

3,774,000 

100,000 

$25,000 

$12,011,900 

3,002,975 

$15,014,875 ' 
Figure 6

Panel Plant Organization

PLANT MANAGER

Psecretary

FOREMAN - 1st. QUALITY CONTROL

MANAGER

Maintenance - skilled

Maintenance - unskilled

Shipping & Mati. Handling (3)

Control men (2)

FOREMAN - 2nd

Maintenance - skilled

Shipping & Mati. Handling (3)

Control men - (2)

FOREMAN - 3rd

Maintenance - skilled

Maintenance - unskilled

Shipping & Matl. Handling (3)

Control Men (2)

Technician

MATERIAL CONTRO

MANAGER

Truck driver 1st.

Truck driver 2nd.

FINANCIAL

MANAGER

 EE-RM-93-801 COMMENT OR5

I 

..... 

CD 

I 

Figure 6 

Panel Plant Organization 

I PLANT MANAGERl 

~ Secretary 

I I I 

FOREMAN - 1 st. QUALITY CONTROL MATERIAL CONTROL 

MANAGER 

c-- Maintenance - skilled 

~ Maintenance - unskilled 

- Shipping & MatI. Handling (3) 

- Control men (2) 

FOREMAN - 2nd 

f-- Maintenance - skilled 

I--Shipping & MatI. Handling (3) 

'-- Control men - (2) 

FOREMAN - 3rd 

Maintenance - skilled 

Maintenance - unskilied 

Shipping & MatI. Handling (3) 

Control Men (2) 

'-- Technician 

MANAGER 

I-- Truck driver 1 st. 

'-- Truck driver 2nd. 

I 

FINANCIAL 

MANAGER 

I 

..... 

CD 

I 

Figure 6 

Panel Plant Organization 

I PLANT MANAGER I 

~ Secretary 

r I I 

FOREMAN - 1 st. QUALITY CONTROL MATERIAL CONTROL 

MANAGER 

f-- Maintenance - skilled 

f-- Maintenance - unskilled 

f-- Shipping & MatI. Handling (3) 

"---- Control men (2) 

FOREMAN - 2nd 

f-- Maintenance - skilled 

f-- Shipping & MatI. Handling (3) 

"-- Control men - (2) 

FOREMAN - 3rd 

Maintenance - skilled 

Maintenance - unskilied 

Shipping & MatI. Handling (3) 

Control Men (2) 

'-- Technician 

MANAGER 

- Truck driver 1 st. 

'-- Truck driver 2nd. 

1 

FINANCIAL 

MANAGER 
Table 4

Annual Operatir"j Cost - Panel Plant

NUMBER HOURLY RATE ANNUAL WAGE BENEFITS OVERHEAD ANNUAL COST

SALARIED PERSONNEL (40%) (140%)

Plant manager 1 $40,000 $16,000 $56,000

Financial manager 1 30,000 12,000 42,000

Quality control manager 1 30,000 12,000 42,000

QC technician 1 20,000 8,000 28,000

Foreman 3 25,000 10,000 105,000

Material control 1 20,000 8,000 28,000

Secretary 1 16,000 6,400 22,400

Total Salaries 323,400

HOURLY PERSONNEL

Maintenance-skilled 3 $15.00 31,200 $43,680 224,640

Maintenance-unskilled 2 8.00 16,640 23,296 79,872

Shipping and materials handlers 9 8.00 16,640 23,296 359,424

Control men 6 12.00 24,960 34,944 359,424

Total Hourly Wages 1,023,360

TRANSPORTATION COST

Truck drivers 2 $15.00 $31,200 $43,680 149,760

Truck operation 48,000

Total Transportation Costs 197,760

OTHER OPERATING COSTS 267,280

TOTAL PLANT OPERATING COST $1,811,800

 EE-RM-93-801 COMMENT OR5

I 

~ 

o 

I 

Table 4 

Annual Operatir'l Cost - Panel.Plant 

NUMBER HOURLY RATE ANNUAL WAGE BENEFITS 

SALARIED PERSONNEL (40%) 

Plant manager 1 $40,000 $16,000 

Financial manager 1 30,000 12,000 

Quality control manager 1 30,000 12,000 

QC technician 1 20,000 8,000 

Foreptan 3 25,000 10,000 

Material control 1 20,000 8,000 

Secretary 1 16,000 6,400 

Total Salaries 

HOURLY PERSONNEL 

Maintenance-skilled 3 $15.00 31,200 

Maintenance-unskilled 2 8.00 16,640 

Shipping and materials handlers 9 8.00 16,640 

Control men 6 12.00 24,960 

Total Hourly Wages 

TRANSPORTATION COST 

Truck drivers 2 $15.00 $31,200 

Truck operation 

Total Transportation Costs 

OTHER OPERATING COSTS 

TOTAL PLANT OPERATING COST 

OVERHEAD ANNUAL COST 

(140%) 

$56,000 

42,000 

42,000 

28,000 

105,000 

28,000 

22,400 

323,400 

$43,680 224,640 

23,296 79,872 

23,296 359,424 

34,944 359,424 

1,023,360 

$43,680 149,760 

48,000 

197,760 

267,280 

$1,811,800 

I 

~ 

o 

I 

Table 4 

Annual Operatir'l Cost - Panel.Plant 

NUMBER HOURLY RATE ANNUAL WAGE BENEFITS 

SALARIED PERSONNEL (40%) 

Plant manager 1 $40,000 $16,000 

Financial manager 1 30,000 12,000 

Quality control manager 1 30,000 12,000 

QC technician 1 20,000 8,000 

Foreptan 3 25,000 10,000 

Material control 1 20,000 8,000 

Secretary 1 16,000 6,400 

Total Salaries 

HOURLY PERSONNEL 

Maintenance-skilled 3 $15.00 31,200 

Maintenance-unskilled 2 8.00 16,640 

Shipping and materials handlers 9 8.00 16,640 

Control men 6 12.00 24,960 

Total Hourly Wages 

TRANSPORTATION COST 

Truck drivers 2 $15.00 $31,200 

Truck operation 

Total Transportation Costs 

OTHER OPERATING COSTS 

TOTAL PLANT OPERATING COST 

OVERHEAD ANNUAL COST 

(140%) 

$56,000 

42,000 

42,000 

28,000 

105,000 

28,000 

22,400 

323,400 

$43,680 224,640 

23,296 79,872 

23,296 359,424 

34,944 359,424 

1,023,360 

$43,680 149,760 

48,000 

197,760 

267,280 

$1,811,800 
C. Silica material

The silica used for filling the panel is FK500LS, supplied by Degussa [4]. A product information sheet is shown in Appendix A. Material cost is assumed to be $0.75/pound, as

stated in a letter from Degussa (formerly North America Silica) to Mr. Alan Fine, EPA, on

June 11,1991 (Appendix B).

Flash drying and densifying equipment provided in this plant would most likely facilitate

the use of a less expensive silica with a larger particle size and higher moisture content.

Thus, it may prove feasible to start with a less expensive silica by doing further processing

in the panel plant. Whether or not this is feasible would have to be determined through R

& D and pilot operations where trade-offs between panel unit cost and insulation efficiency

could be evaluated.

D. Bag materials

The microporous bag, which will contain the silica during compaction and evacuation, is

TYVEK supplied by Snow Filtration, Cincinnati, Ohio [23]. This material is quoted at

$0.036/ square foot in the volumes assumed for this study.

The barrier bag, which retains the vacuum, is VECAT. A multi-layered material supplied

by Fres-Co System USA, Inc., Telford, Pa.[l]. It is quoted at $0.111/square foot at the volumes assumed for this study.

E. Silica material handling

Silica is transferred by a Vac-U-Max pneumatic system (Roessler) [9] from the silica plant,

assumed to be adjacent to the panel plant, into a flash drier located in the panel plant and

then into a silo, as shown in the flow chart in Figure 7. Silica coming into the panel plant

has an average particle size of 3.5 microns, a density of four pounds per cubic foot, and a

moisture content of 3-4%.

 EE-RM-93-801 COMMENT OR5

c. Silica material 

. 

The silica used for filling the panel is FK500lS, supplied by Degussa [4]. A product information sheet is.shown in Appendix A. Material cost is assumed to be $O.75/pound, as 

stated in a letter from Degussa (formerly North America Silica) to Mr. Alan Fine, EPA, on 

June 11,1991 (Appendix B). 

Flash drying and densifying equipment provided in this plant would most likely facilitate 

the use of a less expensive silica with a larger particle size and higher moisture content. 

Thus, it may prove feasible to start with a less expensive silica by doing further processing 

in the panel plant. Whether or not this is feasible would have to be determined through R 

& D and pilot operations where trade-offs between panel unit cost and insulation efficiency 

could be evaluated. 

D. Bag materials 

The microporous bag, which will contain the silica during compaction and evacuation, is 

TYVEK supplied by Snow Filtration, Cincinnati, Ohio [23]. This material is quoted at 

$0.036/ square foot in the volumes assumed for this study. 

The barrier bag, which retains the vacuum, is VECAT. A multi-layered material supplied 

by Fres-Co System USA, Inc., Telford, Pa. [1]. It is quoted at $0.111/ square foot at the volumes assumed for this study. 

E. Silica material handling 

Silica is transferred by a Vac-U-Max pneumatic system (Roessler) [9] from the silica plant, 

assumed to be adjacent to the panel plant, into a flash drier located in the panel plant and 

then into a silo, as shown in the flow chart in Figure 7. Silica coming into the panel plant 

has an average particle size of 3.5 microns, a density of four pounds per cubic foot, and a 

moisture content of 3-4%. 

-21-

c. Silica material 

. 

The silica used for filling the panel is FK500lS, supplied by Degussa [4]. A product information sheet is.shown in Appendix A. Material cost is assumed to be $O.75/pound, as 

stated in a letter from Degussa (formerly North America Silica) to Mr. Alan Fine, EPA, on 

June 11,1991 (Appendix B). 

Flash drying and densifying equipment provided in this plant would most likely facilitate 

the use of a less expensive silica with a larger particle size and higher moisture content. 

Thus, it may prove feasible to start with a less expensive silica by doing further processing 

in the panel plant. Whether or not this is feasible would have to be determined through R 

& D and pilot operations where trade-offs between panel unit cost and insulation efficiency 

could be evaluated. 

D. Bag materials 

The microporous bag, which will contain the silica during compaction and evacuation, is 

TYVEK supplied by Snow Filtration, Cincinnati, Ohio [23]. This material is quoted at 

$0.036/ square foot in the volumes assumed for this study. 

The barrier bag, which retains the vacuum, is VECAT. A multi-layered material supplied 

by Fres-Co System USA, Inc., Telford, Pa. [1]. It is quoted at $0.111/ square foot at the volumes assumed for this study. 

E. Silica material handling 

Silica is transferred by a Vac-U-Max pneumatic system (Roessler) [9] from the silica plant, 

assumed to be adjacent to the panel plant, into a flash drier located in the panel plant and 

then into a silo, as shown in the flow chart in Figure 7. Silica coming into the panel plant 

has an average particle size of 3.5 microns, a density of four pounds per cubic foot, and a 

moisture content of 3-4%. 

-21-
Figure 7

Silica Processing Flow Chart

Transfer from silica

MOISTURE DENSITY

3-4% 41b/ft3

plant to flash dryer

Flash Dry < 1 % 1 lb/ft3

Transfer to silo

Store in silo

Transfer to densifier

Densify

settle back

to 4 lb/ft3

8 - 10 lb/ft3

Transfer to VIP line

Product VIPs < 1 % final density

12 lb/ft3

Silica will flow from the silica plant to the VIP plant at a rate of 2000 to 2200

pounds per hour.

VIPs will be produced at a rate of 900 per hour less losses for downtime,

rejects, etc., and changeovers of one to three hours between panel runs.

 EE-RM-93-801 COMMENT OR5

\ 

Figure 7 

Silica Processing Flow Chart 

MOISTURE DENSITY 

Transfer from silica 3-4% 4lb/ft3 

plant to flash dryer 

I 

Flash Dry <1% 1lb/ft3 

I 

Transfer to silo 

I 

Store in silo settle back 

I to 4Ib/ft3 

Transfer to densifier 

I 

Densify 8 - 10 lb/ft:i 

I 

Transfer to VIP line 

J 

Product VIPs <1% final density 

121b/ft3 

Silica will flow from the silica plant to the VIP plant at a rate of 2000 to 2200 

pounds per hour. 

VIPs will be produced at a rate of 900 per hour less losses for downtime, 

rejects, etc., and changeovers of one to three hours between panel runs. 

-22-

\ 

Figure 7 

Silica Processing Flow Chart 

MOISTURE DENSITY 

Transfer from silica 3-4% 4lb/ft3 

plant to flash dryer 

I 

Flash Dry <1% 1lb/ft3 

I 

Transfer to silo 

J 

Store in silo settle back 

I to 4Ib/ft3 

Transfer to densifier 

I 

Densify 8 - 10 lb/ft:i 

I 

Transfer to VIP line 

I 

Product VIPs <1% final density 

121b/ft3 

Silica will flow from the silica plant to the VIP plant at a rate of 2000 to 2200 

pounds per hour. 

VIPs will be produced at a rate of 900 per hour less losses for downtime, 

rejects, etc., and changeovers of one to three hours between panel runs. 

-22-
Silica usage will average 16,000 to 18,000 pounds per eight hour shift (see Table 5). Maximum usage with the line operating at 100% efficiency, no changeovers and producing the

largest panel (#4 & #6) will be 31,536 pounds per eight hour shift.

F. Flash Drying

Silica coming into the panel plant from the silica plant would first be processed through a

fl ash drier before entering a silo.

Experimental panel manufacturing processes have dried the silica in an oven after it has

been put into the porous bag. This process is acceptable for R & D but was judged too

expensive for high volume production.

The flash drier is designed to reduce the moisture content of the silica from 3 to 4% to less

than 1%. The equipment selected for this application is a Jet-O-Drier® produced by Fluid

Energy Aljet [6]. The Jet-O-Drier is a flash/spray drier with a material retention time of less

than one second. This equipment can accommodate very high inlet temperatures without

causing product degradation while still maintaining a low outlet temperature.

Aljet's description of the Jet-O-Drier operating principle is:

"Drying gas, usually air, is pressurized, heated, and introduced into the Jet-O-Drier

by specially designed nozzles. The energy of the pressurized hot fluid (or wet powder) is converted into velocity. The directional flow from the nozzles develops a

controlled high velocity drier circuit. The system velocity is balanced by mass flow

and evaporative rate which maintains a system pressure inside the drier slightly

above atmospheric. Wet solids are introduced pneumatically or by means of a rotary

vane. The violent action in the drying chamber deagglomerates the individual partides, thereby exposing enormously large drying surfaces. At the drier outlet the

finely dispersed dry particles are removed by the frictional drag of the exhausting

gases and the heavier moist particles are returned to the drying chamber due to their

higher momentum."

-23-

 EE-RM-93-801 COMMENT OR5

Silica usage will average 16,000 to 18,000 P9unds per eight hour shift (see Table 5). Maxi~· 

mw;:n usage wit..'l the line operating at 100% efficiency, no changeovers and producing the 

largest panel (#4 & #6) will be 31,536 pounds per eight hour shift. 

F. Flash Drying 

Silica coming into the panel plant from the silica plant would first be processed through a 

flash drier before entering a silo. 

Experimental panel manufacturing processes have dried the silica in an oven after it has 

been put into the porous bag. This process is acceptable for R&D but was judged too 

expensive for high volume production. 

The flash drier is designed to reduce the moisture content of the silica from 3 to 4% to less 

than 1 %. The equipment selected for this application is a Jet-O-Drier® produced by Fluid 

Energy Aljet [6]. ~e Jet-O-Drier is a flash/spray drier with a material retention time of less 

than one second. This equipment can accommodate very high inlet temperatures without 

causing product degradation while still maintaining a low outlet temperature. 

Aljet's description of the Jet-O-Drier operating principle is: 

"Drying gas, usually air, is pressurized, heated, and introduced into the Jet-O-Drier 

by specially designed nozzles. The energy of the pressurized hot fluid (or wet powder) is converted into velocity. The directional flow from the nozzles develops a 

controlled high velocity drier circuit. The system velocity is balanced by mass flow 

and evaporative rate which maintains a system pressure inside the drier slightly 

above atmospheric. Wet solids are introduced pneumatically or by Il)eans of a rotary 

vane. The violent action in the drying chamber deagglomerates the individual particles, thereby exposing enormously large drying surfaces. At the .drier outlet the 

finely dispersed dry particles are removed by the frictional drag of the exhausting 

gases and the heavier moist particles are returned to the drying chamber due to their 

higher momentum." 

-23-

Silica usage will average 16,000 to 18,000 P9unds per eight hour shift (see Table 5). Maxi~· 

mw;:n usage wit..'l the line operating at 100% efficiency, no changeovers and producing the 

largest panel (#4 & #6) will be 31,536 pounds per eight hour shift. 

F. Flash Drying 

Silica coming into the panel plant from the silica plant would first be processed through a 

flash drier before entering a silo. 

Experimental panel manufacturing processes have dried the silica in an oven after it has 

been put into the porous bag. This process is acceptable for R&D but was judged too 

expensive for high volume production. 

The flash drier is designed to reduce the moisture content of the silica from 3 to 4% to less 

than 1 %. The equipment selected for this application is a Jet-O-Drier® produced by Fluid 

Energy Aljet [6]. ~e Jet-O-Drier is a flash/spray drier with a material retention time of less 

than one second. This equipment can accommodate very high inlet temperatures without 

causing product degradation while still maintaining a low outlet temperature. 

Aljet's description of the Jet-O-Drier operating principle is: 

"Drying gas, usually air, is pressurized, heated, and introduced into the Jet-O-Drier 

by specially designed nozzles. The energy of the pressurized hot fluid (or wet powder) is converted into velocity. The directional flow from the nozzles develops a 

controlled high velocity drier circuit. The system velocity is balanced by mass flow 

and evaporative rate which maintains a system pressure inside the drier slightly 

above atmospheric. Wet solids are introduced pneumatically or by Il)eans of a rotary 

vane. The violent action in the drying chamber deagglomerates the individual particles, thereby exposing enormously large drying surfaces. At the .drier outlet the 

finely dispersed dry particles are removed by the frictional drag of the exhausting 

gases and the heavier moist particles are returned to the drying chamber due to their 

higher momentum." 

-23-
Table 5

Average Silica Use Per 8 Hour Shift

@ 85% Efficiency on Panel Line

PANEL # LBS./PANEL PANELS/8 HRS. TOTAL WEIGHT (LBS.)

1 4.08 612 2497

2 2.77 612 1695

3 2.77 612 1695

4 4.38 612 2681

5 4.08 612 2497

6 4.38 612 2681

7 0.97 612 594

8 1.85 612 1132

9 1.85 612 1132

10 1.85 612 1132

Totals 28.98 6120 17736

NOTE:

1. 17,700 lbs./shift © 4 lbs/ft3 = 4,430 ft3/shift or about 0.6 silos

2. Actual silica use per shift will vary from 5900 lbs (panel #7) to about

30,000 lbs (panel 4&6) depending on which panels are being run.

 EE-RM-93-801 COMMENT OR5

I 

I\,) 

.Ilo 

I 

Table 5 

Average Silica Use Per 8 Hour Shift 

@ 85% Efficiency on Panel Line 

PANEL # LBS'/PANEL P ANELS/8 HRS. TOTAL WEIGHT (LBS.) 

1 4.08 612 

2 2.77 612 

3 2.77 612 

4 4.38 612 

5 4.08 612 

6 4.38 612 

7 0.97 612 

8 1.85 612 

9 1.85 612 

10 1.85 612 

Totals 28.98 6120 

NOTE: 

1. 17,700 lbs./shift @4Ibs/ft3 = 4,430 ft3/shift or about 0.6 silos 

2. Actual silica use per shift will vary from 5900 lbs (panel #7) to about 

30,000 lbs (panel 4&6) depending on which panels are being run. 

2497 

. 1695 

1695 

2681 

2497 

2681 

594 

1132 

1132 

1132 

17736 

I 

I\,) 

.Ilo 

I 

Table 5 

Average Silica Use Per 8 Hour Shift 

@ 85% Efficiency on Panel Line 

PANEL # LBS'/PANEL P ANELS/8 HRS. TOTAL WEIGHT (LBS.) 

1 4.08 612 

2 2.77 612 

3 2.77 612 

4 4.38 612 

5 4.08 612 

6 4.38 612 

7 0.97 612 

8 1.85 612 

9 1.85 612 

10 1.85 612 

Totals 28.98 6120 

NOTE: 

1. 17,700 lbs./shift @4Ibs/ft3 = 4,430 ft3/shift or about 0.6 silos 

2. Actual silica use per shift will vary from 5900 lbs (panel #7) to about 

30,000 lbs (panel 4&6) depending on which panels are being run. 

2497 

. 1695 

1695 

2681 

2497 

2681 

594 

1132 

1132 

1132 

17736 
Immediately after being processed through the flash drier the silica would have a density'

of about one pound per cubic foot. It would redensify to about four pounds per cubic foot

as it settled in the silo. Air would be removed from the top of the silo to speed up densification.

Figure 8 shows a typical Jet-O-Drier system.

G. Silo storage

Two silos will be used; one will receive incoming silica from the flash drier while the other

dispenses silica to the panel manufacturing process. Each silo will be 71 feet high and 14

feet in diameter with a 60 degree hopper. Silos are aluminum with welded construction,

manufactured by Peabody TecTank [171 (Appendix Q.

With a ten foot head clearance, each silo has a capacity of 7000 cubic feet (28,000 pounds @

four pounds per cubic foot). One full silo will support about eight hours of production on

the form, fill, and seal line when producing the largest panel size (l"x28"x30") at 85% efficiency. Changeover from silo to silo will be simple and quick through the use of electronically controlled, rotary actuated valves. Silos will be piped so they can be filled from any of

the flash driers and can, feed any of the densifiers.

Table 6 shows that starting with one full silo and using the scheduling plan shown in Table

7, two silos are adequate to accommodate a continuous flow of silica from the silica plant.

The maximum silica inventory reaches 39,040 pounds at the end of the panel 8,9 and 10 -

run and drops to a low of 14,816 pounds at the end of the.panel 1 and 5 run. Two silos will

hold 56,000 pounds of silica at the planned density of four pounds per cubic foot.

H. Densifying

Silica will flow from the silo into a densifier by means of a pneumatic transfer system. The

densifier will increase the silica density to 8-10 pounds per cubic foot.

 EE-RM-93-801 COMMENT OR5

Immediately after being processed through the flash drier the silica would have a density" "" 

of about one pound per cubic foot. It would redensify to about four pounds per cubic foot 

as it settled in the silo. Air would be removed from the top of the silo to speed up densification. 

Figure 8 shows a typical Jet-O-Drier system. 

G. Silo storage 

Two silos will be used; one will receive incoming silica from the flash drier while the other " 

• 

dispenses silica to the panel manufacturing process. Each silo will be 71 feet high and 14 

feet in diameter with a 60 degree hopper. Silos are aluminum with welded construction, 

manufactured by Peabody TecTank [17] (Appendix C). 

With a ten foot head clearance, each silo has a capacity of 7000 cubic feet (28,000 pounds @ 

four pounds per cubic foot). One full silo will support about eight hours of production on 

the form, fill, and seal line when producing the largest panel size (l"x28"x30") at 85% efficiency. Changeover from silo to silo will be simple and quick through the use of electronically controlled, rotary actuated valves. Silos will be piped so they can be filled from any of 

the flash driers and can feed any of the densifiers. 

Table 6 shows that starting with one full silo and using the scheduling plan shown in Table 

7, two silos are adequate to accommodate a continuous flow of silica froin the silica plant. 

The maximum silica inventory reaches 39,040 pounds at the end of the panel 8, 9 and 10 -

run and drops to a low of 14,816 pounds at the end of the panel 1 and 5 run. Two silos will 

hold 56,000 pounds of silica at the planned density of four pounds per cubic foot. 

H. Densifying 

Silica will flow from the silo into a densifier by means of a pneumatic transfer system. The 

densifier will increase the silica density to 8-10 pounds per cubic foot. 

-25~ 

Immediately after being processed through the flash drier the silica would have a density" "" 

of about one pound per cubic foot. It would redensify to about four pounds per cubic foot 

as it settled in the silo. Air would be removed from the top of the silo to speed up densification. 

Figure 8 shows a typical Jet-O-Drier system. 

G. Silo storage 

Two silos will be used; one will receive incoming silica from the flash drier while the other " 

• 

dispenses silica to the panel manufacturing process. Each silo will be 71 feet high and 14 

feet in diameter with a 60 degree hopper. Silos are aluminum with welded construction, 

manufactured by Peabody TecTank [17] (Appendix C). 

With a ten foot head clearance, each silo has a capacity of 7000 cubic feet (28,000 pounds @ 

four pounds per cubic foot). One full silo will support about eight hours of production on 

the form, fill, and seal line when producing the largest panel size (l"x28"x30") at 85% efficiency. Changeover from silo to silo will be simple and quick through the use of electronically controlled, rotary actuated valves. Silos will be piped so they can be filled from any of 

the flash driers and can feed any of the densifiers. 

Table 6 shows that starting with one full silo and using the scheduling plan shown in Table 

7, two silos are adequate to accommodate a continuous flow of silica froin the silica plant. 

The maximum silica inventory reaches 39,040 pounds at the end of the panel 8, 9 and 10 -

run and drops to a low of 14,816 pounds at the end of the panel 1 and 5 run. Two silos will 

hold 56,000 pounds of silica at the planned density of four pounds per cubic foot. 

H. Densifying 

Silica will flow from the silo into a densifier by means of a pneumatic transfer system. The 

densifier will increase the silica density to 8-10 pounds per cubic foot. 

-25~ 
Figure 8

Jet-O-Drier Flash Drier

Cour" of Fluid Energy Aljet

PI teodrille, PA

Jet-11-Clone

Collector

Bog

Collector Jet-a-Orier

Silica . Input vi th

HZ Moisture

Receiver

Rotary

Airlocks

O

Silica Out with Less

Than IZ Moisture

Screv Conveyor 42 p

Blower

Heater

 EE-RM-93-801 COMMENT OR5

I 

I\) 

Ol 

I 

&g 

Collector 

Silica Out With less 

Than II Moisture 

Figure 8 . 

Jet-O-Drier Flash Drier 

Receiver __ -J 

[WI'~ of Fluid Entrgy Aljrt 

PIIIIISteodvilir. PA 

Si lico IrIJllt with 

3-4% Moistlre I 

I\) 

Ol 

I 

&g 

Collector 

Silica Out With less 

Than II Moisture 

Figure 8 . 

Jet-O-Drier Flash Drier 

[WI'~ of Fluid Entrgy Aljrt 

PIIIIISteodvilir. PA 

Si lico IrIJllt with 

3-4% Moistlre 
Table 6

Silica Silo Invento ry

(@ 900 Panels/hour and 2024 Lbs/hour from Silica Plant

PANEL NUM13ER

BEING PRODUCED

(WEIGHT)

LbsS. IN Lbs. OUT INVENTORY

28000

1&5 2024 3672 26352

(4.08 LBS.) 2024 3672 24704

2024 3672 23056

2024 3672 21408

2024 3672 19760

2024 3672 18112

2024 3672 16464

2024 3672 14816 low

2024 changeover 16840

2024 width & thickness 18864

7 2024 873 20015

(0.97 LBS.) 2024 873 21166

2024 873 22317

2024 873 23468

2024 873 24619

2024 873 25770

2024 873 26921

2024 873 28072

2024 changeover 30096

2024 width 32120

8, 9, & 10 2024 1665 32479

(1.85 LBS.) 2024 1665 32838

2024 1665 33197

2024 1665 33556

2024 .1665 33915

2024 1665 34274

2024 1665 34633

2024 1665 34992

2024 changeover 37016

2024 length & thickness 39040 high

2&3 2024 2493 38571

(2.77 LBS.) 2024 2493 38102

2024 2493 37633

2024 2493 37164

PANEL NUMBER

BEING PRODUCED

(WEIGHT)

Lbs. IN Lbs. OUT INVENTORY

2024 2493 36695

2024 2493 36226'

2024 2493 35757

2024 2493 35288

2024 changeover 37312

2024 length 39336

4&6 2024 3942 37418

(4.38 LBS.) 2024 3942 35500

2024 3942 33582

2024 3942 31664

2024 3942 29746

2024 3942 27828

2024 3942 25910

2024 3942 23992

2024 changeover 26016

2024 length 28040

1&5 2024 3672 26392

(4.08 LBS.) 2024 3672 24744

2024 3672 23096

2024 3672 21448

2024 3672 19800

2024 3672 18152

2024 3672 16504

2024 3672 14856 low

2024 changeover 16880

2024 width & thickness 18904

7 2024 873 20055

(0.97 LBS.) 2529 873 21711

2529 873 23367

2529 873 25023

2529 873 26679

2529 873 28335

2529 873 29991

2529 873 31647

 EE-RM-93-801 COMMENT OR5

I 

N 

..., 

I 

PANEL NUMBER 

BEING PRODUCED 

(WEIGHT) 

1&:5 

(4.08 LBS.) 

7 

(0.97LBS.) 

8,9, &: 10 

(1.85 LBS.) 

2&:3 

(2.77LBS.) 

LbsS.IN 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

Table 6 

Silica Silo Inventory 

(@ 900 Panels/hour and 2024 Lbslhour from Silica Plant 

PANEL NUMBER 

Lbs.OUT INVENTORY BEING PRODUCED Lbs.IN 

(WEIGHT) 

28000 - 3672 26352 2024 

3672 24704 2024 

3672 23056 2024 

3672 21408 2024 

3672 19760 2024 

3672 18112 2024 

3672 16464 4&:6 2024 

3672 14816 low (4.38 LBS.) 2024 

changeover 16840 2024 

width &: thickness 18864 2024 

873 20015 2024 

873 21166 2024 

873 22317 2024 

873 23468 2024 

873 24619 2024 

873 25770 2024 

873 26921 1&:5 2024 

873 28072 (4.08 LBS.) 2024 

changeover 30096 2024 

width 32120 2024 

1665 32479 j 2024 

1665 32838 2024 

1665 33197 2024 

1665 33556 2024 

.1665 33915 2024 

1665 34274 2024 

1665 34633 7 2024 

1665 34992 (0.97LBS.) 2529 

changeover 37016 2529 

length &: thickness 39040 high 2529 

2493 38571 2529 

2493 38102 2529 

2493 37633 2529 

2493 37164 , 2529 

\(. 

Lbs.OUT INVENTORY 

2493 36695 

2493 36226' 

2493 35757 

2493 35288 

changeover 37312 

length 39336 

3942 37418 

3942 35500 

3942 33582 

3942 31664 

3942 29746 

3942 27828 

3942 25910 

3942 23992 

changeover 26016 

length 28040 

3672 26392 

3672 24744 

3672 23096 

3672 21448 

3672 19800 

3672 18152 

3672 16504 

3672 14856 low 

changeover 16880 

width &: thickness 18904 

873 20055 

873 21711 

873 23367 

873 25023 

873 26679 

873 28335 

873 29991 

' 873 31647 

I 

N 

..., 

I 

PANEL NUMBER 

BEING PRODUCED 

(WEIGHT) 

1&:5 

(4.08 LBS.) 

7 

(0.97LBS.) 

8,9, &: 10 

(1.85 LBS.) 

2&:3 

(2.77LBS.) 

LbsS.IN 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

2024 

Table 6 

Silica Silo Inventory 

(@ 900 Panels/hour and 2024 Lbslhour from Silica Plant 

PANEL NUMBER 

Lbs.OUT INVENTORY BEING PRODUCED Lbs.IN 

(WEIGHT) = 28000 

3672 26352 2024 

3672 24704 2024 

3672 23056 2024 

3672 21408 2024 

3672 19760 2024 

3672 18112 2024 

3672 16464 4&:6 2024 

3672 14816 low (4.38 LBS.) 2024 

changeover 16840 2024 

width &: thickness 18864 2024 

873 20015 2024 

873 21166 2024 

873 22317 2024 

873 23468 2024 

873 24619 2024 

873 25770 2024 

873 26921 1&:5 2024 

873 28072 (4.08 LBS.) 2024 

changeover 30096 2024 

width 32120 2024 

1665 32479 j 2024 

1665 32838 2024 

1665 33197 2024 

1665 33556 2024 

.1665 33915 2024 

1665 34274 2024 

1665 34633 7 2024 

1665 34992 (0.97LBS.) 2529 

changeover 37016 2529 

length &: thickness 39040 high 2529 

2493 38571 2529 

2493 38102 2529 

2493 37633 2529 

2493 37164 , 2529 

\(. 

Lbs.OUT INVENTORY 

2493 36695 

2493 36226' 

2493 35757 

2493 35288 

changeover 37312 

length 39336 

3942 37418 

3942 35500 

3942 33582 

3942 31664 

3942 29746 

3942 27828 

3942 25910 

3942 23992 

changeover 26016 

length 28040 

3672 26392 

3672 24744 

3672 23096 

3672 21448 

3672 19800 

3672 18152 

3672 16504 

3672 14856 low 

changeover 16880 

width &: thickness 18904 

873 20055 

873 21711 

873 23367 

873 25023 

873 26679 

873 28335 

873 29991 

' 873 31647 
Table 7

Form, Fill, and Seal Line

Changeovers and Scheduling

i

PANEL NUMBER DIMENSIONS

N UMBER OF DIMENSIONS CHANGED WH

CHANGING TO PANEL_ NUMBER

LENGTH WIDTH THICKNESS 7 8,9,&10 1 2&3 4&6 1&5

1&5 28 21 2 1

7 28 10 1/2 3 3 2

8,9,&10 28 19 1/2 1 3 2

2&3 21 19 1 3 2 1

4&6 1 30 1 21 1 3 3 1

 EE-RM-93-801 COMMENT OR5

PANEL NUMBER 

I 1&:5 

I\) 

CD 

I 7 

8,9, &: 10 

2&:3 

4&:6 

Table 7 

Form, Fill, and Seal Line 

Changeovers and Scheduling 

DIMENSIONS 

NUMBER OF DIMENSIONS GlANGED WHEN 

CHANGING TO PANEL NUMBER 

lENGTH WIDTH THICKNESS 7 8,9, &: 10 2 &: 3 4 &: 6 1&:5 

28 21 1 2 1 1 

28 10 1/2 3 3 2 

28 19 1/2 1 :::::j:::::j::::::I:I:::j~:j:j:::::::j::I:::j:::jj::j 3 2 

21 19 1 3 2 :::::::I::::::j:j:j::::j:j::jl::~~j::~:j::j:~:~t:::::::~j 1 

30 21 1 3 3 1 ::jj:I::::::::~:~:I:::i:~:I::I::::j::::::::::j:::: 

PANEL NUMBER 

I 1&:5 

I\) 

CD 

I 7 

8,9, &: 10 

2&:3 

4&:6 

Table 7 

Form, Fill, and Seal Line 

Changeovers and Scheduling 

DIMENSIONS 

NUMBER OF DIMENSIONS GlANGED WHEN 

CHANGING TO PANEL NUMBER 

lENGTH WIDTH THICKNESS 7 8,9, &: 10 2 &: 3 4 &: 6 1&:5 

28 21 1 2 1 1 

28 10 1/2 3 3 2 

28 19 1/2 1 :::::j:::::j::::::I:I:::j~:j:j:::::::j::I:::j:::jj::j 3 2 

21 19 1 3 2 :::::::I::::::j:j:j::::j:j::jl::~~j::~:j::j:~:~t:::::::~j 1 

30 21 1 3 3 1 ::jj:I::::::::~:~:I:::i:~:I::I::::j::::::::::j:::: 
Fluid Energy Aljet builds a VACUPRESS densifier designed to increase the densities of

very fine powders (finer than 40 microns) where their high air content hinders further

processing [6].

. Aljet 's description of the VACUPRESS operating principle is:

"The densifying effect is achieved by a combination of vacuum and mechanical pressure. The VACUPRESS process is achieved by means of two drums

turning in opposite directions, designated filter drum and pressure drum.

[Figure 9]

"The product to be densified encloses the filter drum and thereby allows the

filter or de-aeration action to take place. As the drum revolves, the particles

rearrange to form by vacuum effect a continuous layer on the surface of the

filter drum and pre-densify by the exhausting air passed through. The layer

of de-aerated powder passes through the gap between the filter and pressure

drums where it is subjected to a preselected rolling pressure. The rolling

pressure action brings the de-aerated powder particles closer together as

dense powder or soft agglomerates. Afterwards, the densified product is

continuously stripped off the filter drum up to the filter layer and leaves the

machine."

A typical VACUPRESS installation is shown in Figure 10.

1. Bag filling

Dry and dense silica at eight to ten pounds per cubic foot and less than one percent moisture is transferred from the densifier into an auger feeder via a pneumatic conveying system.

The microprocessor-controlled auger feeder measures and feeds a volumetric fill for each

panel size. Different weights for different pa nel sizes are held in the feeder memory and

29

 EE-RM-93-801 COMMENT OR5

Fluid Energy ~jet builds a V ACUPRESS ~ensifier designed to increase the densities of . 

very fine powders (finer than 40 microns) where their high air content hinders further 

processing [6]. 

Aljet 's description of the V ACUPRESS operating principle is: 

liThe densifying effect is achieved by a combination .of vacuum and mechanical pressure. The V ACUPRESS process is achieved by means of two drums 

turning in opposite directions, designated filter drum and pressure drum. 

[Figure 9] 

''The product to be densified encloses the filter drum and thereby allows the 

filter or de-aeration action to take place. As the drum revolves, the particles 

rearrange to form by vacuum effect a continuous layer on the surface of the 

filter drum and pre-densify by the exhausting air passed through. The layer 

of de-aerat~d powder passes through the gap between the filter and pressure 

drums where it is subjected to a preselected rolling pressure. The rolling 

pressure action brings the de-aerated powder particles closer together as 

dense powder or soft agglomerates. Mterwards, the densified product is 

continuously stripped off the filter drum up to the filter layer and leaves the 

machine." 

A typical V ACUPRESS installation is shown in Figure 10. 

I. Bag filling 

Dry and dense silica at eight to ten pounds per cubic foot and less than one percent moisture is transferred from the densifier into an auger feeder via a pneumatic conveying system. 

The microprocessor-controlled auger feeder measures and feeds a volumetric fill for each 

panel size. Different weights for different panel sizes are held in the feeder memory and 

-29-

Fluid Energy ~jet builds a V ACUPRESS ~ensifier designed to increase the densities of . 

very fine powders (finer than 40 microns) where their high air content hinders further 

processing [6]. 

Aljet 's description of the V ACUPRESS operating principle is: 

liThe densifying effect is achieved by a combination .of vacuum and mechanical pressure. The V ACUPRESS process is achieved by means of two drums 

turning in opposite directions, designated filter drum and pressure drum. 

[Figure 9] 

''The product to be densified encloses the filter drum and thereby allows the 

filter or de-aeration action to take place. As the drum revolves, the particles 

rearrange to form by vacuum effect a continuous layer on the surface of the 

filter drum and pre-densify by the exhausting air passed through. The layer 

of de-aerat~d powder passes through the gap between the filter and pressure 

drums where it is subjected to a preselected rolling pressure. The rolling 

pressure action brings the de-aerated powder particles closer together as 

dense powder or soft agglomerates. Mterwards, the densified product is 

continuously stripped off the filter drum up to the filter layer and leaves the 

machine." 

A typical V ACUPRESS installation is shown in Figure 10. 

I. Bag filling 

Dry and dense silica at eight to ten pounds per cubic foot and less than one percent moisture is transferred from the densifier into an auger feeder via a pneumatic conveying system. 

The microprocessor-controlled auger feeder measures and feeds a volumetric fill for each 

panel size. Different weights for different panel sizes are held in the feeder memory and 

-29-
Figure 9

Vacupress Densifier

 EE-RM-93-801 COMMENT OR5

1 Filter Drum 

2 Knives 

3 Pressure Drum 

I 

~ 

Figure 9 

Vacupress Densifi~r 

Silica @ 4lbs/ft3 

1 2 . Silica @ 

8-1 0 Ibs/ft3 

Courtesy of Fluid EnlMg)' AI)9t 

PlumsteadvJ1le, Pa. 

3 

1 Filter Drum 

2 Knives 

3 Pressure Drum 

I 

~ 

Figure 9 

Vacupress Densifi~r 

Silica @ 4lbs/ft3 

1 2 . Silica @ 

8-1 0 Ibs/ft3 

Courtesy of Fluid EnlMg)' AI)9t 

PlumsteadvJ1le, Pa. 

3 
Figure 10

Vacupress Installation

Q

I VACLPRESS nochine with variable-speed drive

2 Vocuun regulating valve

3 Solenoid Valve

4 Vocuun Tank

5 Water inlet

6 Vocuun punp station

7 Water circulation container

8 Air outlet

9 Water outlet

Silico iron Silo

z oo

Courtesy of FLUID ENERGY ALJET

Plunsteodvi l le, PA S i I i co to Auger Feeder

 EE-RM-93-801 COMMENT OR5

I 

'" .... 

8 

9 

Courtesy of FLUID ENERGY ALJET 

Plunsteodville, PA· 

7 

Figure 10 

Vacupress Installati,on 

VA[UPRESS nachine with variable-speed drive 

2 Vacuun regulating valve 

3 Solenoid Valve 

4 Vocuun Tonk 

5 Water inle~ 

6 Vacuun punp stotion 

7 Woter circulation container 

B Air outlet 

9 Water outlet 

3 2 

.s 4 

Silieo fran Silo 

00 

Si I ieo to Auger Feeder 

I 

'" .... 

8 

9 

Courtesy of FLUID ENERGY ALJET 

Plunsteodville, PA· 

7 

Figure 10 

Vacupress Installati,on 

VA[UPRESS nachine with variable-speed drive 

2 Vacuun regulating valve 

3 Solenoid Valve 

4 Vocuun Tonk 

5 Water inle~ 

6 Vacuun punp stotion 

7 Woter circulation container 

B Air outlet 

9 Water outlet 

3 2 

.s 4 

Silieo fran Silo 

00 

Si I ieo to Auger Feeder 
changed with the push of a button. Fills for each panel are controlled to plus or minus a

few grams.. Five different fills are required for the panels used in this study. Change over

would be instantaneous.

A Mateer-Burt Neotron System Series 1900 (Appendix D) was selected for this application

[3]. The 1900 is designed for application on automatic form, fill, and seal machines and has

an accuracy of plus or minus two to three grams.

J. Panel Manufacturing Line

The auger filler feeds a vertical form, fill, and seal machine which bags the silica in a porous bag [1]. The machine then places the porous bag into a multi-layer plastic bag which is

inserted into a vacuum chamber where it is evacuated and sealed. Process specifications for

the form, fill, and seal line are shown in Figure 11.

Horizontal equipment could be used and should be reviewed further before discounting it

[2]. Also, some other types of equipment can vacuum form the barrier bag into a tray. This

could be an advantage, but was not considered because it was felt that the multi-layer

barrier bag could not be vacuum formed without destroying its integrity. This capability

should be investigated further before ruling it out. Vertical equipment was assumed to be

best suited for manufacturing VIPs.

 EE-RM-93-801 COMMENT OR5

changed with the push of a button. Fills for each panel are controlled to plus or minus a 

.few grams. Five different fills are required for the panels used in this study. Change over 

would be instantaneous. 

A Mateer-Burt Neotron System Series 1900 (Appendix D) was selected for this application 

[3]. The 1900 is designed for application on automatic form, fill, and seal machines and has 

an accuracy of plus or minus two to three grams. 

J. Panel Manufacturing line 

The auger filler feeds a vertical form, fill, and seal machine which bags the silica in a p0-

rous bag [1). The machine then places the porous bag into a multi-layer plastic bag which is 

inserted into a vacuum chamber where it is evacuated and sealed. Process specifications for 

the form, fill, and seal line are shown in Figure 11. 

Horizontal equipment could be used and should be reviewed further before discounting it 

[2]. Also, some other types of equipment can vacuum form the barrier bag into a tray. This 

could be an advantage, but was not considered because it was felt that the multi-layer 

barrier bag could not be vacuum formed without destroying its integrity. This capability 

should be investigated further before ruling it out. Vertical equipment was assumed to be .'. 

best suited for manufacturing VIPs. 

-32-

changed with the push of a button. Fills for each panel are controlled to plus or minus a 

.few grams. Five different fills are required for the panels used in this study. Change over 

would be instantaneous. 

A Mateer-Burt Neotron System Series 1900 (Appendix D) was selected for this application 

[3]. The 1900 is designed for application on automatic form, fill, and seal machines and has 

an accuracy of plus or minus two to three grams. 

J. Panel Manufacturing line 

The auger filler feeds a vertical form, fill, and seal machine which bags the silica in a p0-

rous bag [1). The machine then places the porous bag into a multi-layer plastic bag which is 

inserted into a vacuum chamber where it is evacuated and sealed. Process specifications for 

the form, fill, and seal line are shown in Figure 11. 

Horizontal equipment could be used and should be reviewed further before discounting it 

[2]. Also, some other types of equipment can vacuum form the barrier bag into a tray. This 

could be an advantage, but was not considered because it was felt that the multi-layer 

barrier bag could not be vacuum formed without destroying its integrity. This capability 

should be investigated further before ruling it out. Vertical equipment was assumed to be .'. 

best suited for manufacturing VIPs. 

-32-
Figure 11

Process Specifications - Form, Fill, and Seal Line

Equipment operation sequence:

• form porous pouch

• fill with silica

• lay pouch down

• vibrate flat

• compress

• form barrier bag around porous pouch

• seal on three sides and tack on forth

• cut apart

• insert bag into vacuum chamber

• compress at controlled vacuum

• seal forth side

• remove panel from chamber

1. Fully automatic

2. Cycle time-4 seconds

3. Evacuation time-5 minutes

4. Vacuum-1 millimeter of mercury (1 Torr)

5. Maximum panel size-l"x 21"x 30"

6. Semiautomatic changeover for thickness and length

7. Capability for two thicknesses (0.5" & 1.0"), and two lengths (21" & 28")

8. Five pounds maximum fill

9. 85% efficient

10. Reject rate < 1 % at steady state

11. Materials: porous bag-Snow Filtration TYVEK

barrier bag-Fres-Co VECAT

silica-Degussa-FK 500LS

 EE-RM-93-801 COMMENT OR5

Figure 11 

Process Specifications- Form, Fill, and Seal Line. 

Equipment operation sequence: 

• form porous pouch 

• fill with silica 

• lay pouch down 

• vibrate flat 

• compress 

• form barrier bag around porous pouch 

• seal on three sides and tack on forth 

• cut apart 

• insert bag into vacuum chamber 

• compress at controlled vacuum 

• seal forth side 

• remove panel from chamber 

1. Fully automatic 

2. Cycle time-4 seconds 

3. Evacuation time--S minutes 

4. Vacuum-l millimeter of mercury (1 Torr) 

5. Maximum panel size-l"x 21 "x 30" 

6. Semiautomatic changeover for thickness and length 

7. Capability for two thicknesses (OS' & 1.0"), and two lengths (21" & 28") 

8. Five pounds maximum fill 

9. 85% efficient 

10~ Reject rate < 1 % at steady state 

11. Materials: porous bag-Snow Filtration TYVEK 

barrier bag-Fres-Co VECAT 

silica-Degussa. FK SOOLS 

-33-

Figure 11 

Process Specifications- Form, Fill, and Seal Line. 

Equipment operation sequence: 

• form porous pouch 

• fill with silica 

• lay pouch down 

• vibrate flat 

• compress 

• form barrier bag around porous pouch 

• seal on three sides and tack on forth 

• cut apart 

• insert bag into vacuum chamber 

• compress at controlled vacuum 

• seal forth side 

• remove panel from chamber 

1. Fully automatic 

2. Cycle time-4 seconds 

3. Evacuation time--S minutes 

4. Vacuum-l millimeter of mercury (1 Torr) 

5. Maximum panel size-l"x 21 "x 30" 

6. Semiautomatic changeover for thickness and length 

7. Capability for two thicknesses (OS' & 1.0"), and two lengths (21" & 28") 

8. Five pounds maximum fill 

9. 85% efficient 

10~ Reject rate < 1 % at steady state 

11. Materials: porous bag-Snow Filtration TYVEK 

barrier bag-Fres-Co VECAT 

silica-Degussa. FK SOOLS 

-33-
Form, fill, and seal machines have long been used in the food industry for vacuum packed

products such as coffee, and are a proven technology (Appendix E). Although VIPs are

somewhat larger than the typical food package , it is felt that these machines can be designed to produce them. Form, fill, and seal machines typically run from 80 to 100 pieces

per minute. The VIIP process will run only 15 panels per minute. Figure 12 shows the layout

of a form, fill, and seal machine for food packaging.

The process sequence in the form, fill, and seal machine for VIPs would be:

Station 1 - Form porous bag, seal bottom, fill with silica, seal top (which is bottom

of next bag), cut off and drop on belt conveyor. The bag is formed as a

continuous tube which is filled by the volumetric auger filler. The tube

is sealed at selected dimensions by a resistance heated hot bar and cut

off by a shear.

Station 2 - Locate bag, vibrate to level silica and press to compact.

Station 3 - Form barrier bag around porous ba , seal on three sides and tack o;

fourth side.

Station 4 - Load and unload evacuation chambers. Four panels per chamber.

Station 5 - Evacuation. Inside each chamber the control sequence will be: a. compress at a controlled vacuum; b. secondary vacuum; c. final compression; d. final vacuum; e. seal fourth side; and f. exit chamber.

There are 26 vacuum chambers and 20 vacuum lids on the line. With

four panels per chamber, five and one-third minutes of evacuation will

occur for each panel at the four second line cycle.

Station 6 - Secondary seal all four sides of barrier bag-three hot bar. hits per side.

Station 7 - Transfer to belt conveyor.

Changeovers from one size panel to another will necessitate changing porous bag and

barrier bag material sizes, changing mandrel for porous bag forming, adjusting both bag

stations, adjusting compression stations outside and inside vacuum chambers when a

 EE-RM-93-801 COMMENT OR5

Form, fill, and se~ machines have long been used in the food industry for vacuum packed 

products such as coffee, and are a proven technology (Appendix E). Although VIPs are 

somewhat larger than the typical food package, it is felt that these machines can be designed to produce them. Form, fill, and seal machines typically run from 80 to 100 pieces 

per minute. The VIP process will run only 15 panels per minute. FIgure 12 shows the layout 

of a form, fill, and seal machine for food packaging. 

The process sequence in the form, fill, and seal machine for VIPs would be: 

Station 1 - Form porous bag, seal bottom, fill with silica, seal top (which is bottom 

of next bag), cut off and drop on belt conveyor. The bag is formed as a 

continuous tube which is fIlled by the volumetric auger filler. The tube 

is sealed at selected dimensions by a resistance heated hot bar and cut 

off by a shear. 

Station 2 - Locate bag, vibrate to level silica and press to compact. 

Station 3 - Form barrier bag around porous ba(>" seal on three sides and tack /.); 

fourth side. 

Station 4 - Load and unload evacuation chambers. Four panels per chamber. 

Station 5 Evacuation. Inside each chamber the control sequence will be: a. com- .. 

press at a controlled vacuum; b. secondary vacuum; c. final compression; d. final vacuum; e. seal fourth side; and f. exit chamber. 

There are 26 vacuum chambers and 20 vacuum lids on the line. With 

four panels per chamber, five and one-third minutes of evacuation will 

occur for each panel at the four second line cycle. 

Station 6 - Secondary seal all four sides of barrier bag-three hot bar. hits per side. 

Station 7 - Transfer to belt conveyor. 

Changeovers from one size panel to another will necessitate changing porous bag and 

barrier bag material sizes, changing mandrel for porous bag forming, adjusting both bag 

stations, adjusting compression stations outside and inside vacuum chambers when a 

-34-

Form, fill, and se~ machines have long been used in the food industry for vacuum packed 

products such as coffee, and are a proven technology (Appendix E). Although VIPs are 

somewhat larger than the typical food package, it is felt that these machines can be designed to produce them. Form, fill, and seal machines typically run from 80 to 100 pieces 

per minute. The VIP process will run only 15 panels per minute. FIgure 12 shows the layout 

of a form, fill, and seal machine for food packaging. 

The process sequence in the form, fill, and seal machine for VIPs would be: 

Station 1 - Form porous bag, seal bottom, fill with silica, seal top (which is bottom 

of next bag), cut off and drop on belt conveyor. The bag is formed as a 

continuous tube which is fIlled by the volumetric auger filler. The tube 

is sealed at selected dimensions by a resistance heated hot bar and cut 

off by a shear. 

Station 2 - Locate bag, vibrate to level silica and press to compact. 

Station 3 - Form barrier bag around porous ba(>" seal on three sides and tack /.); 

fourth side. 

Station 4 - Load and unload evacuation chambers. Four panels per chamber. 

Station 5 Evacuation. Inside each chamber the control sequence will be: a. com- .. 

press at a controlled vacuum; b. secondary vacuum; c. final compression; d. final vacuum; e. seal fourth side; and f. exit chamber. 

There are 26 vacuum chambers and 20 vacuum lids on the line. With 

four panels per chamber, five and one-third minutes of evacuation will 

occur for each panel at the four second line cycle. 

Station 6 - Secondary seal all four sides of barrier bag-three hot bar. hits per side. 

Station 7 - Transfer to belt conveyor. 

Changeovers from one size panel to another will necessitate changing porous bag and 

barrier bag material sizes, changing mandrel for porous bag forming, adjusting both bag 

stations, adjusting compression stations outside and inside vacuum chambers when a 

-34-
Figure 12 .

Form , Fill, and Seal Line

courtesy Fres-co

System USA, Inc.

Telford, PA

FORM BAG

AIR03M'

FILL BAG SEAL EVACUATE

VACUUM PUMP

Epf'

ti

ELECTRICAL CABINET

317ES ARE APPROXIMATE

SIZES ARE IN MILLIMETERS

 EE-RM-93-801 COMMENT OR5

I 

(..) 

<.n 

I 

Figure 12 

Form, Fill, and Seal Line 

rORM BAG SEAL 

ELECTRICAL CABINET 

-----_ 11375 ... _--_._ .... 

CourteR)' keR-Co 

System USA. Inc. 

Tellord. PA 

EVACUATE 

VACUUM PUMP 

Y*,CU\IM 

_, liT '--_______ -' 

S 1ZE5 ARE APPAOXIMA TE 

SIZES ARE IN MillIMETERS 

.. _-_._-+---' 

I 

(..) 

<.n 

I 

Figure 12 

Form, Fill, and Seal Line 

rORM BAG SEAL 

ELECTRICAL CABINET 

-----_ 11375 ... _--_._ .... 

CourteR)' keR-Co 

System USA. Inc. 

Tellord. PA 

EVACUATE 

VACUUM PUMP 

Y*,CU\IM 

_, liT '--_______ -' 

S 1ZE5 ARE APPAOXIMA TE 

SIZES ARE IN MillIMETERS 

.. _-_._-+---' 
thickness change is made, and adjusting hot bar sealers. It is estimated that changeovers

will take from one hour for a one dimension change to three hours for a three dimension

change.

The line can be scheduled so that there are no three dimension changeovers. The best run

sequence which requires two one dimension changes and only three two dimension

changes is shown in Table 7. Planning run and changeover sequence will reduce overall

setup time which is the major component of efficiency loss. The line normally will run each

panel for eight hours and then change to another. This plan will produce a maximum of

7200 panels on each run, i.e., one week's requirement for one panel for the refrigerator

plant (6980 units/week).

With a five day, 24 hour work week, this schedule allows 80 hours per week for production

(10 panels x 8 hours per panel), 20 hours for changeovers (10 changeovers x 2 hours average time per changeover), and 20 hours for maintenance, downtime, and other losses.

 EE-RM-93-801 COMMENT OR5

thickness change is made, and adjusting hot 1>ar sealers. It is estimated that changeovers 

will take from one hour for a one dimension change to three hours for a three dimension 

change. 

The line can be scheduled so that there are no three dimension changeovers. The best run 

sequence which requires two one dimension changes and only three two dimension 

chartges is shown in Table 7. Planning run and changeover sequence will reduce overall 

setup time which is the major component of efficiency loss. The line normally will run each 

panel for eight hours and then change to another. This plan will produce a maximum of 

7209 panels on each run, i.e., one week's requirement for one panel for the refrigerator 

plant (6980 units/week). 

With a five day, 24 hour work week, this schedule allows 80 hours per week for production 

(10 panels x 8 hours per pane!), 20 hours for changeovers (10 changeovers x 2 hours average time per changeover), and 20 hours for maintenance, downtime, and other losses. 

-36-

thickness change is made, and adjusting hot 1>ar sealers. It is estimated that changeovers 

will take from one hour for a one dimension change to three hours for a three dimension 

change. 

The line can be scheduled so that there are no three dimension changeovers. The best run 

sequence which requires two one dimension changes and only three two dimension 

chartges is shown in Table 7. Planning run and changeover sequence will reduce overall 

setup time which is the major component of efficiency loss. The line normally will run each 

panel for eight hours and then change to another. This plan will produce a maximum of 

7209 panels on each run, i.e., one week's requirement for one panel for the refrigerator 

plant (6980 units/week). 

With a five day, 24 hour work week, this schedule allows 80 hours per week for production 

(10 panels x 8 hours per pane!), 20 hours for changeovers (10 changeovers x 2 hours average time per changeover), and 20 hours for maintenance, downtime, and other losses. 

-36-
Table 7

Form , Fill, and Seal Line

Changeovers and Scheduling

PANEL NUMBER

LENGTH I

DIMENSIONS

WIDTH THICKNESS

N

7

UMBER OF DI

CHANGI

8,9,&10 1

MENSIONS CH

NG TO PANEL

2&3 1

ANGED WHE

NUMBER

4&6

N

1&5

1&5 28 21 2 1 1

7 28 10 1/2 3 3 2

8,9,&10 28 19 1/2 1 3 2

2&3 21 19 1 3 2 1

4&6 . 1 30 1 21 1 3 3 1

 EE-RM-93-801 COMMENT OR5

PANEL NUMBER 

LENGTH 

1&5 28 

I 7 28 (.0) 

....... 

I 

8,9, & 10 28 

2&:3 21 

4&6 30 

Table 7 

Form, Fill, and Seal Line 

Changeovers and Scheduling 

NUMBER OF DIMENSIONS CHANGED WHEN 

DIMENSIONS CHANGING TO PANEL NUMBER 

WIDTH THICKNESS 7 8,9, & 10 2&:3 4&:6 1&:5 

21 1 2 1 1 

10 1/2 ::::::::::~1:~:1:::::::::::11:::J~::::::11:::11~:11:1:::1:::1:::: 3 3 2 

19 1/2 1 ::::I111:::1:::::1~::1:11:~11:~:~:1:11111:::1111:1::1::1::1': 3 2 

19 1 3 2 :'::::::::::::::::::::::::::::::1:::::::::::::::::::::::::::::': 1 

21 1 3 3 1 ::::1~::{1:::::1:::::::Im:1~:~:'::::::::::::::::::::::: 

PANEL NUMBER 

LENGTH 

1&5 28 

I 7 28 (.0) 

....... 

I 

8,9, & 10 28 

2&:3 21 

4&6 30 

Table 7 

Form, Fill, and Seal Line 

Changeovers and Scheduling 

NUMBER OF DIMENSIONS CHANGED WHEN 

DIMENSIONS CHANGING TO PANEL NUMBER 

WIDTH THICKNESS 7 8,9, & 10 2&:3 4&:6 1&:5 

21 1 2 1 1 

10 1/2 ::::::::::~1:~:1:::::::::::11:::J~::::::11:::11~:11:1:::1:::1:::: 3 3 2 

19 1/2 1 ::::I111:::1:::::1~::1:11:~11:~:~:1:11111:::1111:1::1::1::1': 3 2 

19 1 3 2 :'::::::::::::::::::::::::::::::1:::::::::::::::::::::::::::::': 1 

21 1 3 3 1 ::::1~::{1:::::1:::::::Im:1~:~:'::::::::::::::::::::::: 
K. Quality Control

'Panels coming off the panel line would be 100% tested to determine whether or not the

pressure was below an established limit. This test would be done in the four second cycle

and panels without the proper vacuum would be diverted into a reject bin and an alarm

would be sounded. Controls would be integrated so that the line could be shut down and a

control person summoned if a panel failed the test limit.

This test would be done using a single head transducer which generates an electromagnetic

impulse which then creates an audible tone. The frequency or pitch of the tone indicates the

relative vacuum or pressure in the panel. A high pitch denotes high vacuum and a low

pitch represents low vacuum [14].

This technology is proven, and equipment which is now being used to test vacuum bagged

products is commercially available (Appendix F). Further development would be required

for this specific application and for determining the actual vacuum range which could be

measured.

Control operators would salvage the silica from rejected panels and take scrap bag material

from the plant to an outside dumpster daily.

A quality control laboratory would perform more accurate vacuum measurements on an

audit basis. Laboratory equipment would be a different type, which would-allow an entire

panel to be placed into a vacuum chamber which would be pulled down until an equilibrium with the internal vacuum in the panel was reached. Optic sensors would detect a

slight movement of. the outer panel membrane at this point.

This equipment, which would be accurate within one or two Torr, has been produced for

laboratory use [16] (Appendix G). Equipment which would use only a small vacuum head

placed against the panel but using the same principle is being developed at ORNL [15].

 EE-RM-93-801 COMMENT OR5

K. Quality Control 

-Panels coming off the panel line would be 100% tested to determine whether or not the 

pressure was below an established limit. This test would be done in the four second cycle 

and panels without the proper vacuum would be diverted into a reject bin and an alarm 

would be sounded. Controls would be integrated so that the line could be shut down and a 

control person summoned if a panel failed the test limit. 

This test would be done using a single head transducer which generates an electromagnetic 

impulse which then creates an audible tone. The frequency or pitch of the tone indicates the 

relative vacuum or pressure in the panel. A high pitch denotes high vacuum and a low 

pitch represents low vacuum [14]. 

This technology is proven, and equipment which is now being used to test vacuum bagged 

products is commercially available (Appendix F). Further development would be required 

for this specific application and for determining the actual vacuum range which could be 

measured. 

Control operators would salvage the silica from rejected panels and take scrap bag material 

from the plant to an outside dumpster daily. 

A quality control laboratory would perform more accurate vacuum measurements on .an 

audit basis. Laboratory equipment would be a different type, which would -allow an entire 

panel to be placed into a vaCl,lum chamber which would be pulled down until an equilibrium with the internal vacuum in the panel was reached. Optic sensors would detect a 

slight movement of the outer panel membrane at this point. 

This equipment, which would be accurate within one or two Torr, has been produced for 

laboratory use [16] (Appendix G). Equipment which would use only a small vacuum head 

placed against the panel but using the same principle is being developed at ORNL [15]. 

-38-

K. Quality Control 

-Panels coming off the panel line would be 100% tested to determine whether or not the 

pressure was below an established limit. This test would be done in the four second cycle 

and panels without the proper vacuum would be diverted into a reject bin and an alarm 

would be sounded. Controls would be integrated so that the line could be shut down and a 

control person summoned if a panel failed the test limit. 

This test would be done using a single head transducer which generates an electromagnetic 

impulse which then creates an audible tone. The frequency or pitch of the tone indicates the 

relative vacuum or pressure in the panel. A high pitch denotes high vacuum and a low 

pitch represents low vacuum [14]. 

This technology is proven, and equipment which is now being used to test vacuum bagged 

products is commercially available (Appendix F). Further development would be required 

for this specific application and for determining the actual vacuum range which could be 

measured. 

Control operators would salvage the silica from rejected panels and take scrap bag material 

from the plant to an outside dumpster daily. 

A quality control laboratory would perform more accurate vacuum measurements on .an 

audit basis. Laboratory equipment would be a different type, which would -allow an entire 

panel to be placed into a vaCl,lum chamber which would be pulled down until an equilibrium with the internal vacuum in the panel was reached. Optic sensors would detect a 

slight movement of the outer panel membrane at this point. 

This equipment, which would be accurate within one or two Torr, has been produced for 

laboratory use [16] (Appendix G). Equipment which would use only a small vacuum head 

placed against the panel but using the same principle is being developed at ORNL [15]. 

-38-
This approach could reduce the cost of laboratory equipment. Its capability to meet a four

second manufacturing cycle and be feasible on a manufacturing line is yet to be established. If it should prove feasible, accuracy would probably be significantly improved over

the magnetic pulse approach.

L. Packaging

Panels coming off the form, fill, and seal line every four seconds will be automatically

stacked into bundles and strapped. Bundles are sized so they can be handled manually to

avoid the need for skids and fork lift handling. Weights for each size bundle are shown in

Table 8. A cardboard top and bottom cap will be placed on each bundle as it is stacked by

an automatic stacking machine.

Each stack will be transferred automatically into a Cyklop ASM-lA (Appendix H) automatic strapping station where each bundle will be secured with two plastic straps [13]. This

equipment, supplied by Zelerbach, heat seals the strap an€ makes high strength seal joints

which are easily removable without tools. The ASM lA is fully automatic and incorporates

a powered belt conveyor and photo-electric controls.

Alternative packaging considered included shrink bundling and shrink wrap. These alternates were discarded because more dunnage would be generated at the refrigerator plant

and the extra protection was not warranted since the bundles will be handled automatically or manually without fork lifts.

Bundles of panels will be transported automatically by belt conveyors to an Adjustoveyor

(Appendix I) which will carry them into a van trailer where they will be unloaded and

stacked manually. The Adjustoveyor will be mounted on tracks to allow it to travel between shipping docks [10].

39

 EE-RM-93-801 COMMENT OR5

This approach could reduce the cost of laboratory equipment. Its capability to meet a four 

second manufacturing cycle and be feasible on a manufacturing line is yet to be estalr 

lished. H it should prove feasible, accuracy would probably be significantly improved over 

the magnetic pulse approach. 

L. Packaging 

Panels coming off the form, fill, and seal line every four seconds will be automatically 

stacked into bundles and strapped. Bundles are sized so they can be handled manually to 

avoid the need for skids and fork lift handling. Weights for each size bundle are shown in 

Table 8. A cardboard top and bottom cap will be placed on each bundle as it is stacked by 

an automatic stacking machine. 

Each stack will be transferred automatically into a Cyklop ASM-lA (Appendix H) automatic strapping station where each bundle will be secured with two plastic straps [13]. This 

equipment, supplied by Ze]erbach, heat seals the strap anc1. makes high strength seal joints -

which are easily removable without tools. The ASM lA is fully automatic and incorporates 

a powered belt conveyor and photo-electric controls. 

Alternative packaging considered included shrink bundling and shrink wrap. These alternates were discarded because more dunnage would be generated at the refrigerator plant 

and the extra protection was not warranted since the bundles will be handled automatically or manually without fork lifts. 

Bundles of panels will be transported automatically by belt conveyors to an Adjustoveyor 

(Appendix I) which will carry them into a van trailer where they will be ~oaded and· 

stacked manually. The Adjustoveyor will be mounted on tracks to allow it to tra:vel between shipping docks [10]. 

-39-

This approach could reduce the cost of laboratory equipment. Its capability to meet a four 

second manufacturing cycle and be feasible on a manufacturing line is yet to be estalr 

lished. H it should prove feasible, accuracy would probably be significantly improved over 

the magnetic pulse approach. 

L. Packaging 

Panels coming off the form, fill, and seal line every four seconds will be automatically 

stacked into bundles and strapped. Bundles are sized so they can be handled manually to 

avoid the need for skids and fork lift handling. Weights for each size bundle are shown in 

Table 8. A cardboard top and bottom cap will be placed on each bundle as it is stacked by 

an automatic stacking machine. 

Each stack will be transferred automatically into a Cyklop ASM-lA (Appendix H) automatic strapping station where each bundle will be secured with two plastic straps [13]. This 

equipment, supplied by Ze]erbach, heat seals the strap anc1. makes high strength seal joints -

which are easily removable without tools. The ASM lA is fully automatic and incorporates 

a powered belt conveyor and photo-electric controls. 

Alternative packaging considered included shrink bundling and shrink wrap. These alternates were discarded because more dunnage would be generated at the refrigerator plant 

and the extra protection was not warranted since the bundles will be handled automatically or manually without fork lifts. 

Bundles of panels will be transported automatically by belt conveyors to an Adjustoveyor 

(Appendix I) which will carry them into a van trailer where they will be ~oaded and· 

stacked manually. The Adjustoveyor will be mounted on tracks to allow it to tra:vel between shipping docks [10]. 

-39-
Table 8

Average Daily Panel Requirements

for Refrigerator Assembly Line

(60% of two shift production a) 85% efficiency)

PANEL #

PANELS/

DAY

PANELS/

BUNDLE

WEIGHT/

BUNDLE

BUNDLES/

DAY

1&5 2,792 10 40.8 280

2&3 2,792 15 41.6 187

4&6 2,792 10 43.8 280

7 1,396 40 38.8 35

8,9&10 4,188 20 37.0 210

Total 1 13,960 ( ( . 1 992

 EE-RM-93-801 COMMENT OR5

PANEL # 

I 

S 

1&5 

2&3 

4&6 

7 

8,9& 10 

Total 

Table 8 

Average Daily Panel Requirements 

. for Refrigerator Assembly Line 

(600/0 of two shift production @ 850/0 efficiency) 

PANELS/ PANELS/ WEIGHT/ 

DAY BUNDLE BUNDLE 

2,792 10 40.8 

2,792 15 41.6 

2,792 10 43.8 

1,396 40 38.8 

4,188 20 37.0 

13,960 

BUNDLES/ 

DAY 

280 

187 

280 

35 

210 

992 

PANEL # 

I 

S 

1&5 

2&3 

4&6 

7 

8,9& 10 

Total 

Table 8 

Average Daily Panel Requirements 

. for Refrigerator Assembly Line 

(600/0 of two shift production @ 850/0 efficiency) 

PANELS/ PANELS/ WEIGHT/ 

DAY BUNDLE BUNDLE 

2,792 10 40.8 

2,792 15 41.6 

2,792 10 43.8 

1,396 40 38.8 

4,188 20 37.0 

13,960 

BUNDLES/ 

DAY 

280 

187 

280 

35 

210 

992 
M. Bar coding

Each bundle of panels will receive a label bar code to identify the panel size and date of

manufacture. Label bar coding was selected because of its superior clarity over ink jet bar

coding when applied to cardboard. Labels will be printed at the line and placed on the

cardboard cap of each bundle of panels automatically. Equipment selected for this application is the LPA/80T thermal label printer /applicator manufactured by Lord Label Systems,

Inc. [13] (Appendix J).

N. Shipping and Transportation

Panels will be shipped to the refrigerator plant on a just-in-time basis by a captive trailer

fleet. Trailers will be Dorsey vans (48'L X 8.5'W X 13.5'H) which will be retrofitted to give

maximum protection to the panels. Tractors will be Kenworth T600A, fuel efficient day

cabs with a five year, 750,000 mile warranty [19].

All production from the panel plan: will be loaded directly into trailers. A sufficient number of trailers is provided to store the equivalent of two shifts of production for the refrigerator plant in addition to having one being loaded and an empty standing by.

The average daily requirement for production at the refrigerator plant will be about 14,000

panels or 1000 bundles (Table 8). An average of one trailer per day will be needed to deliver this requirement (Table 9).

0. Safety and Environmental Considerations

FSK50OLS silica is an odorless, dry, white powder. The material is completely safe to the

panel plant employees. It is neither toxic nor flammable and there is no explosion hazard.

Adequate ventilation is required and, where dust occurs, a NIOSH-approved dust respirator is recommended.

A Material Safety Data Sheet is shown in Appendix K.

-41-

 EE-RM-93-801 COMMENT OR5

M. Bar coding 

Each bundle of panels will receive a label bar code to identify the panel size and date of 

manufacture. Label bar coding was selected because of its superior clarity over ink jet bar 

coding when applied to cardboard. Labels will be printed at the line and placed on the 

cardboard cap of each bundle of panels automatically. Equipment selected for this applicati,on is the LP A/BOT thermal label printer / applicator manufactured by Lord Label Systems, 

. Inc. [13] (Appendix n. 

N. Shipping and Transportation 

Panels will be shipped to the refrigerator plant ona just-in-time basis by a captive trailer 

fleet. Trailers will be Dorsey vans (48'L X 8.5'W X 13.5'H) which will be r~trofitted to give 

maximum protection to the panels. Tractors will be Kenworth T600A, fuel efficient day 

cabs with a five year, 750,000 mile warranty [19]. 

All production from the panel plan~ will be loaded directly into trailers. A sufficient mim- . 

ber of trailers is provided to store the equivalent of two shifts of production for the refrigerator plant in addition to having one being loaded and an empty standing by. 

The average daily requirement for production at the refrigerator plant will be about 14,000 

panels or 1000 bundles (Table 8). An average of one trailer per day will be needed to deliver this requirement (Table 9). 

o. Safety and Environmental Considerations 

FSKSOOLS silica is an odorless, dry, white powder. The material is completely safe to the 

panel plant employees. It is neither toxic nor flammable and there is no explosion hazard. 

Adequate ventilation is required and, where dust occurs, a NIOSH-approved dust respirator is recommended. 

A Material Safety Data Sheet is shown in Appendix K. 

-41-

M. Bar coding 

Each bundle of panels will receive a label bar code to identify the panel size and date of 

manufacture. Label bar coding was selected because of its superior clarity over ink jet bar 

coding when applied to cardboard. Labels will be printed at the line and placed on the 

cardboard cap of each bundle of panels automatically. Equipment selected for this applicati,on is the LP A/BOT thermal label printer / applicator manufactured by Lord Label Systems, 

. Inc. [13] (Appendix n. 

N. Shipping and Transportation 

Panels will be shipped to the refrigerator plant ona just-in-time basis by a captive trailer 

fleet. Trailers will be Dorsey vans (48'L X 8.5'W X 13.5'H) which will be r~trofitted to give 

maximum protection to the panels. Tractors will be Kenworth T600A, fuel efficient day 

cabs with a five year, 750,000 mile warranty [19]. 

All production from the panel plan~ will be loaded directly into trailers. A sufficient mim- . 

ber of trailers is provided to store the equivalent of two shifts of production for the refrigerator plant in addition to having one being loaded and an empty standing by. 

The average daily requirement for production at the refrigerator plant will be about 14,000 

panels or 1000 bundles (Table 8). An average of one trailer per day will be needed to deliver this requirement (Table 9). 

o. Safety and Environmental Considerations 

FSKSOOLS silica is an odorless, dry, white powder. The material is completely safe to the 

panel plant employees. It is neither toxic nor flammable and there is no explosion hazard. 

Adequate ventilation is required and, where dust occurs, a NIOSH-approved dust respirator is recommended. 

A Material Safety Data Sheet is shown in Appendix K. 

-41-
Table 9

48 Foot Trailer Loading

PANEL #

BUNDLE

DIMENSION

(INCHES)

LOAD BUNDLES/DAY

PATTERN REQUIRED

BUNDLES/

TRAILER

DAILY

TRAILER

UIREMENTS

I & 5 23 x 30 x 10.5 4W(23") x 19L x 14H 280 1064 0.26

2 & 3 23 x 21 x 15.5 4W(23") x 27L x 10H 187 1080 0.17

4 & 6 23 x 32 x 10.5 4W(23") x 17L x 14H 280 952 0.29

7 30 x 12 x 20.5 8W(12") x 19L x 7H 35 1064 0.03

8,9 & 10 30 x 21 x 10.5 3W(30") x 27L x 14H 210 1 134 0.19

Total 0.95

Noon

1. Trailer Dimensions: 98"W x 570"L x 156"H

2. Actual trailer loads would probably be made up of I to 3 different

panels, depending on panel plant and refrigerator plait scheduling.

 EE-RM-93-801 COMMENT OR5

I 

~ 

N 

I 

Table 9 

48 Foot Trailer Loading 

BUNDlE WAD / BUNDLES/DA Y 

PANEL 1# DIMENSION PATfERN REQUIRED 

(INCHES) 

1 & 5 23 x 30 x 10.5 4W(23") x 19L x 14H 280 

2&3 23 x 21 x 15.5 4W(23") x 27L x lOH 187 

4&6 23 x 32 x 10.5 4W(23") x 17L x 14H 280 

7 30 x 12 x 20.5 8W(12") x 19L x 7H 35 

8,9& 10 30 x 21 x 10.5 3W(30") x 27L x 14H 210 

Total 

Nom: 

1. Trailer Dimensions: 98"W x 570"L x 156"H 

2. Actual trailer loads would probably be made up of 1 to 3 different 

panels, depending on panel plant and refrigerator pIa.It scheduling. 

BUNDLES! DAILY 

TRAILER 'tRAILER 

REQUlREMENfS 

1064 0.26 

1080 0.17 

952 0.29 

1064 0.03 

1134 0.19 

--

0.95 

I 

~ 

N 

I 

Table 9 

48 Foot Trailer Loading 

BUNDlE WAD / BUNDLES/DA Y 

PANEL 1# DIMENSION PATfERN REQUIRED 

(INCHES) 

1 & 5 23 x 30 x 10.5 4W(23") x 19L x 14H 280 

2&3 23 x 21 x 15.5 4W(23") x 27L x lOH 187 

4&6 23 x 32 x 10.5 4W(23") x 17L x 14H 280 

7 30 x 12 x 20.5 8W(12") x 19L x 7H 35 

8,9& 10 30 x 21 x 10.5 3W(30") x 27L x 14H 210 

Total 

Nom: 

1. Trailer Dimensions: 98"W x 570"L x 156"H 

2. Actual trailer loads would probably be made up of 1 to 3 different 

panels, depending on panel plant and refrigerator pIa.It scheduling. 

BUNDLES! DAILY 

TRAILER 'tRAILER 

REQUlREMENfS 

1064 0.26 

1080 0.17 

952 0.29 

1064 0.03 

1134 0.19 

--

0.95 
PANEL INSTALLATION INTO REFRIGERATORS

This section describes the facility modifications and equipment needed at the refrigerator

plant.to receive, handle, and install 3,000,000 VIPs per year into three hundred thousand. 21

or 24 cubic foot refrigerators. Modifications are based on generic plant assumptions and

would be different for an actual plant and vary from one plant to another. Panel installation is discussed in the following sections.

A. In-plant receiving, material handling and storage

B. Delivery to assembly areas

C. Adhesive application and panel insertion

D. Quality control

E. Foaming around VIPs

F. Refrigerator plant equipment and incremental operating costs

A. In plant receiving, material handling, and storage .

Panels would be received at two new docks in a new 9,774 square foot building addition.

(Figure 13) Panels would be unloaded using an extendable adjustoveyor in reverse of the

loading method at the panel plant. The adjustoveyor would feed a sortation conveyor.

which would feed eleven, five tier, flow-through racks which hold each of the ten panels

for a refrigerator [11]. A bar code reader integrated with the conveyor controller would

select a tier that was not full and divert the bundle to that tier. A second reader would

divert the bundle into the proper flow-through rack. Each five tier rack would hold from

195 bundles (panel # 1,4,5 & 6) to 350 bundles (panel # 7).

The eleven lanes would hold enough panels to allow the refrigerator assembly line to run

two continuous shifts of models with VIPs. (Table 10) The delivery conveyor will hold

almost enough panels for another shift's run. Since the assumption is that the assembly

lines would average running VIP models only six shifts per week, this is a very conservative inventory plan.

 EE-RM-93-801 COMMENT OR5

PANEL INSTALLATION INTO REFRIGERATORS 

This section describes the facility modifications and equipment needed at the refrigerator 

plant to receive, handle, and install 3,000,000 VIPs per year into three hundred thousand. 21 

or 24 0lbic foot refrigerators. Modifications are based on generic plant assumptions and 

would be different for an actual plant and vary from one plant to another. Panel installation is discussed in the following sectionS. 

A. In-plant receiving, material handling and storage 

B. Delivery to assembly areas 

C. Adhesive application and panel insertion 

~. Quality control 

E. Foaming around VIPs 

F. Refrigerator plant equipment and incremental operating costs 

A. In plant receiving, material handling, and storage 

Panels would be received at two new docks in a new 9,774 square foot building addition. 

(Figure 13) Panels would be unloaded using an extendable adjustoveyor in reverse of the 

loading method at the panel plant. The adjustoveyor would feed a ~rtation conveyor. 

which would feed eleven, five tier, flow-through racks which hold each of the ten panels 

for a refrigerator [11]. A bar code reader integrated with the conveyor controller would 

select a tier that was not full and divert the bundle to that tier. A second reader would 

divert the bundle into the proper flow-through rack. Each five tier rack would hold from 

195 bundles (panel # 1,4,5 & 6) to 350 bundles (panel # 7). 

The eleven lanes would hold enough panels to allow the refrigerator assembly line to run 

two continuous shifts of models with VIPs. (Table 10) The delivery conveyor will hold 

almost enough panels for another shift's run. Since the assumption is that the assembly 

lines would average running VIP models only six shifts per week, this is a very conservative inventory plan. 

-43-

PANEL INSTALLATION INTO REFRIGERATORS 

This section describes the facility modifications and equipment needed at the refrigerator 

plant to receive, handle, and install 3,000,000 VIPs per year into three hundred thousand. 21 

or 24 0lbic foot refrigerators. Modifications are based on generic plant assumptions and 

would be different for an actual plant and vary from one plant to another. Panel installation is discussed in the following sectionS. 

A. In-plant receiving, material handling and storage 

B. Delivery to assembly areas 

C. Adhesive application and panel insertion 

~. Quality control 

E. Foaming around VIPs 

F. Refrigerator plant equipment and incremental operating costs 

A. In plant receiving, material handling, and storage 

Panels would be received at two new docks in a new 9,774 square foot building addition. 

(Figure 13) Panels would be unloaded using an extendable adjustoveyor in reverse of the 

loading method at the panel plant. The adjustoveyor would feed a ~rtation conveyor. 

which would feed eleven, five tier, flow-through racks which hold each of the ten panels 

for a refrigerator [11]. A bar code reader integrated with the conveyor controller would 

select a tier that was not full and divert the bundle to that tier. A second reader would 

divert the bundle into the proper flow-through rack. Each five tier rack would hold from 

195 bundles (panel # 1,4,5 & 6) to 350 bundles (panel # 7). 

The eleven lanes would hold enough panels to allow the refrigerator assembly line to run 

two continuous shifts of models with VIPs. (Table 10) The delivery conveyor will hold 

almost enough panels for another shift's run. Since the assumption is that the assembly 

lines would average running VIP models only six shifts per week, this is a very conservative inventory plan. 

-43-
Figure 13

VIP Receiving Area - Refrigerator Plant

Refrigerator

Plant

O Monorail Conveyor

to Prefoon Areas

Flow Thru Rocks

(36" x 75' )

® Sortu'^ion

Conveyor

Adjustoveyor

® 4B' Trailers

® Material Handlers

%ft

181.0

54.0

 EE-RM-93-801 COMMENT OR5

Figure 13 

VI P Receiving Area - Refrigerator Plant 

~------------------------~--~~ ~ 

r-, .... trc;<)v I I 1~5) 

CD 

(2) 

(3) 

CD 

(5) 

00 

Refrigerator 

Plant 

Monorai I Conveyor 

to Prefoan Areas 

Flow Thru Racks 

(36/1 X 75' ) 

Sorto~ i on 

Conveyor 

Adjustoveyor 

48' T ra i I ers 

Material Handlers 

-44-

I 

I 

(2) 

I II~ 

I I 

I I 

/--1 

I I 

I I 

I I 

I I 

~--I 

I I 

I I 

I I 

!'-!-' ~ 

Q) ~ 

;; 

1 ...... .. --54.0---..1.1 

181 .0 

.< 

Figure 13 

VI P Receiving Area - Refrigerator Plant 

~v--------------------------~~~ ~ 

n'ifl:<\'V 

I IIQ; 

CD 

(2) 

(3) 

CD 

(5) 

00 

Refrigerator 

Plant 

Monorai I Conveyor 

to Prefoan Areas 

Flow Thru Racks 

(36/1 X 75' ) 

Sorto~ i on 

Conveyor 

Adjustoveyor 

48' T ra i I ers 

Material Handlers 

-44-

I 

(2) 

. I I 

I I 

I I 

/--1 

I I 

I I 

I I 

I I 

~--I 

I I 

I I 

I I 

V:r f'-!-' 

Q) ~ 

-/ 

1 ..... . --54.0 ----..1.1 

181 .0 

.' 
Table 10

Flow Thru Rack Requirements

(Racks 32"W x 75'L x 5 Lanes High)

BUNDLE PANEL

PANEL # DIMENSIONS ORIENTATION

30"

1&5 23x30x10.5

2&3 23x21x15.5

4&6 23x32x10.5

7 30x 12x20.5

8, 9 & 10 30x'21 x 10.5

T 23"

23"

T 21"

32"

30"

30

23"

12"

21"

BUNDLES/

BUNDLES USED

PER HOUR AT

LANES

REQUIRED LANES

LANE REFRIG. ASSY. FOR 2 SHIFTS PLANNED

(@ 180/hour)

195 36 2.8 3

210 24 1.8 2

195 36 2.8 - 3

375 9 0.4 1

210 27 2.0 . 2

11

 EE-RM-93-801 COMMENT OR5

BUNDI.E 

PANEL H DIMENSIONS 

1 & 5 23 x 30 x 10.5 

I 

~ 2&3 23 x 21 x 15.5 

I 

4&6 23 x 32 x 10.5 

7 30 x 12 x 20.5 

8,9& 10 30 x '21 x 10.5 

Table 10 

Flow Thru Rack Requirements 

(Racks 32"W x 75'L x 5 Lanes High) 

BUNDLES USED 

PANEL BUNDLES! PER HOUR AT 

ORIENTATION LANE REFRIG. ASSY. 

(@ 180/hour) 

30" 

W23" 195 36 

23" 

W21" 210 24 

32" 

i 123" 195 36 

30" 

i \t2" 375 9 

30"-

i 121 " 210 27 

LANES 

REQUIRED LANES 

FOR 2 SHIFTS PLANNED 

2.8 3 

1.8 2 

2.8 3 

0.4 1 

2.0 2 

1 1 

BUNDI.E 

PANEL H DIMENSIONS 

1 & 5 23 x 30 x 10.5 

I 

~ 2&3 23 x 21 x 15.5 

I 

4&6 23 x 32 x 10.5 

7 30 x 12 x 20.5 

8,9& 10 30 x '21 x 10.5 

Table 10 

Flow Thru Rack Requirements 

(Racks 32"W x 75'L x 5 Lanes High) 

BUNDLES USED 

PANEL BUNDLES! PER HOUR AT 

ORIENTATION LANE REFRIG. ASSY. 

(@ 180/hour) 

30" 

W23" 195 36 

23" 

W21" 210 24 

32" 

i 123" 195 36 

30" 

i \t2" 375 9 

30"-

i 121 " 210 27 

LANES 

REQUIRED LANES 

FOR 2 SHIFTS PLANNED 

2.8 3 

1.8 2 

2.8 3 

0.4 1 

2.0 2 

1 1 
Both the sortation conveyor and the flow-through racks would be center drive belt conveyors controlled by a common controller and integrated with laser bar code readers [11].

Three hourly paid material handlers, on each of two shifts, would unload the panels from

the van trailers onto the adjustoveyor and from the flow-through racks onto a continuous

conveyor for delivery to the pre-foam areas.

B. Delivery to assembly areas

Four options were considered to move the panels from the receiving area to the case, liner,

and door pre-foam areas-fork trucks, automatic guided vehicles (AGVs), belt conveyor,

and overhead monorail. Both fork trucks and AGVs would require an overpack and a skid.

These methods would reduce truck loads and create dunnage removal problems. They

would also add to product cost.

Belt conveyor would offer the possibility of feeding individual panels to specific stations on

each Li by the use of bar coding. Pant-.s could be automatically fed into magazines for

robotic pick up, eliminating the need for manual material transfer. However, it would be

difficult and costly to retrofit most existing plants with such a system.

The overhead monorail conveyor method was assumed for costing in this study [12]. This

system could probably be installed in most plants even though considerable rearrangement

of existing facilities may be required.

Fifteen hundred feet of enclosed track conveyor with 250 four tray hangers on six foot

centers would be installed. The conveyor would run about 18 feet per minute, which would

provide as many as 120 panels per minute to any one station. The case line would require

only 18 panels per minute.

This system, with required drives and other auxiliary equipment, was estimated by

Unibuilt, a division of Jervis B. Webb Company (Appendix L) to cost approximately $110

per foot, installed [12].

 EE-RM-93-801 COMMENT OR5

BOth the sortation conveyor and the flow-through racks would be center drive belt conveyors controlled by a common controller and integrated with laser bar code readers [11]. 

Three hourly paid material handlers, on each of two shifts, would unload the panels from 

the van trailers onto the adjustoveyor and from the flow-through racks onto a continuous 

conveyor for delivery to the pre-foam areas. 

B. Delivery to assembly areas 

Four options were considered to move the panels from the receiving area to the case, liner, 

and door pre-foam areas-fork trucks, automatic guided vehicles (AGVs), belt conveyor, 

and overhead monorail. Both fork trucks and AGVs would require an overpack and a skid. 

These methods would reduce truck loads and create dunnage removal problems. They 

would also add to product cost. 

Belt conveyor would offer the possibility of feeding individual panels to specific stations on 

each lir:e by the use of bar coding. Pant:'; could be automati(:.illy fed into magazines for 

robotic pick up, eliminating the need for manual material transfer. Iiowever, it would be 

difficult and costly to retrofit most existing plants with such a system. 

The overhead monorail conveyor method was assumed for costing in this study [12]. This 

system could probably be installed in most plants even though considerable rearrangement 

of existing facilities may be required. 

Fifteen hundred feet of enclosed track conveyor with 250 four tray hangers on six foot 

centers would be installed. The conveyor would run about 18 feet per minute, which would 

provide as many as 120 panels per minute to anyone station. The case line would require 

only 18 panels per minute. 

This system, with required drives and other auxiliary equipment, was estimated by 

Unibuilt, a division of Jervis B. Webb Company (Appendix L) to cost approximately $110 

per foot, installed [12]. 

-46-

BOth the sortation conveyor and the flow-through racks would be center drive belt conveyors controlled by a common controller and integrated with laser bar code readers [11]. 

Three hourly paid material handlers, on each of two shifts, would unload the panels from 

the van trailers onto the adjustoveyor and from the flow-through racks onto a continuous 

conveyor for delivery to the pre-foam areas. 

B. Delivery to assembly areas 

Four options were considered to move the panels from the receiving area to the case, liner, 

and door pre-foam areas-fork trucks, automatic guided vehicles (AGVs), belt conveyor, 

and overhead monorail. Both fork trucks and AGVs would require an overpack and a skid. 

These methods would reduce truck loads and create dunnage removal problems. They 

would also add to product cost. 

Belt conveyor would offer the possibility of feeding individual panels to specific stations on 

each lir:e by the use of bar coding. Pant:'; could be automati(:.illy fed into magazines for 

robotic pick up, eliminating the need for manual material transfer. Iiowever, it would be 

difficult and costly to retrofit most existing plants with such a system. 

The overhead monorail conveyor method was assumed for costing in this study [12]. This 

system could probably be installed in most plants even though considerable rearrangement 

of existing facilities may be required. 

Fifteen hundred feet of enclosed track conveyor with 250 four tray hangers on six foot 

centers would be installed. The conveyor would run about 18 feet per minute, which would 

provide as many as 120 panels per minute to anyone station. The case line would require 

only 18 panels per minute. 

This system, with required drives and other auxiliary equipment, was estimated by 

Unibuilt, a division of Jervis B. Webb Company (Appendix L) to cost approximately $110 

per foot, installed [12]. 

-46-
It was assumed that 2000 square feet of floor space would have to be added, either as a

mezzanine or a building appendage, to offset the space consumed by rearrangement to

install this system. Actual rearrangement requirements and costs would have to be adjusted for a given plant and would depend on that plant's construction, layout, and available floor space.

This conveyor would deliver panels to case pre-foam, door'pre-foam, and liner pre-foam,

and have storage capacity for about eight hours of production.

Panels will be unloaded manually from the monorail conveyor, the strap will be removed,

and individual panels will be placed on the appropriate queuing conveyor at each case line,

liner line, or door line station. Two material handlers per shift will service the case and

liner lines, and one material handler per shift will service door pre-foam . Queuing conveyors will have appropriate indexing devices to locate each panel for accurate robot pick up.

C. Adhesive application and panel ir-aertion

On the case pre-foam line, the case will be positioned via shot pins or some other positioning and holding mechanism and a GMF S-500, six-axis, articulated, electric robot (Appendix M) will apply an adhesive dispensed from a bulk unit to the case interior [8]. Two.

robots will be required to spray patterns needed to hold the six VIPs to be placed at the

succeeding stations. Both robots will be supplied from a common Nordson hot melt unit

(Appendix N) [5]. The hot melt material cost is included ® $0.08 / square foot. Three more

GMF S-500 robots will be used to place six panels into the case as shown in Figure 14. Each

robot will place two panels.

Hot melt and panel placement stations would be added between the existing case seal

stations and the foam release stations, requiring some line rearrangement. The existing

foam release stations would be converted to panel adhesive application and two new foam

release stations would be added after panel insertion.

 EE-RM-93-801 COMMENT OR5

It was assumed that 2000 square feet of floor space would have to be added, either as a 

mezzanine or a building appendage, to offset the space consumed by rearrangement to 

install this system. Actual rearrangement requirements and costs would have to be adjusted for a given plant and would depend on that plant's construction, layout, and available floor space. 

This conveyor would deliver panels to case pre-foam, door· pre-foam, and liner pre-foam,· 

and have storage capacity for about eight hours of production. 

Panels will be unloaded manually from the monorail conveyor, the strap will be removed, 

and individual panels will be placed on the appropriate queuing conveyor at each case line, 

liner line, or door line station. Two material handlers per shift will service the case and 

liner lines, and one material handler per shift will service door pre-foam. Queuing conveyors will have appropriate indexing devices to locate each panel for accurate robot pick up. 

C. Adhesive application and panel irisertion 

On the case pre-foam line, the case will be positioned via shot pins or some other positioning and holding mechanism and a GMF 5-500, six-axis, articulated, electric robot (Appendix M) will apply an adhesive dispensed from a bulk unit to the case interior [8]. Two. 

robots will be required to spray patterns needed to hold the six VIPs to be placed at the 

succeeding stations. Both robots will be supplied from a common Nordson hot melt unit 

(Appendix N) [5]. The hot melt material cost is included @$O.08 / square foot. Three more 

GMF 5-500 robots will be used to place six panels into the case as shown in Figure 14. Each 

robot will place two panels. 

. 

Hot melt and panel placement stations would be added between the existing case seal 

stations and the foam release stations, requiring some line rearrangement. The existing 

foam release stations would be converted to panel adhesive application and two new foam 

release stations would be added aIter panel insertion. 

-47-

It was assumed that 2000 square feet of floor space would have to be added, either as a 

mezzanine or a building appendage, to offset the space consumed by rearrangement to 

install this system. Actual rearrangement requirements and costs would have to be adjusted for a given plant and would depend on that plant's construction, layout, and available floor space. 

This conveyor would deliver panels to case pre-foam, door· pre-foam, and liner pre-foam,· 

and have storage capacity for about eight hours of production. 

Panels will be unloaded manually from the monorail conveyor, the strap will be removed, 

and individual panels will be placed on the appropriate queuing conveyor at each case line, 

liner line, or door line station. Two material handlers per shift will service the case and 

liner lines, and one material handler per shift will service door pre-foam. Queuing conveyors will have appropriate indexing devices to locate each panel for accurate robot pick up. 

C. Adhesive application and panel irisertion 

On the case pre-foam line, the case will be positioned via shot pins or some other positioning and holding mechanism and a GMF 5-500, six-axis, articulated, electric robot (Appendix M) will apply an adhesive dispensed from a bulk unit to the case interior [8]. Two. 

robots will be required to spray patterns needed to hold the six VIPs to be placed at the 

succeeding stations. Both robots will be supplied from a common Nordson hot melt unit 

(Appendix N) [5]. The hot melt material cost is included @$O.08 / square foot. Three more 

GMF 5-500 robots will be used to place six panels into the case as shown in Figure 14. Each 

robot will place two panels. 

. 

Hot melt and panel placement stations would be added between the existing case seal 

stations and the foam release stations, requiring some line rearrangement. The existing 

foam release stations would be converted to panel adhesive application and two new foam 

release stations would be added aIter panel insertion. 

-47-
Figure 14

Case and Liner Pre-Foam Areas with VIPs

1, Seal Case

2. Apply Foam Release

3, Foam Release Cure Ovens

4. Liner Insert Station

5. Adhesive Application Stations

6. Panel Placement Stations

7. Overhead Panel Delivery Conveyor

Manual Operators

(8) Added Material Hanr^^r^ L, ,;riir't

Cases From

Fabrication

7

 EE-RM-93-801 COMMENT OR5

I 

~ 

co 

I 

Figure 14 

Case and Liner Pre-Foam Areas with VIPs 

Liners frorl 

VQCUUI'I ForPl 

• 

l. Seal Case 

2, Apply F OQM ReleQse 

3, F OQM Release eire Ovens 

4, Liner Insert Station 

5, Adhesive ApplicQtion Stations 

6, Panel PlaceMent StQ tiOns 

7, Dvemend Panel Delivery Conveyor 

<X) Manual Dpern tors 

® Added Material HQnd!l'!"s :/Shift 

3 

~ I 6 t®_J--

C4ses Frol'l 

F QbrlcQ tion .. 

r----, 

:~~I :.4--V..1"~ 

__ I ~I~I 

L ___ --..1 

7 

I 

~ 

co 

I 

Figure 14 

Case and Liner Pre-Foam Areas with VIPs 

Liners frorl 

VQCUUI'I Forl'l 

• 

l. Seal Case 

2, Apply F OQM ReleQse 

3, F OQM Release eire Ovens 

4, Liner Insert Station 

5, Adhesive Applicntion Stations 

6, Panel PlaceMent StatiOns 

7, Dvemend Panel Delivery Conveyor 

<X) Manual Dpern tors 

® Added Material HQnd!l'!"s :/Shift 

~ I 6 

t®_J 

C4ses Frol'l 

F QbrlcQ tion .. 

r----, 

:~~I 

__ I ~I~I 

L ___ --..1 

7 
On the liner pre-foam line, one GMF S-500 will apply adhesive to the fresh food back panel

and place the panel on the liner back (Figure 14 ). A third Nordson hot melt unit would be

used for this robot.

Two GMF S-500 robots will be required on the door pre-foam line. Each of these robots will

apply adhesive inside the doors and place one or two panels into the doors. The robots will

place one or two panels on alternate cycles to meet the station cycle time. Figure 15 shows

the modified layout of the door pre-foam area. Some rearrangement also will be required

on this line. A common Nordson hot melt unit would feed both of these robots.

It was assumed that 4000 square feet of mezzanine or building appendage would have to

be added to accommodate rearrangement required to make room for the adhesive and

panel insertion stations. Actual rearrangement requirements and costs would have to be

adjusted for any given plant and would depend on that plant's layout and available floor

space.

A budget estimate of the cost for these stations, including eight robots, end effectors, panel

and case/liner/door positioning stations and hot melt units was developed by Remtec, Inc.

and is shown in Appendix 0 [7]. Remtec's cost estimates for the hot melt and pre-foam

stations were deemed to be considerably low. Based on an estimate from Nordson, the hot

melt stations were re-estimated at about 160% higher than Remtec's estimate. Also, UK

engineers replaced the Remtec estimate for pre-foam stations with one about 250% higher.

D. Quality Control

Each panel will be checked for vacuum before it is placed into the case, door, or onto the

liner. This will be done using a TapTone magnetic impulse unit as part of the robot end

effector or as an independent unit at the end of the panel queues [14].

49

 EE-RM-93-801 COMMENT OR5

On the liner pre-foam line, one GMF 5-500 will apply adhesive to the fresh food back panel 

and plaCe the panel on the liner back (Figure 14). A third Nordson hot melt unit would ~ 

used for this robot. 

Two GMF 5-500 robots will be required on the door pre-foam line. Each of these robots will 

apply adhesive inside the doors and place one or two panels into the doors. The robots will 

place one or two panels on alternate cycles to meet the station cycle time. Figure 15 shows· 

the modified layout of the door pre-foam area. Some rearrangement also will be required 

on this line. A common Nordson hot melt unit would feed both of these robots. 

It was assumed that 4000 square feet of mezzanine or building appendage would have to 

be added to accommodate rearrangement required to make room for the adhesive and 

panel insertion stations. Actual rearrangement requirements and costs would have to be I 

adjusted for any given plant and would depend on that plant's layout and available floor 

space. 

A budget estimate of the cost for these stations, including eight robots, end effectors, panel 

and case/liner / door positioning stations and hot melt units was developed by Remtec, Inc. 

and is shown in Appendix 0 [7]. Remtecs cost estimates for the hot melt and pre-foam . 

stations were deemed to be considerably low. Based on an estimate from Nordson, the hot 

melt stations were re-estimated at about 160% higher than Remtec's estimate. Also, UK 

engineers replaced the Remtec estimate for pre-foam stations with one about 259% higher. 

D. Quality Control 

Each panel will be checked for vacuum before it is placed into the case, door, or onto the 

liner. This will be done using a TapTone magnetic impulse unit as part of the robot end 

effector or as an independent unit at the end of the panel queues [14]. 

-49-

On the liner pre-foam line, one GMF 5-500 will apply adhesive to the fresh food back panel 

and plaCe the panel on the liner back (Figure 14). A third Nordson hot melt unit would ~ 

used for this robot. 

Two GMF 5-500 robots will be required on the door pre-foam line. Each of these robots will 

apply adhesive inside the doors and place one or two panels into the doors. The robots will 

place one or two panels on alternate cycles to meet the station cycle time. Figure 15 shows· 

the modified layout of the door pre-foam area. Some rearrangement also will be required 

on this line. A common Nordson hot melt unit would feed both of these robots. 

It was assumed that 4000 square feet of mezzanine or building appendage would have to 

be added to accommodate rearrangement required to make room for the adhesive and 

panel insertion stations. Actual rearrangement requirements and costs would have to be I 

adjusted for any given plant and would depend on that plant's layout and available floor 

space. 

A budget estimate of the cost for these stations, including eight robots, end effectors, panel 

and case/liner / door positioning stations and hot melt units was developed by Remtec, Inc. 

and is shown in Appendix 0 [7]. Remtecs cost estimates for the hot melt and pre-foam . 

stations were deemed to be considerably low. Based on an estimate from Nordson, the hot 

melt stations were re-estimated at about 160% higher than Remtec's estimate. Also, UK 

engineers replaced the Remtec estimate for pre-foam stations with one about 259% higher. 

D. Quality Control 

Each panel will be checked for vacuum before it is placed into the case, door, or onto the 

liner. This will be done using a TapTone magnetic impulse unit as part of the robot end 

effector or as an independent unit at the end of the panel queues [14]. 

-49-
Figure 15

Door Pre-Foam Area with VIPs

Door

DeI ivery

fron Paint

ff^

Door Foon

Systen

)i

OO 5

To Inner Door

I AssenbIy

1. Freezer Door

2. Fresh Food Door

3. Load Foon Conveyor

4. Unload Foon Conveyor

5. Panel Delivery Conveyor

5. Adhesive Application &

Panel Placenent Robots

Maria l Operators

Added Material Handler

 EE-RM-93-801 COMMENT OR5

Door 

Delivery 

fron Point 

CD 

3 

Figure 15 

\ 

\ 

Door Pre-Foam Area with VIPs 

To lmer lbor 

Asseri>ly 

L-~~~~~r - - - - - --' 

) 1 

Door Foan 

Systen 

I I 

I I 

I I 

. I I 

I I 

I I 

J J ~~=rr~~=,~~~nm~ - - - - - --/ 

® 5 

-50-

1. Freezer Door 

2. Fresh Food Ibr 

3. lood Foon. (mveyor 

4. tillood Foon Conveyor 

5. Pone I Del ivery Conveyor 

6. Attesive Awl icotion & 

Pone I Plocenent Robots 

CD fblUl I ~Qtors ® Adred fbteriol ItlOOler 

Door 

Delivery 

fron Point 

CD 

3 

Figure 15 

\ 

\ 

Door Pre-Foam Area with VIPs 

To lmer lbor 

Asseri>ly 

® 

-50-

------, 

Door Foan 

Systen 

) 1 

I I 

I I 

I I 

. I I 

I I 

I I 

J J ~~il_+_------/ 

~~r - - - -._-

5 

1. Freezer Door 

2. Fresh Food Ibr 

3. lood Foon. (mveyor 

4. tillood Foon Conveyor 

5. Pone I Del ivery Conveyor 

6. Attesive Awl icotion & 

Pone I Plocenent Robots 

CD fblUl I ~Qtors ® Adred fbteriol ItlOOler 
E. Foaming around VIPs

After VIPs are positioned in the cases and doors and on the liner back, units will enter the

respective foam systems where the VIPs will be foamed in place. Both the dimensions and

location of the VIPs will affect the foam flow path and, therefore the quality of the fill.

Panel sizes used in this study were developed with this consideration. Considerable development of VIP sizes and foam chemical compositions and distribution will be required

prior to implementation of a production system. Compatibility between foam chemicals

and barrier envelopes could also be an issue which may require further development.

F. Refrigerator plant equipment and incremental operating cost

Equipment required for the refrigerator plant is summarized in Table 11, along with the

associated costs. A 25% contingency is included. Additional personnel and incremental

operating costs are summarized in Table 12.

 EE-RM-93-801 COMMENT OR5

E. Foaming ar.ound VIPs 

After VIPs are positioned in the cases and doors and on the liner back, units will enter the 

respective fOaIl) systems where the VIPs will be foamed in place. Both the dimensions and 

location of the VIPs will affect the foam flow path and, therefore the quality of the fill. 

Panel sizes used in this study were developed with this consideration. Considerable development of VIP sizes and foam chemical compositions and distribution will be required 

prior to implementation of a production system. Compatibility between foam chemicals 

and barrier envelopes could also be an issue which may require further development. 

F. Refrigerator plant equipment and Incremental operating cost 

Equipment required for the refrigerator plant is summarized in Table 11, along with the 

associated costs. A 25% contingency is included. Additional personnel and incrementciI 

operating costs are summarized in Table 12. 

-51-

E. Foaming ar.ound VIPs 

After VIPs are positioned in the cases and doors and on the liner back, units will enter the 

respective fOaIl) systems where the VIPs will be foamed in place. Both the dimensions and 

location of the VIPs will affect the foam flow path and, therefore the quality of the fill. 

Panel sizes used in this study were developed with this consideration. Considerable development of VIP sizes and foam chemical compositions and distribution will be required 

prior to implementation of a production system. Compatibility between foam chemicals 

and barrier envelopes could also be an issue which may require further development. 

F. Refrigerator plant equipment and Incremental operating cost 

Equipment required for the refrigerator plant is summarized in Table 11, along with the 

associated costs. A 25% contingency is included. Additional personnel and incrementciI 

operating costs are summarized in Table 12. 

-51-
Table 11

Refrigerator Plant Equipment

EQUIPMENT NUMBER VENDOR COST/EACH TOTAL SHIPPING NSTALLATIO TOTAL COST

Receiving docks 2 $20,000 $40,000 $40,000

Receiving area 9774 sq. ft. $40/sq. ft. 390,960 390,960

Adjustoveyors 1 STEWARTGLAPA 45,000 45,000 $1,350 $4,500 50,850

Flow thru, racks 11 MATHEWS 29,000 319,000 5,000 31,900 355,900

Sortation conveyor I MATHEWS 65,000 65,000 3,000 6,500 74,500

Bar code readers 6 3,000 18,000 500 1,800 20,300

Overhead conveyor 1500 ft. UNIBUILT $110/ft. 165,000 INCLUDED INCLUDED 165,000

Conveyor drives 3 UNIBUILT 6,000 18,000 INCLUDED INCLUDED 18,000

Hangers 250 UNIBUILT 100 25,000 1,000 1,000 27,000

Robots 8 GMF 100,000 800,000 12,000 80,000 892,000

Robot tooling-case REMTEC 28,000 2,800 30,800

Robot tooling-door REMTEC 12,000 1,200 13,200

Robot tooling-liner REMTEC 8,000 800 8,800

Hot melt stations 3 NORDSON 41,000 123,000 3,690 12,300 138,990

Vacuum check 5 BENTHOS 26,000 130,000 1,300 .13,000 144,300

Asm. line stations

Case line 5 REMTEC 20,000 100,000 3,000 10,000 113,000

Door line 2 REMIEC 20,000 40,000 1,200 4,000 45,200

Liner line I REIVITEC 20,000 20,000 $600 $2,000 22,600

Rearrangement 6,000 sq. ft. $50/sq. ft. 300,000 300,000

Spare parts $95,000 $95 000

Total cost $2,946,400

25% Contingency 736,600

Total with contingency $3,683,000

 EE-RM-93-801 COMMENT OR5

I 

<II 

I'll 

I 

EQUWMENT 

Receiving docks 

Receiving area 

Adjustoveyors 

Flow thru racks 

Sortation conveyor 

Bar code readers 

dverhead conveyor 

Conveyor drives 

Hangers 

Robots 

Robot tooling-case 

Robot tooling-door 

Robot tooling-liner 

Hot melt stations 

Vacuum check 

Asm. line stations 

Case line 

Door line 

Liner line 

Rearrangement 

Spare parts 

Total cost 

25% Contingency 

Total with contingency 

NUMBER 

2 

9774 sq. ft. 

1 

1 1 

1 

6 

1500 ft. 

3 

250 

8 

3 

5 

5 

2 

1 

6,000 sq. ft. 

Table 11 

Refrigerator Plant Equipment 

VENDOR COST lEACH TOTAL SHIPPING 

$20,000 $40,000 

$40/sq. ft. 390,960 

STEWART GLAPAT 45,000 45,000 $1,350 

MATHEWS 29,000 319,000 5,000 

MATHEWS 65,000 65,000 3,000 

3,000 18,000 500 

UNIBUILT $110/ft. 165,000 IN(l.UOED 

NST ALLATIOI\ 

$4,500 

31,900 

6,500 

1,800 

IN(l.UOED 

UNIBUILT 6,000 18,000 IN(l.UOED . IN(l.UOED 

UNIBUILT 100 25,000 1,000 1,000 

GMF 100,000 800,000 12,000 80,000 

REMIEC 28,000 2,800 

REMIEC 12,000 1,200 

REMIEC 8,000 800 

NORDSON 41,000 123,000 3,690 12,300 

BENTHOS 26,000 130,000 1,300 . 13,000 

REMIEC 20,000 100,000 3,000 10,000 

REMIEC 20,000 40,000 1,200 4,000 

REMIEC 20,000 20,000 $600 $2,000 

$50/sq. ft. 300,000 

$95,000 

TOfALCOST 

$40,000 

390,960 

50,850 

355,900 

74,500 

20,300 

165,000 

18,000 

27,000 

892,000 

30,800 

13,200 

8,800 

138,990 

144,300 

113,000 

45,200 

22,600 

300,000 

$95,000 

$2,946,400 

736,600 

$3,683,000 

I 

<II 

I'll 

I 

EQUWMENT 

Receiving docks 

Receiving area 

Adjustoveyors 

Flow thru racks 

Sortation conveyor 

Bar code readers 

dverhead conveyor 

Conveyor drives 

Hangers 

Robots 

Robot tooling-case 

Robot tooling-door 

Robot tooling-liner 

Hot melt stations 

Vacuum check 

Asm. line stations 

Case line 

Door line 

Liner line 

Rearrangement 

Spare parts 

Total cost 

25% Contingency 

Total with contingency 

NUMBER 

2 

9774 sq. ft. 

1 

1 1 

1 

6 

1500 ft. 

3 

250 

8 

3 

5 

5 

2 

1 

6,000 sq. ft. 

Table 11 

Refrigerator Plant Equipment 

VENDOR COST lEACH TOTAL SHIPPING 

$20,000 $40,000 

$40/sq. ft. 390,960 

STEWART GLAPA 1 45,000 45,000 $1,350 

MATHEWS 29,000 319,000 5,000 

MATHEWS 65,000 65,000 3,000 

3,000 18,000 500 

UNIBUILT $110/ft. 165,000 IN(l.UOED 

~NSTALLATION 

$4,500 

31,900 

6,500 

1,800 

IN(l.UOED 

UNIBUILT 6,000 18,000 IN(l.UOED . IN(l.UOED 

UNIBUILT 100 25,000 1,000 1,000 

GMF 100,000 800,000 12,000 80,000 

REMIEC 28,000 2,800 

REMIEC 12,000 1,200 

REMIEC 8,000 800 

NORDSON 41,000 123,000 3,690 12,300 

BENTHOS 26,000 130,000 1,300 . 13,000 

REMIEC 20,000 100,000 3,000 10,000 

REMIEC 20,000 40,000 1,200 4,000 

REMIEC 20,000 20,000 $600 $2,000 

$50/sq. ft. 300,000 

$95,000 

TOfALCOST 

$40,000 

390,960 

50,850 

355,900 

74,500 

20,300 

165,000 

18,000 

27,000 

892,000 

30,800 

13,200 

8,800 

138,990 

144,300 

113,000 

45,200 

22,600 

300,000 

$95 000 

$2,946,400 

736,600 

$3,683,000 
Table 12

Additional Operating Cost Refrigerator Plant

NUMBER HOURLY RATE ANNUAL WAGE* BENEFITS

(40%)

OVERHEAD

(200%)

ANNUAL COST

SALARIED PERSONNEL

Foreman 2 $30,000 $12,000 $84,000

HOURLY PERSONNEL

Receiving 6 $12 21,120 42,240 380,160

Maintenance 2 $21 36,960 73,920 221,760

Material Handlers 6 $15 $26,400 $52,800 475,200

$1,077,120

Total additional

annual operating cost $1,161,120

*Based on 220 days/year for hourly personnel

 EE-RM-93-801 COMMENT OR5

Table 12 

Additional Operating Cost - Refrigerator Plant 

NUMBER HOURLYRAlE ANNUAL WAGE· BENEFITS OVERHEAD ANNUAL COST 

(40%) (200%) 

SALARIED PERSONNEL 

Foreman 2 $30,000 $12,000 $84,000 

. HOURLY PERSONNEL 

I Receiving 6 $12 21,120 42,240 380,160 

~ Maintenance 2 $21 36,960 73,920 221,760 

I Material Handlers 6 $15 $26,400 $52,800 475,200 

$1,077,120 

Total additional 

annual operating cost $1,161,120 

*Based on 220 days/year for hourly personnel 

Table 12 

Additional Operating Cost - Refrigerator Plant 

NUMBER HOURLYRAlE ANNUAL WAGE· BENEFITS OVERHEAD ANNUAL COST 

(40%) (200%) 

SALARIED PERSONNEL 

Foreman 2 $30,000 $12,000 $84,000 

. HOURLY PERSONNEL 

I Receiving 6 $12 21,120 42,240 380,160 

~ Maintenance 2 $21 36,960 73,920 221,760 

I Material Handlers 6 $15 $26,400 $52,800 475,200 

$1,077,120 

Total additional 

annual operating cost $1,161,120 

*Based on 220 days/year for hourly personnel 
TOTAL PROGRAM AND PRODUCT COST FOR

VACUUM INSULATION PANEL PRODUCTION AND INSTALLATION

Program Cost

Program.costs are non-recurring costs to plan and implement the project. These costs

indude investment to purchase and install facilities and equipment, expense for tooling,

and any rearrangement expense required in the existing refrigerator plant. Historic ratios

of investment and expense for similar projects were used.

Program costs also include manpower to plan and implement the project, and start-up cost

incurred in both the panel plant and the refrigerator plant. Seventy-five thousand dollars

per man year was used for manpower cost.

Start-up costs for the panel plant includes manpower, as described in the section on

'Troject Schedule and Start-up," associated overhead and material for 50,000 development

panels, and lost labor and rn aterial from the start-up curve. An assumption was made that

60% of the silica can be reclaimed from panels produced during development. An estimate

of start-up cost at the refrigerator plant also is included.

A summary of the program cost is shown in Table 13.

. Product Costs

Product cost includes all direct material and direct labor included in or added to the product or its packaging and shipping and associated overhead cost. Overhead includes items

such as overtime premium, night shift bonus, rework, scrap, and hourly employee benefits

(medical insurance, vacation and holiday pay, etc.).

Other operating costs include utilities, trash removal, taxes, insurance, office expenses,

security, safety, etc. No added warranty costs are included although there is likely to be

additional warranty cost as a result of the incorporation of VIPs. Some amount of warranty

reserves should be planned for service calls which may result from V1Ps.

54

 EE-RM-93-801 COMMENT OR5

TOTAL PROGRAM AND PRODUCT COST FOR 

VAC,UUM INSULATION PANEL PRODUCTION AND INSTALLATION 

Program Cost 

Program,costs are non-recurring costs to plan and implement the project. These costs 

indude investment to purchase and install facilities and equipment, expense for tooling, 

and any rearrangement expense required in'the existing refrigerator plant. Historic ratios 

of investment and expense for similar projects were used. 

Program costs also include manpower to plan and implement the project, and start-up cost 

incurred in both the panel plant and the refrigerator plant. Seventy-five thousand dollars 

pet man year was used for manpower cost. 

Start-up costs for the panel plant includes manpower, as described in the section on 

''Project Schedule and Start-up," associated overhead and material for 50,000 development 

panels, and lost labor and rn~terial from the start-up curve. An assumption was made that 

60% of the silica can be reclaimed from panels produced during development. An estimate 

of start-up cost at the refrigerator plant also is included. 

A summary of the program cost is shown in Table 13. 

Product Costs 

Product cost includes all direct material and direct labor included in or added to the product or its packaging and shipping and associated overhead cost. Overhead includes items 

such as overtime premium, night shift bonus, rework, scrap, and hourly employee benefits 

(medical insurance, vacation and holiday pay, etc.). 

Other operating costs include utilities, trash removal, taxes, insurance, office expenses, 

security, safety, etc. No added warranty costs are included although there is likely to be 

additional warranty cost as a result of the incorporation of VIPs. Some amount of warranty 

reservE;?S should be planned for service calls whlch may result from VIPs. 

-54-

TOTAL PROGRAM AND PRODUCT COST FOR 

VAC,UUM INSULATION PANEL PRODUCTION AND INSTALLATION 

Program Cost 

Program,costs are non-recurring costs to plan and implement the project. These costs 

indude investment to purchase and install facilities and equipment, expense for tooling, 

and any rearrangement expense required in'the existing refrigerator plant. Historic ratios 

of investment and expense for similar projects were used. 

Program costs also include manpower to plan and implement the project, and start-up cost 

incurred in both the panel plant and the refrigerator plant. Seventy-five thousand dollars 

pet man year was used for manpower cost. 

Start-up costs for the panel plant includes manpower, as described in the section on 

''Project Schedule and Start-up," associated overhead and material for 50,000 development 

panels, and lost labor and rn~terial from the start-up curve. An assumption was made that 

60% of the silica can be reclaimed from panels produced during development. An estimate 

of start-up cost at the refrigerator plant also is included. 

A summary of the program cost is shown in Table 13. 

Product Costs 

Product cost includes all direct material and direct labor included in or added to the product or its packaging and shipping and associated overhead cost. Overhead includes items 

such as overtime premium, night shift bonus, rework, scrap, and hourly employee benefits 

(medical insurance, vacation and holiday pay, etc.). 

Other operating costs include utilities, trash removal, taxes, insurance, office expenses, 

security, safety, etc. No added warranty costs are included although there is likely to be 

additional warranty cost as a result of the incorporation of VIPs. Some amount of warranty 

reservE;?S should be planned for service calls whlch may result from VIPs. 

-54-
Table 13

Vacuum Insulated Panel Manufacturing

Program Cost ($ million)

i

F

ITEM INVESTMENT EXPENSE MANPOWER START-UP TOTAL

Panel Plant $11.6 $3.4 $0.9 $1.1 $17.0

Refrigerator Plant $2.3 $1.4 $1.1 $1.8 $6.6

Totals $13.9 $4.8 $2.0 $2.9 $23.6

 EE-RM-93-801 COMMENT OR5

ITEM 

I 

81 Panel Plant 

I 

Refrigerator Plant 

Totals 

Table 13 

Vacuum Insulated Panel Manufacturing 

Program Cost ($ million) 

INVESTMENT EXPENSE MANPOWER START-UP 

$11.6 $3.4 $0.9 $1.1 

$2.3 $1.4 $1.1 $1.8 

$13.9 $4.8 $2.0 $2.9 

TOTAL 

$17.0 

$6.6 

$23.6 

ITEM 

I 

81 Panel Plant 

I 

Refrigerator Plant 

Totals 

Table 13 

Vacuum Insulated Panel Manufacturing 

Program Cost ($ million) 

INVESTMENT EXPENSE MANPOWER START-UP 

$11.6 $3.4 $0.9 $1.1 

$2.3 $1.4 $1.1 $1.8 

$13.9 $4.8 $2.0 $2.9 

TOTAL 

$17.0 

$6.6 

$23.6 
Table 14 summarizes the added product cost to add 29 board feet of VIPs to 21 or 24 cubic

-foot refrigerators being produced at a volume of 300,000 per year.

Some appliance manufacturers may have designs with condenser loops to heat the mullion

or cross braces in the doors. These parts may need to be retooled to remove interference

with VIPs. Cost to retool these parts and the added product cost, if they require additional

material, is not included in these summaries.

_ Sensitivity Analysis

To test the sensitivity of costs per board foot of VIPs, a sensitivity analysis was made by

varying certain elements of product cost and program cost and recalculating the resultant

cost per board foot. In order to include program cost in this analysis, these cost were amortized over a five year period or 43.5 million board feet of VIPs (300,000 refrigerators/ year x

29 board feet of VIEW refrigerator x five years). This analysis is shown in Table 15.

Project Schedule and Start-Up

After feasibility is established and funds are appropriated, it would take about two and one

half years to be in production as depicted in Figure 16. Since product redesign is limited to

the addition of VIPs to existing refrigerators, the longest tasks are equipment procurement,

installation, and development. Some minor modifications to existing refrigerator parts

tooling may be necessary and considerable product evaluation would be required.

The panel plant would be staffed with partial crews six months prior to start-up. These

would include the plant manager, quality control manager, material control manager,

financial manager, one foreman, one skilled maintenance person, one control person, and

one material handler. The full plant crew would be added two months prior to production.

It is estimated that after a four to five month development period about seven weeks

would be required to bring the plant up to rate as depicted in Figure 17. Current users of

 EE-RM-93-801 COMMENT OR5

Table 14 summarizes the added product cost to add 29 board feet of VIPs to 21 or 24 cubic 

'foot refrigerators being produced at a volume of 300,000 per year. 

Some appliance manufacturers may have designs with condenser loops to heat the mullion 

or cross braces in the doors. These parts may need to be retooled to remove interference 

with VIPs. Cost to retool these parts and the added product cost, if they require additional 

material, is not included in these summaries. 

Sensitivity Analysis 

To test.the sensitivity of costs per board foot of VIPs, a sensitivity analysis was made by 

varying certain elements of product cost and program cost and recalculating the resultant 

cost per board foot. In order to include program cost in this analysis, these cost were amortized over a five year period or 43.5 million board feet of VIPs (300,000 refrigerators/year x 

29 board feet of VIPs/refrigerator x five years). This analysis is shown in Table 15. 

Project Schedule and Start-Up 

After feasibility is established and funds are appropriated, it would take a.bout two and one 

half years to be in production as depicted in Figure 16. Since product redesign is limited to 

the addition of VIPs to existing refrigerators, the longest tasks are equipment procurement, 

installation, and development. Some minor modifications to existing refrigerator par~ 

tooling may be necessary and considerable product evaluation would be required. 

The panel plant would be staffed with partial crews six months prior to start-up. These 

would include the plant manager, quality control manager, material control manager, 

financial manager, one foreman, one skilled maintenance person, one control person, and 

one material handler. The full plant crew would be added two months prior to production. 

It is estimated that after a four to five month development period about seven weeks 

would be required to ~ring the plant up to rate as depicted in Figure 17. Current users of 

-56-

Table 14 summarizes the added product cost to add 29 board feet of VIPs to 21 or 24 cubic 

'foot refrigerators being produced at a volume of 300,000 per year. 

Some appliance manufacturers may have designs with condenser loops to heat the mullion 

or cross braces in the doors. These parts may need to be retooled to remove interference 

with VIPs. Cost to retool these parts and the added product cost, if they require additional 

material, is not included in these summaries. 

Sensitivity Analysis 

To test.the sensitivity of costs per board foot of VIPs, a sensitivity analysis was made by 

varying certain elements of product cost and program cost and recalculating the resultant 

cost per board foot. In order to include program cost in this analysis, these cost were amortized over a five year period or 43.5 million board feet of VIPs (300,000 refrigerators/year x 

29 board feet of VIPs/refrigerator x five years). This analysis is shown in Table 15. 

Project Schedule and Start-Up 

After feasibility is established and funds are appropriated, it would take a.bout two and one 

half years to be in production as depicted in Figure 16. Since product redesign is limited to 

the addition of VIPs to existing refrigerators, the longest tasks are equipment procurement, 

installation, and development. Some minor modifications to existing refrigerator par~ 

tooling may be necessary and considerable product evaluation would be required. 

The panel plant would be staffed with partial crews six months prior to start-up. These 

would include the plant manager, quality control manager, material control manager, 

financial manager, one foreman, one skilled maintenance person, one control person, and 

one material handler. The full plant crew would be added two months prior to production. 

It is estimated that after a four to five month development period about seven weeks 

would be required to ~ring the plant up to rate as depicted in Figure 17. Current users of 

-56-
Table 14

Variable Manufacturing Transportation & Installation Cost for VIPs

for One 21 Cubic Foot Refrigerator (29 Board Feet of VIPs)

1991 DOLLARS

ITEM DIRECT MATERIAL DIRECT LABOR &

OVERHEAD

OTHER OPERATING

COST

TOTALS

Silica (29 LBS) $21.75 $21.75

Porous Bag (80 F12) $2.88 $2.88

Barrier (83 FF2) $9.21 $9.21

Adhesive $2.27 $2.27

Panel packaging $0.16 $0.16

Displaced foam $5.81 ($5.81)

Panel manufacturing $4.49 $0.89 $5.38

Panel transportation $0.66 $0.66

Panel installation $3.87 $3.87

Totals $30.46 $8.36 $1.55 $40.37

($1.39/board foot)

 EE-RM-93-801 COMMENT OR5

I 

<.n 

...., 

I 

Table 14 

Variable Manufacturing Transportation & Installation Cost for VIPs 

for One 21 Cubic Foot Refrigerator (29 Board Feet of VIPs) . 1991 DOLLARS 

ITEM DIRECT MATERIAL DIRECT LABOR &: OTHER OPERATING TOTALS 

OVERHEAD COST 

Silica (29 LBS) $21.75 $21.75 

Porous Bag (80 FI'2) $2.88 $2.88 

Barrier (83 FI'2) $9.21 $9.21 

Adhesive $2.27 $2.27 

Panel packaging $0.16 $0.16 

Displaced foam $5.81 ($5.81) 

Panel manufacturing $4.49 $0.89 $5.38 

Panel transportation $0.66 $0.66 

Panel installation $3.87 $3.87 

Totals $30.46 $8.36 $1.55 $40.37 

($1.39/board foot) 

I 

<.n 

...., 

I 

Table 14 

Variable Manufacturing Transportation & Installation Cost for VIPs 

for One 21 Cubic Foot Refrigerator (29 Board Feet of VIPs) . 1991 DOLLARS 

ITEM DIRECT MATERIAL DIRECT LABOR &: OTHER OPERATING TOTALS 

OVERHEAD COST 

Silica (29 LBS) $21.75 $21.75 

Porous Bag (80 FI'2) $2.88 $2.88 

Barrier (83 FI'2) $9.21 $9.21 

Adhesive $2.27 $2.27 

Panel packaging $0.16 $0.16 

Displaced foam $5.81 ($5.81) 

Panel manufacturing $4.49 $0.89 $5.38 

Panel transportation $0.66 $0.66 

Panel installation $3.87 $3.87 

Totals $30.46 $8.36 $1.55 $40.37 

($1.39/board foot) 
Table 15

VIP Cost

Sensitivity Analysis

VARIABLE MFG. COST/ *PROGRAM COST/ TOTAL COST/

BOARD FOOT BOARD FOOT BOARD FOOT

$1.39 $0.54 $1.93

MATERIALS:

Silica

+10% $1.47 $2.01

-10% $1.32 $1.86

-20% $1.24 $1.78

Foam

+10% $1.37 $1.91

+20% $1.35 $1.89

+30% $1.33 $1.87

PANEL PLANT OPERATING COSTS:

+25% $1.44 $1.98

-25% $1.34 $1.88

PROGRAM COSTS:

Buy existing building

at $25/squre foot $0.48 $1.87

Building at 0$ cost from

industrial development

organization $0.45 $1.84

Manpower

+25% $0.55 $1.94

-25% $0.53 $1.92

Panel plant

Start-up costs

+25%a $0.56 $1.95

-25% $0.52 $1.91

* $23.6/MM amortized over 5 years or 43.5MM board feet

58

 EE-RM-93-801 COMMENT OR5

':::::::::.:: 

.... :;:;::::;. 

MATERIALS: 

Silica 

+10% 

-10% 

-20% 

Foam 

+10% 

+20% 

+30% 

Table 15 

VIP Cost 

Sensitivity Analysis 

VARIABLE MFG. COST / "PROGRAM COST / 

BOARD FOOT . BOARD FOOT 

$1.39 $0.54 

$1.47 

$1.32 

$1.24 

$1.37 

$1.35 

$1.33 

PANEL PLANT OPERATING COSTS: 

+25% $1.44 

-25% $1.34 

PROGRAM COSTS: 

Buy existing building 

at $25/ squre foot $0.48 

Building at 0$ cost from 

industrial development 

organization $0.45 

Manpower 

+25% $0.55 

-25% $0.53 

. Panel plant 

Start-up costs 

.+25% $0.56 

-25% $0.52 

.. $23.6/MM amortized over 5 years or 43.5MM board feet 

-58-

TOTAL COST/ 

BOARD FOOT 

$1.93 

$2.01 

$1.86 

$1.78 

$1.91 

$1.89 

$1.87 

$1.98 

$1.88 

. $1.87 

$1.84 

$1.94 

$1.92 

$1.95 

$1.91 

lK1ArlB~'$::::::::: 

MATERIALS: 

Silica 

+10% 

-10% 

-20% 

Foam 

+10% 

+20% 

+30% 

Table 15 

VIP Cost 

Sensitivity Analysis 

VARIABLE MFG. COST / "PROGRAM COST / 

BOARD FOOT . BOARD FOOT 

$1.39 $0.54 

$1.47 

$1.32 

$1.24 

$1.37 

$1.35 

$1.33 

PANEL PLANT OPERATING COSTS: 

+25% $1.44 

-25% $1.34 

PROGRAM COSTS: 

Buy existing building 

at $25/ squre foot $0.48 

Building at 0$ cost from 

industrial development 

organization $0.45 

Manpower 

+25% $0.55 

-25% $0.53 

. Panel plant 

Start-up costs 

.+25% $0.56 

-25% $0.52 

.. $23.6/MM amortized over 5 years or 43.5MM board feet 

-58-

TOTAL COST/ 

BOARD FOOT 

$1.93 

$2.01 

$1.86 

$1.78 

$1.91 

$1.89 

$1.87 

$1.98 

$1.88 

. $1.87 

$1.84 

$1.94 

$1.92 

$1.95 

$1.91 
Figure 16

VIP Project Schedule

TASK DESCRIPTION

PRODUCT DESIGN

REFRIG ERATOR

PANELS

PRODUCT TOOLING

EVALUATION

PANEL PLANT

FACILITY DESIGN

FACILITY BUILD

EQUIPMENT SPECS.

EQUIPMENT PROCUREMENT

INSTALL & DEVELOP

REFRIGERATOR PLANT

FACILITY MODIFICATIONS

EQUIPMENT SPECS.

EQUIPMENT PROCUREMENT

INSTALL & DEVELOP

TEST RUNS

PILOT RUNS

PRODUCTION

YEAR 1 1 YEAR 2

mmemisommumm

0

YEAR 3

 EE-RM-93-801 COMMENT OR5

I 

0'1 

CD 

I 

Figure 16 

1 VIP Project Schedule 

TASK DESCRIPTION YEAR 1 

PRODUCT DESIGN 

REFRIG ERATOR 

PANELS 

PRODUCT TOOLING 

EVALUATION 

PANEL PLANT 

FACILITY DESIGN 

FACILITY BUILD 

EQUIPMENT SPECS. 

EQUIPMENT PROCUREMENT 

INSTALL & DEVELOP 

REFRIGERATOR PLANT 

FACILITY MODIFICATIONS 

EQUIPMENT SPECS. 

EQUIPMENT PROCUREMENT 

INSTALL & DEVELOP 

TEST RUNS 

PILOT RUNS 

PRODUCTION 

YEAR 2 YEAR 3 I 

I 

I11III 

II1II 

I 

0'1 

CD 

I 

Figure 16 

1 VIP Project Schedule 

TASK DESCRIPTION YEAR 1 

PRODUCT DESIGN 

REFRIG ERATOR 

PANELS 

PRODUCT TOOLING 

EVALUATION 

PANEL PLANT 

FACILITY DESIGN 

FACILITY BUILD 

EQUIPMENT SPECS. 

EQUIPMENT PROCUREMENT 

INSTALL & DEVELOP 

REFRIGERATOR PLANT 

FACILITY MODIFICATIONS 

EQUIPMENT SPECS. 

EQUIPMENT PROCUREMENT 

INSTALL & DEVELOP 

TEST RUNS 

PILOT RUNS 

PRODUCTION 

YEAR 2 YEAR 3 I 

I 

I11III 

II1II 
form, fill, and seal equipment felt this was a conservative estimate, considering the development period planned [181.

60

 EE-RM-93-801 COMMENT OR5

form, fill, and seal equipment felt this was a conservative estimate, considering the develQpment period planned [18]. 

-60-

form, fill, and seal equipment felt this was a conservative estimate, considering the develQpment period planned [18]. 

-60-
Figure 17

Startup Curve - VIP Plant

100%

% OF

SCHEDULE

---------- -------------------------------------------.----------------------------------------------------------x----------------------------

x x

x

x

x

50%

x

1 1 2 1 3 14 1 5 1 6 7 8

WEEKS

 EE-RM-93-801 COMMENT OR5

I 

G) 

.... 

Figure 17 

Startup Curve - VIP PI-ant· 

100 % - -- ----- ----- ------ ---- ----- ----- ----- _. --- ----- ----- ----- ----- ----- ----- ----- ----- ----- ----- ----- ----- ----- ----- -----)( --- ----- ----- ----- -- --- ----- -----

x x 

',{,OF 

SCHEDULE 

50%-

x 

x 

x 

x 

15 16 18 

WEEKS 

I 

G) 

.... 

I 

Figure 17 

Startup Curve - VIP PI-ant· 

100 % - -- ----- ----- ------ ---- ----- ----- ----- _. --- ----- ----- ----- ----- ----- ----- ----- ----- ----- ----- ----- ----- ----- ----- -----)( --- ----- ----- ----- -- --- ----- -----

x x 

',{,OF 

SCHEDULE 

50%-

x 

x 

x 

x 

15 16 18 

WEEKS 
THICK WALL ALTERNATIVE

Another approach to increasing the thermal resistance of the refrigerator cabinet is to

increase thickness by adding additional non-CFC foam insulation. This section estimates

the manufacturing cost impact of increasing insulation. Since this scenario is more likely on

smaller refrigerators (<21') an 18' refrigerator, which represents a major share of the market, was used for this analysis.

Facility Assumptions

A facility producing five hundred thousand 18 cubic foot refrigerators per year was assumed. Multiple models in multiple sizes would further complicate this analysis and

would definitely affect the cost estimates.

Scenarios

Four increases in insulation thickness from the current representative product vv,3re studied. These were +0.5", +1.0", +1.5", or +2.0". Thickness was increased on top, bottom, back,

doors, and both sides.

Four methods were used for increasing the external dimensions to accommodate the

thicker insulation.

• Case "All" allowed all external dimensions of the unit to increase. This case maintained the exact internal dimensions as well as the width of the front flange.

• ..Case "H" allowed only the height of the unit to change to accommodate the change in

thickness, and reconfigured the inside to maintain 18 cubic feet of storage space. For

example, when 1" of insulation is added to the top, bottom, back, doors, and both

sides, the new height must become 74.5" since the width is held at 29.5" and the depth

at 31.5" (Table 16). The liner would be long and narrow.

 EE-RM-93-801 COMMENT OR5

THICK WALL ALTERNATIVE 

Another approach to increasing the thermal ;resistance of the refrigerator cabinet is to 

increase thickness by adding additional non-CFC foam insulation. This section estimates 

the manufacturing cost impact of increasing insulation. Since this scenario is more likely on 

smaller refrigerators «21') an 18' refrigerator, which represents a major share of the market, was used for this analysis. 

Facility Assumptions 

A facility producing five hundred thousand 18 cubic foot refrigerators per year was assumed. Multiple models in multiple sizes would further complicate this analysis and 

would definitely affect the cost estimates. 

Scenarios 

Four increases in insulation thickiless from the current representative product w\~re studied. These were +0.5", +1.0", +1.5", or +2.0". Thickness was increased on top, bottom, back, 

doors, and both sides. 

Four methods were used for increasing the external dimensions to accommodate the· 

thicker insulation. 

• Case 1/ All" allowed all external dimensions of the unit to increase. ThiS case maintained the exact internal dimensions as well as the width of the front flange. 

• : Case "H" allowed only the height of the unit to change to accommodate the change in 

thickness, and reconfigured the inside to maintain 18 cubic feet of storage space. For 

example, when 1" of insulation is added to the top, bottom, back, doors, and both 

sides, the new height must become 74.5" since the width is held at 29.5" and the depth 

at 31.5" (Table 16). The liner would be long and narrow. 

-62-

THICK WALL ALTERNATIVE 

Another approach to increasing the thermal ;resistance of the refrigerator cabinet is to 

increase thickness by adding additional non-CFC foam insulation. This section estimates 

the manufacturing cost impact of increasing insulation. Since this scenario is more likely on 

smaller refrigerators «21') an 18' refrigerator, which represents a major share of the market, was used for this analysis. 

Facility Assumptions 

A facility producing five hundred thousand 18 cubic foot refrigerators per year was assumed. Multiple models in multiple sizes would further complicate this analysis and 

would definitely affect the cost estimates. 

Scenarios 

Four increases in insulation thickiless from the current representative product w\~re studied. These were +0.5", +1.0", +1.5", or +2.0". Thickness was increased on top, bottom, back, 

doors, and both sides. 

Four methods were used for increasing the external dimensions to accommodate the· 

thicker insulation. 

• Case 1/ All" allowed all external dimensions of the unit to increase. ThiS case maintained the exact internal dimensions as well as the width of the front flange. 

• : Case "H" allowed only the height of the unit to change to accommodate the change in 

thickness, and reconfigured the inside to maintain 18 cubic feet of storage space. For 

example, when 1" of insulation is added to the top, bottom, back, doors, and both 

sides, the new height must become 74.5" since the width is held at 29.5" and the depth 

at 31.5" (Table 16). The liner would be long and narrow. 

-62-
• Case "W" allowed only the width of the unit to change and maintained the internal

volume.

• Case "D"allowed only the depth of the unit to change and maintained the internal

volume.

All cases except Case "All" change the internal dimensions of the refrigerator. Typically, a

given size box is used for numerous models which then have different internal parts or

features to upgrade the model. For this reason, retooling cost for these scenarios could be

$5 - $10 million more than case "All".

This analysis was made with the understanding that there are restrictions to dimensional

changes:

• Any increase in depth beyond the current 27.75" (w/o door) prohibits entry through

28" doors and, reduces the market served; shallowness is an important consumer

feature and any increase in depth makes the box less marketable. From a

manufacturer's viewpoint, a common depth across several models enhances factory

productivity.

• Height is limited in FHA homes, and most others, to 84". This is-caused by having an

eight foot ceiling with a 12" soffit. Typically, a 12" cabinet under the soffit further

reduces the limit to 72". The ability to reach into the back of a top mount freezer is an

important consumer consideration, which puts practical limitations on height.

• Width also is limited in FHA specifications to 36". Non-FHA homes also have width

limitations. Increases in width will reduce the potential market.

Thicker foam walls may present process control problems such as bowed liners, which

can make shelves difficult to install at final assembly, and bowed cases, which may

cause appearance problems as well as kitchen fit problems. These problems will have

to be assessed and resolved during development.

 EE-RM-93-801 COMMENT OR5

• Case 'W" allowed only the width of the unit to change and maintained the internal 

volume. 

• Case ''D''allowed only the depth of the unit to change and maintained the internal 

volume. 

All cases except Case "All" change the internal dimensions of the refrigerator. Typically, a 

given size box is used for numerous models which then have different internal parts or 

features to upgrade the model. For this reason, retooling cost for these scenarios could be 

$5 - $10 million more than case "All". 

This analysis was made with the understanding that there are restrictions to dimensional 

. changes: 

• Any increase in depth beyond the current 27.75" (w / 0 door) prohibits entry through 

28" doors and, reduces the market served; shallowness is an important consumer 

feature and any increase in depth makes the box less marketable. From a 

manufacturer's viewpoint, a common depth across several models enhances fa~tory 

productivity. 

• Height is limited in FHA homes, and most others, to 84". This is'caused by having an 

eight foot ceiling with a 12" soffit. Typically, a 12" cabinet under the soffit further 

reduces the limit to 72". The ability to reach into the back of a top mount freezer is an 

important consumer consideration, which puts practical limitations on height. 

• Width. also is limited in FHA specifications to 36". Non-FHA homes also have width 

limitations. Increases in width will reduce the potential market. 

Thicker foam walls may present process control problems such as bowed liners, which 

can make shelves difficult to install at final assembly, and bowed cases, which may 

cause appearance problems as well as kitchen fit problems. These problems will have 

to be assessed and resolved during development. 

-63-

• Case 'W" allowed only the width of the unit to change and maintained the internal 

volume. 

• Case ''D''allowed only the depth of the unit to change and maintained the internal 

volume. 

All cases except Case "All" change the internal dimensions of the refrigerator. Typically, a 

given size box is used for numerous models which then have different internal parts or 

features to upgrade the model. For this reason, retooling cost for these scenarios could be 

$5 - $10 million more than case "All". 

This analysis was made with the understanding that there are restrictions to dimensional 

. changes: 

• Any increase in depth beyond the current 27.75" (w / 0 door) prohibits entry through 

28" doors and, reduces the market served; shallowness is an important consumer 

feature and any increase in depth makes the box less marketable. From a 

manufacturer's viewpoint, a common depth across several models enhances fa~tory 

productivity. 

• Height is limited in FHA homes, and most others, to 84". This is'caused by having an 

eight foot ceiling with a 12" soffit. Typically, a 12" cabinet under the soffit further 

reduces the limit to 72". The ability to reach into the back of a top mount freezer is an 

important consumer consideration, which puts practical limitations on height. 

• Width. also is limited in FHA specifications to 36". Non-FHA homes also have width 

limitations. Increases in width will reduce the potential market. 

Thicker foam walls may present process control problems such as bowed liners, which 

can make shelves difficult to install at final assembly, and bowed cases, which may 

cause appearance problems as well as kitchen fit problems. These problems will have 

to be assessed and resolved during development. 

-63-
Table 16

Thick Insulation Alternatives

External Dimensions (inches)

for 18' Refrigerators

VARYING DIMENSION (Inches)

Current

Dimensions

Added .

Insulation

+0.5

+1.0

+1.5

+2.0

ALL I HEIGHT I WIDTH I DEPTH I CAB. DEPTH

H-65.0

W-303

D-32.5*

H-66.0

W-313

D-33.5*

H-67.0

W-32.5

D-34.5*

H-68.0

W-333

D35.5*

64.0

69.0

29.5

31.5

74.5***

29.5

31.5

80.0***

29.5

31.5

85.5**

29.5

31.5

29.5

64.0

32.0

31.5

64.0

34.6

31.5

64.0

37.1**

31.5

64.0

39.7**

31.5

31.5

64.0

29.5

33.9*

64.0

29.5

36.3*

64.0

29.5

38.7*

64.0

29.5

41.1*

NOTES: * Will not fit through 28" door with refrigerator doors removed.

Exceeds FHA specification dimensions.

*"* Exceeds FHA dimensions with 12" cabinet under soffit.

27.8

29.7*

32.1*

34.5* .

36.9*

64

 EE-RM-93-801 COMMENT OR5

Current 

Dimensions 

Added 

Insulation 

+0.5 

+1.0 

+1.5 

+2.0 

Table 16 

Thick Insulation Alternatives 

External Dimensions (inches) 

for 18' Refrigerators 

VARYING OIMENSION (Inches) 

ALL HEIGHT WIDTH OEP1H 

64.0 29.5 31.5 

H-6S.0 69.0 64.0 64.0 

W-30.5 29.5 32.0 29.5 

0-32.5" 31.5 31.5 33.9" 

H-66.0 74.5- 64.0 64.0 

W-31.5 29.5 34.6 29.5 

0-33S 31.5 31.5 36.3" 

H-67.0 80.0- 64.0 64.0 

W-32.5 29.5 37.1 .... 29.5 

0-34.5" 31.5 31.5 38.7!t 

H-68.0 85.5 .... 64.0 64.0 

W-33.5 29.5 39.7" 29.5 

0-35.5" 31.5 31.5 41.1" 

NOTES: .. Will not fit through 28" door with refrigerator doors removed . 

.... Exceeds FHA specification dimensions . 

...... Exceeds FHA dimensions with 12" cabinet under soffit. 

-64-

CAB.OEP1H 

27.8 

29.7!t 

32.1" 

34.5" . 

36.~ 

Current 

Table 16 

Thick Insulation Alternatives 

External Dimensions (inches) 

for 18' Refrigerators 

VARYING OIMENSION (Inches) 

ALL HEIGHT WIDTH OEP1H 

64.0 29.5 31.5 

Dimensions 

Added 

Insulation 

+0.5 H-6S.0 69.0 64.0 64.0 

W-30.5 29.5 32.0 29.5 

0-32.5" 31.5 31.5 33.9" 

+1.0 H-66.0 74.5- 64.0 64.0 

W-31.5 29.5 34.6 29.5 

0-33S 31.5 31.5 36.3" 

+1.5 H-67.0 80.0- 64.0 64.0 

W-32.5 29.5 37.1 .... 29.5 

0-34.5" 31.5 31.5 38.7'" 

+2.0 H-68.0 85.5 .... 64.0 64.0 

W-33.5 29.5 39.7" 29.5 

0-35.5" 31.5 31.5 41.1" 

NOTES: .. Will not fit through 28" door with refrigerator doors removed . 

.... Exceeds FHA specification dimensions . 

...... Exceeds FHA dimensions with 12" cabinet under soffit. 

-64-

CAB.OEP1H 

27.8 

29.7'" 

32.1" 

34.5" . 

36.~ 
Table 16 is a matrix of dimensions for each-scenario. Some combination of the above cases

may be the best solution when all factors are considered.

Cost Analysis-.

A cost impact analysis was completed for all four levels of thickness increase, using Case

"All". A retooling matrix was done for the other three cases but cost analyses were not

completed. All foam insulation costs were based on CFC 11. Alternative blowing agents

would very likely make these changes more expensive, at least initially.

• Variable manufacturing cost increase-An analysis of the required changes was completed for each case and the percent increase in part size was calculated. Using detailed part and material cost information obtained from an appliance manufacturer,

via a nondisclosure agreement, a variable manufacturing cost increase for each part

was calculated. The major contributor, by far, to the increased cost was the cost of the

additional foam insulation, which accounted for well over half of the increase.

• Transportation cost increase-Carton sizes were calculated for each new dimension

for all four cases (Table 17). Using standard 48' trailer dimensions and 60' high cube

rail car dimensions, the number of refrigerators per load was calculated for eachthickness increase in case "All" and compared to the existing load size. Using an

estimated average mileage to a distribution center, an average cost per truck and rail

car and an estimated percentage of truck versus rail, a transportation cost increase per

refrigerator was calculated. _

Cost of additional warehouse space at the factory, distribution centers and dealers

was not estimated. As product/carton sizes increase more floor space will be needed.

Cost of adding this space would be $100 to $125 per square foot. If inventory levels

were reduced in lieu of adding warehouse space, service to dealers would be adversely affected, resulting in lost sales.

 EE-RM-93-801 COMMENT OR5

Table 16 is a matrix of dimensions for each' scenario. Some combination of the above cases 

may be the best solution when all factors are considered. 

Cost Analysis'. 

A cost impact analysis was completed for all four levels of thickness increase, using Case 

"All". A retooling matrix was done for the other three cases but cost analyses were not 

. completed. All foam insulation costs were based on CFC 11. Alternative blowing agents 

would very likely make these changes more expensive, at least initially. 

• Variable manufacturing cost increase-An analysis of the required changes was completed for each case and the percent increase in part size was calculated. Using detailed part and material cost information obtained from an appliance manufacturer, 

via a nondisclosure agreement, a variable manufacturing cost increase for each part 

was calculated. The major contributor, by far, to the increased cost was the cost of the 

additional foam insulation, which accounted for well over half of the increase. 

• Transportation cost increase-Carton sizes were calculated for each new dimension 

for all four cases (Table 17). Using standard 48' trailer dimensions and 60' high cube 

rail car dimensions, the number of refrigerators per load was calculated for each . 

thickness increase in case "All" and compared to the existing load size. Using an 

estimated average mileage to a distribution center, an average cost per truck and rail 

car and an estimated percentage of truck versus rail, a transportation cost increase per 

refrigerator was calculated. 

Cost of additional warehouse space at the factory, distribution centers and dealers 

was not estimated. As product/ carton sizes increase more floor space will be needed. 

Cost of adding this space would be $100 to $125 per square foot. If inventory levels 

were reduced in lieu of adding warehouse space, service to dealers would be adversely affected, resulting in lost sales. 

-65-

Table 16 is a matrix of dimensions for each' scenario. Some combination of the above cases 

may be the best solution when all factors are considered. 

Cost Analysis'. 

A cost impact analysis was completed for all four levels of thickness increase, using Case 

"All". A retooling matrix was done for the other three cases but cost analyses were not 

. completed. All foam insulation costs were based on CFC 11. Alternative blowing agents 

would very likely make these changes more expensive, at least initially. 

• Variable manufacturing cost increase-An analysis of the required changes was completed for each case and the percent increase in part size was calculated. Using detailed part and material cost information obtained from an appliance manufacturer, 

via a nondisclosure agreement, a variable manufacturing cost increase for each part 

was calculated. The major contributor, by far, to the increased cost was the cost of the 

additional foam insulation, which accounted for well over half of the increase. 

• Transportation cost increase-Carton sizes were calculated for each new dimension 

for all four cases (Table 17). Using standard 48' trailer dimensions and 60' high cube 

rail car dimensions, the number of refrigerators per load was calculated for each . 

thickness increase in case "All" and compared to the existing load size. Using an 

estimated average mileage to a distribution center, an average cost per truck and rail 

car and an estimated percentage of truck versus rail, a transportation cost increase per 

refrigerator was calculated. 

Cost of additional warehouse space at the factory, distribution centers and dealers 

was not estimated. As product/ carton sizes increase more floor space will be needed. 

Cost of adding this space would be $100 to $125 per square foot. If inventory levels 

were reduced in lieu of adding warehouse space, service to dealers would be adversely affected, resulting in lost sales. 

-65-
Table 17

Carton Sizes for 18' Refrigerators

with Thicker Insulation

VARYING DIMENSION (Inches)

ALL HEIGHT WIDTH DEPTH

Current

Dimensions 67.0" 32.0" 34.8"

Added

Insulation

+0.5 H-68.0" 72.0" ,6' 0" 67.0"

W - 33.0" 32.0" 34.5" 32.0"

D - 35.8" 34.8" 34.8" 36.8"

+1.0 H - 69.0" 77.5" 67.0" 67.0"

W - 34.0" 32.0" 37.1" 32.0"

D - 36.8" 34.8" 34.8" 39.2"

+1.5 H - 70.0" 82.0" 67.0" 67.0"

W - 35.0" 32.0" 39.6" 32.0"

D - 37.8" 34.8" 34.8" 42.0"

+2.0 H-71.0" 89.5" 67.0" 67.0"

W - 36.0" 32.0" 42.2" 32.0"

D - 38.8" 34.8" 34.8" 44.4"

66

 EE-RM-93-801 COMMENT OR5

Current 

Dimensions 

Added 

Insulation 

+0.5 

+1.0 

+1.5 

+2.0 

Table 17 

Carton Sizes for 1S' Refrigerators 

with Thicker Insulation 

VARYING DIMENSION (Inches) 

ALL HEIGHT WIDTH 

67.0" 32.0" 

-

- H-68.0" 72.0" '67 Q" 

W -33.0" 32.0" 34.5" 

0-35.8" 34.8" 34.8" 

H-69.0" 77.5" 67.0" 

W -34.0" 32.0" 37.1" 

0-36.8" 34.8" 34.8" 

H-70.0" 82.0" 67.0" 

W -35.0" 32.0" 39.6" 

0-37.8" 34.8" 34.8" 

H-71.0" 89.5" 67.0" 

W -36.0" 32.0" 42.2" 

0-38.8" 34.8" 34.8" 

-66-

DEPTH 

34.8" 

67.0" 

32.0" 

36.8" 

67.0" 

32.0" 

39.2" 

67.0'( 

32.0" 

42.0" 

67.0" 

32.0" 

44.4" 

Current 

Dimensions 

Added 

Insulation 

+0.5 

+1.0 

+1.5 

+2.0 

Table 17 

Carton Sizes for 1S' Refrigerators 

with Thicker Insulation 

VARYING DIMENSION (Inches) 

ALL HEIGHT WIDTH 

67.0" 32.0" 

-

- H-68.0" 72.0" '67 Q" 

W -33.0" 32.0" 34.5" 

0-35.8" 34.8" 34.8" 

H-69.0" 77.5" 67.0" 

W -34.0" 32.0" 37.1" 

0-36.8" 34.8" 34.8" 

H-70.0" 82.0" 67.0" 

W -35.0" 32.0" 39.6" 

0-37.8" 34.8" 34.8" 

H-71.0" 89.5" 67.0" 

W -36.0" 32.0" 42.2" 

0-38.8" 34.8" 34.8" 

-66-

DEPTH 

34.8" 

67.0" 

32.0" 

36.8" 

67.0" 

32.0" 

39.2" 

67.0'( 

32.0" 

42.0" 

67.0" 

32.0" 

44.4" 
• Tooling and Investment cost-Required tooling and facility changes were developed

for each scenario using the representative 18' refrigerator and a representative manufacturing facility. Costs were then estimated for each retool or facility change for each

of the four levels of thickness change in case "All". Increases in foam demold time,

caused by thicker walls, were off-set by adding foam fixtures in +1.0", +1.5", and +2.0"

scenarios.

A 20% contingency was added to these numbers. This is a typical contingency factor

for an estimate of this quality. A matrix of required changes is shown in Table 18.

Investment costs are for capital expenditures and can be depreciated over several

years. Tooling and other expenses must be written off as they are incurred. The same

is true for manpower and start up cost.

• Manpower cost-Design engineering, manufacturing engineering, quality assurance,

and other man years were estimated to implement each level of change in case "All".

Seventy-five thousand dollars per man year was used to calculate manpower cost.

• Startup costs-Costs to build development models and run trial runs in the plant, plus

the cost of lost units while each change is implemented, were estimated.

Product cost, including transportation, for thicker foam insulation ranges from $12.28 for

one-half inch to $37.65 for two inches. Program costs range from $16.6 million to $22.5

million. Thicker foam only on the doors would cost $3.23 and $12.28, respectively and the

program cost would be about 25% of the numbers above.

A summary of all cost impact elements is shown in Table 19. A sensitivity analysis for

product cost increase/unit when the cost of foam material is increased is shown in Table

20. The cost impact of increasing insulation thickness on doors only is shown in Table 21.

 EE-RM-93-801 COMMENT OR5

• Tooling and Investment cost-Required tooling and facility changes were developed 

for each scenario using the representative 18' refrigerator and a representative manufacturing facility. Costs were then estimated for each retool or facility change for each 

of the four levels of thickness change in case 1/ All". Increases in foam demold time, 

caused by thicker walls, were off-set by adding foam fixtures in +1.0", +1.5", and +2.0" 

scenarios. 

A 20% contingency was added to these numbers. This is a typical contingency factor 

for an estimate of this quality. A matrix of required changes is shown in Table 18. 

Investment costs are for capital expenditures and can be depreciated over several 

years. Tooling and other expenses must be written off as they are incurred. The same 

is true for manpower and start up cost. 

• Manpower cost-Design engineering, manufacturing engineering, quality assurance, 

and other man years were estimated to implement each level of change in case "All". 

Seventy-five thousand dollars per man year was used to calculate manpower cost. 

• Startup costs-Costs to build development models and run trial runs in the plant, plus 

the cost of lost units while each change is implemented, were estimated. 

Product cost, including transportation, for thicker foam insulation ranges from $12.28 for 

one-half inch to $37.65 for two inches. Program costs range from $16.6 million to $22.5 

million. Thicker foam only on the doors would cost $3.23 and $12.28, respectively and the _ 

program cost would be about 25% of the numbers above. 

A summary of all cost impact elements is shown in Table 19. A sensitivity analysis for 

product cost increase/unit when the cost of foam material is increased is shown in Table 

20. The cost impact of increasing insulation thickness on doors only is shown in Table 21. 

-67-

• Tooling and Investment cost-Required tooling and facility changes were developed 

for each scenario using the representative 18' refrigerator and a representative manufacturing facility. Costs were then estimated for each retool or facility change for each 

of the four levels of thickness change in case 1/ All". Increases in foam demold time, 

caused by thicker walls, were off-set by adding foam fixtures in +1.0", +1.5", and +2.0" 

scenarios. 

A 20% contingency was added to these numbers. This is a typical contingency factor 

for an estimate of this quality. A matrix of required changes is shown in Table 18. 

Investment costs are for capital expenditures and can be depreciated over several 

years. Tooling and other expenses must be written off as they are incurred. The same 

is true for manpower and start up cost. 

• Manpower cost-Design engineering, manufacturing engineering, quality assurance, 

and other man years were estimated to implement each level of change in case "All". 

Seventy-five thousand dollars per man year was used to calculate manpower cost. 

• Startup costs-Costs to build development models and run trial runs in the plant, plus 

the cost of lost units while each change is implemented, were estimated. 

Product cost, including transportation, for thicker foam insulation ranges from $12.28 for 

one-half inch to $37.65 for two inches. Program costs range from $16.6 million to $22.5 

million. Thicker foam only on the doors would cost $3.23 and $12.28, respectively and the _ 

program cost would be about 25% of the numbers above. 

A summary of all cost impact elements is shown in Table 19. A sensitivity analysis for 

product cost increase/unit when the cost of foam material is increased is shown in Table 

20. The cost impact of increasing insulation thickness on doors only is shown in Table 21. 

-67-
Table 18

Thick Foam Alternatives

Retooling Requirements

18' Refrigerators

VARYING DIMENSION

ALL HEIGHT

CABINET

case blank X X

blank pierce & notch X X

roll former spacers X

u-folder, shuttle, etc. X X

front rail X

rear rail X

mullion t- brackets X

mullion package

mullion X

mullion breaker strips X

condensor loop X X

bottom/back X X

vertical bars X X

foam fixtures X X

rear access cover X

grill X

FOOD LINER:

thermoform molds X X

pierce & trim tools X X

METAL DOOR:

door fab line X X

door blank X X'

door braces X X

DOOR LINER:

thermoform molds X

pierce & trim X X

foam fixtures

foam cure tunnel X X

WIDTH DEPTH

X

X

X

X

X

X

X

X

X

X

X

gasket racks

retainer strips

inner door asm.

gasket insertion

SHELVES & PANS

shelf tracks

shelves

veg. pans

veg. pan cvr.

veg. pan handles

SYSTEM

evaporator

condensor

evap cvr.

unit mount

X

X

X

X

X

X

X

X

MISCELLANEOUS

fresh food top

frz. bottom

door handles

PACKAGING

carton

top & bottom caps

skid

pad

bander

final asm.

VARYING DIMENSION

ALL HEIGHT WIDTH DEPTH

X X X

X X X

X X X

X X X

X

X X

X X

X X

X X

X X

X

X X

X X

X X

X X

X X X X

X X

X X

X X X

X X X X

X X

 EE-RM-93-801 COMMENT OR5

CABINET 

case blank 

blank pierce & notch 

roll former spacers 

u-folder, shuttle, etc. 

front rail 

rear rail 

mullion t-brackets 

mullion package 

mullion 

mullion breaker strips 

condensor loop 

I bottom/back 

~ vertical bars 

foam fixtures 

rear access cover 

grill 

FOOD LINER: 

Ihermoform molds 

pierce & trim tools 

METALOOOR: 

door fab line 

door blank 

door braces 

OOORLINER: 

thermoform molds 

pierce & trim 

foam fixtures 

foam cure tunnel 

V ARYING DIMENSION 

Table 18 

Thick Foam Alternatives 

Retooling Requirements 

18' Refrigerators 

ALL HEIGHT WIDTH DEPTII 

X X X X gasket racks 

X X X X retainer strips 

X X inner door asm. 

X X X X gasket insertion 

X X 

X X SHELVES & PANS 

X X shelf tracks 

X X shelves 

X X veg.pans 

X X veg. pan cvr. 

X X X veg. pan handles 

X X X 

X X SYSTEM 

X X X X evaporator 

X X condensor 

X X evap cvr. 

unit mount 

X X X X MISCELLANEOUS 

X X X X fresh fOod top 

frz. bottom 

door handles 

X X X : 

X X' X PACKAGING 

X X X carton 

top & bottom caps 

skid 

X X X· pad 

X X X : 

X X X· X 

Ibander 

final asm. 

X , X X 

VARYING DIMENSION 

ALL I HEIGHT I WIDTH DEPTH 

X X X 

X X X 

X X X 

X X X 

X 

X X 

X X 

X X 

" X 

X X 

X X 

X 

X X 

X X 

X X 

X X 

X X X X 

X X X -

/ 

X X X 

X X X 

X X X X 

X X X X 

CABINET 

case blank 

blank pierce & notch 

roll former spacers 

u-folder, shuttle, etc. 

front rail 

rear rail 

mullion t-brackets 

mullion package 

mullion 

mullion breaker strips 

condensor loop 

I bottom/back 

~ vertical bars 

foam fixtures 

rear access cover 

grill 

FOOD LINER: 

Ihermoform molds 

pierce & trim tools 

METALOOOR: 

door fab line 

door blank 

door braces 

OOORLINER: 

thermoform molds 

pierce & trim 

foam fixtures 

foam cure tunnel 

V ARYING DIMENSION 

Table 18 

Thick Foam Alternatives 

Retooling Requirements 

18' Refrigerators 

ALL HEIGHT WIDTH DEPTII 

X X X X gasket racks 

X X X X retainer strips 

X X inner door asm. 

X X X X gasket insertion 

X X 

X X SHELVES & PANS 

X X shelf tracks 

X X shelves 

X X veg.pans 

X X veg. pan cvr. 

X X X veg. pan handles 

X X X 

X X SYSTEM 

X X X X evaporator 

X X condensor 

X X evap cvr. 

unit mount 

X X X X MISCELLANEOUS 

X X X X fresh fOod top 

frz. bottom 

door handles 

X X X : 

X X' X PACKAGING 

X X X carton 

top & bottom caps 

skid 

X X X· pad 

X X X : 

X X X· X 

Ibander 

final asm. 

X , X X 

VARYING DIMENSION 

I ALL HEIGHT WIDTH DEPTH 

X X X 

X X X 

X X X 

X X X 

X 

X X 

X X 

X X 

" X 

X X 

X X 

X 

X X 

X X 

X X 

X X 

X X X X 

X X X / 

X X X 

X X X 

X X X X 

X X X X 
Table 19

Cost.to Increase Insulation Thickness on 18' Refrigerators

Internal Dimensions Maintained/External Dimensions Varied

(1991 Jollars)

THICKNESS

INCREASE

PRODUCT COST

INCREASE/UNIT

TRANSPORTATION

INCREASE/UNIT

INVESTMENT

($millions)

EXPENSE

($millions)

MANPOWER

($millions)

START-UP

($millions)

0.5" $6.81 $5.47 3.6 7.2 4.6 1.2

1.0" 13.46 7.36 4.3 7.5 5.1 1.2

1.5" 21.16 7.36 5.4 7.8 5.6 1.5

2.0" $29.20 $8.45 6.8 8.0 6.2 1.5

NOTES: 1. Equipment modification or replacement (if deemed necessary) to accommodate

larger tools not included.

2. Margin loss due to lost sales/reduced market not included.

 EE-RM-93-801 COMMENT OR5

I 

en 

CD 

I 

I I 

Table 19 

Cost to Increase Insulation Thickness on 18' Refrigerators 

Internal Dimensions Maintained/External Dimensions Varied 

(1991 .Jollars) 

THICKNESS PRODUCT COST TRANSPORTATION INVESTMENT 

INCREASE INCREASE/UNIT INCREASE/UNIT ($millions) 

0.5" $6.81 $5.47 3.6 

1.0" 13.46 7.36 4.3 

1.5" 21.16 7.36 5.4 

2.0" $29.20 $8.45 6.8 

NOTES: 1. Equipment modification or replacement (if deemed necessary) to accommodate 

larger tools not included. 

2. Margin loss due to lost sales/reduced market not included. 

EXPENSE MANPOWER 

($millions) ($millions) 

7.2 4.6 

7.5 5.1 

7.8 5.6 

8.0 6.2 

, . 

START-UP 

($millions) 

1.2 

1.2 

1.5 

1.5 

I 

en 

CD 

I 

I I 

Table 19 

Cost to Increase Insulation Thickness on 18' Refrigerators 

Internal Dimensions Maintained/External Dimensions Varied 

(1991 .Jollars) 

THICKNESS PRODUCT COST TRANSPORTATION INVESTMENT 

INCREASE INCREASE/UNIT INCREASE/UNIT ($millions) 

0.5" $6.81 $5.47 3.6 

1.0" 13.46 7.36 4.3 

1.5" 21.16 7.36 5.4 

2.0" $29.20 $8.45 6.8 

NOTES: 1. Equipment modification or replacement (if deemed necessary) to accommodate 

larger tools not included. 

2. Margin loss due to lost sales/reduced market not included. 

EXPENSE MANPOWER 

($millions) ($millions) 

7.2 4.6 

7.5 5.1 

7.8 5.6 

8.0 6.2 

, . 

START-UP 

($millions) 

1.2 

1.2 

1.5 

1.5 
Table 20

- Thick Wall Product Cost Sensitivity Analysis

Thickness

Increase

Product Cost

Increase/Unit

+10% Foam

Cost

+20% Foam

Cost

+30% Foam

Cost

0.5" $6.81 $7.25 $7.69 $8.13

1.0" 13.46 14.35 15.24 16.13

1.5" 21.16 22.53 23.90 25.27

2.0" 29.20 31.19 33.18 35.17

 EE-RM-93-801 COMMENT OR5

Table 20 

Thick Wall Product Cost Sensitivity Analysis 

Thickness Product Cost +10% Foam +20% Foam +30% Foam 

Increase Increase/Unit Cost . Cost Cost 

0.5" $6.81 $7.25 $7.69 $8.13 

1.0" 13.46 14.35 15.24 16.13 

1.5" 21.16 22.53 23.90 25.27 

2~0" 29.20 31.19 33.18 35.17 

-70-

Table 20 

Thick Wall Product Cost Sensitivity Analysis 

Thickness Product Cost +10% Foam +20% Foam +30% Foam 

Increase Increase/Unit Cost . Cost Cost 

0.5" $6.81 $7.25 $7.69 $8.13 

1.0" 13.46 14.35 15.24 16.13 

1.5" 21.16 22.53 23.90 25.27 

2~0" 29.20 31.19 33.18 35.17 

-70-
Table 21

Cost to Increase Insulation Thickness on 18' Refrigerator Doors Only

Internal Dimensions Maintained/External Dimensions Varied

(1991 Dollars)

THICKNESS

INCREASE

PRODUCT COST

INCREASE/UNIT

TRANSPORTATION

INCREASE/UNIT

INVESTMENT

($millions)

EXPENSE

($millions)

MANPOWER

($millions)

START-UP

($millions)

0.5" $2.06 $1.17 0.3 2.5 1.6 0.3

1.0" 4.11 4.22 0.4 2.6 1.7 0.3

1.5" 6.25 4. 22 0.5 2.8 1.9 0.4

2.0" $8.13 $5 .79 0.6 2.8 .2.1 0.4

NOTES: 1. Equipment modification or replacement (if deemed necessary) to accomodate

larger tools not included.

2. Margin loss due to lost sales/reduced market not included.

 EE-RM-93-801 COMMENT OR5

I 

.... 

..... 

·' t " , " 

\ Table 21 I 

Cost to Increase Insulation Thickness on 18' Refrigerator Doors Onl'y 

Internal Dimensions Maintained/External Dimensions Varied 

(1991 Dollars) 

THICKNESS PRODUCT COST TRANSPORTATION INVESTMENT 

INCREASE INCREASElUNIT INCREASElUNIT ($millions) 

0.5" $2.06 $1.17 0.3 

1.0" 4.11 4.22 0.4 

1.5" 6.25 4.22 0.5 

2.0" $8.13 $5.79 0.6 

NOTES: 1. Equipment modification or replacement (if deemed necessary) to accomodate 

larger tools not included. 

2. Margin loss due to lost sales/reduced market not included . 

. . 

EXPENSE MANPOWER START-UP 

($millions) ($millions) ($millions) 

2.5 1.6 0.3 

2.6 1.7 0.3 

2:8 1.9 0.4 

2.8 .2.1 0.4 

I 

.... 

..... 

·' t " , " 

\ Table 21 I 

Cost to Increase Insulation Thickness on 18' Refrigerator Doors Onl'y 

Internal Dimensions Maintained/External Dimensions Varied 

(1991 Dollars) 

THICKNESS PRODUCT COST TRANSPORTATION INVESTMENT 

INCREASE INCREASElUNIT INCREASElUNIT ($millions) 

0.5" $2.06 $1.17 0.3 

1.0" 4.11 4.22 0.4 

1.5" 6.25 4.22 0.5 

2.0" $8.13 $5.79 0.6 

NOTES: 1. Equipment modification or replacement (if deemed necessary) to accomodate 

larger tools not included. 

2. Margin loss due to lost sales/reduced market not included . 

. . 

EXPENSE MANPOWER START-UP 

($millions) ($millions) ($millions) 

2.5 1.6 0.3 

2.6 1.7 0.3 

2:8 1.9 0.4 

2.8 .2.1 0.4 
Implementation Timetable

Changes of this magnitude woud take at least one and one-half to two years to design and

implement, depending on the manufacturer's model mix and production equipment flexibility. The major time elements would be product redesign, tool and equipment redesign

and procurement, and prototype evaluation.

 EE-RM-93-801 COMMENT OR5

Implementation Timetable 

Changes of this magnitude woud take at least one and one-half to two years to design and 

implement, depending on the manufacturer's model mix and production equipment flexibility. The major time elements would be product redesign, tool and equipment redesign 

and procurement, and prototype evaluation. 

-72-

Implementation Timetable 

Changes of this magnitude woud take at least one and one-half to two years to design and 

implement, depending on the manufacturer's model mix and production equipment flexibility. The major time elements would be product redesign, tool and equipment redesign 

and procurement, and prototype evaluation. 

-72-
ENERGY ANALYSIS

The total energy consumption of 18 cubic foot refrigerators with thicker foam insulation or

vacuum insulation was modeled using the EPA Refrigerator Analysis program [211. A

"typical" 1991 refrigerator was used as the baseline for the analyses. Some of the dimensions and characteristics of the baseline unit, i.e. the unit without thicker walls or vacuum

insulation, are shown in Table 22. Additional details can be found in the description of

Model D given-in reference 22. Thicker foam calculations were made on the 18 cubic foot

unit with 0.5,1,1.5 or 2 inches of foam added on all of the exterior surfaces, including

doors.

Refrigerators which had 18, 21 or 24 cubic feet total volumes and contained vacuum panels

having a resistivity of 25 h ft2 °F / (Btu inch) and the dimensions shown in Table 2 were

also modeled. The 21 and 24 cubic foot units were identical to the 18 with the exception of

one inch added to the exterior dimensions of the 18 to make a 21 cubic foot unit and 2

inches added to the 18 to make it into a 24.

Calculated energy consumption per day decreased by as much as 24 percent for adding

two inches of foam to the exterior of the 18 cubic foot unit, see Table 23. Similar energy,

reductions would occur for adding insulation to the exterior of the 21 and 24 cubic foot

units.

Incorporating the vacuum panels into the refrigerator produced an average 16 percent

energy reduction, with the 18 cubic foot unit having a slightly better improvement and the

24 slightly worse. Since panels sized for the 18 were modeled in all three units, the panels

cover less of the area in the larger units and the energy reduction decreases accordingly.

Finally, comparison of the calculations for the 18 cubic foot unit indicates that addition of

one inch of foam produces the same energy reduction as the inclusion of the vacuum panels. Similar results would be expected for the larger units.

 EE-RM-93-801 COMMENT OR5

ENERGY ANALYSIS 

The total energy consumption of 18 cubic ~oot refrigerators with thicker foam insulation ·or 

vacuum insulation was modeled using the EPA Refrigerator Analysis program [21]. A .. 

IItypkal" 1991 refrigerator was used as the baseline for the analyses. Some of the dimensions and characteristics of the baseline unit, i.e. the unit without thicker walls or vacuum 

insulation, are shown in Table 22. Additional details can be found in the description of 

Model D given-in reference 22. Thicker foam calculations were made on the 18 cubic foot 

unit with 0.5, 1, 1.5 or 2 inches of foam added on all of the exterior surfaces, including 

doors. 

Refrigerators which had 18,21 or 24 cubic feet total volumes and contained vacuum panels 

having a resistivity of 25 h ft2 OF / (Btu inch) and the dimensions shown in Table 2 were 

also modeled. The 21 and 24 cubic foot units were identical to the 18 with the exception of 

one inch added to the exterior dimensions of the 18 to make a 21 cubic foot unit and 2 

inches added to the 18 to make it into a 24. 

Calculated energy consumption per day decreased by as much as 24 percent for adding 

two inches of foam to the exterior of the 18 cubic foot unit, see Table 23. Similar energy. 

reductions would occur for adding insulation to the exterior of the 21 and 24 cubic foot 

units. 

" 

Incorporating the vacuum panels into the refrigerator produced an average 16 percent 

energy reduction, with the 18 cubic foot unit having a slightly better improvement and the 

24 slightly worse. Since panels sized for the 18 were modeled in all three units, the pariels 

cover less of the area in the larger units and the energy reduction decreases accordingly. 

Finally, comparison of the calculations for the 18 cubic foot unit indicates that addition of 

one inch of foam produces the same energy red.uction as the inclusion of the vacuum panels. Similar results would be expected for the larger units. 

-73-

ENERGY ANALYSIS 

The total energy consumption of 18 cubic ~oot refrigerators with thicker foam insulation ·or 

vacuum insulation was modeled using the EPA Refrigerator Analysis program [21]. A .. 

IItypkal" 1991 refrigerator was used as the baseline for the analyses. Some of the dimensions and characteristics of the baseline unit, i.e. the unit without thicker walls or vacuum 

insulation, are shown in Table 22. Additional details can be found in the description of 

Model D given-in reference 22. Thicker foam calculations were made on the 18 cubic foot 

unit with 0.5, 1, 1.5 or 2 inches of foam added on all of the exterior surfaces, including 

doors. 

Refrigerators which had 18,21 or 24 cubic feet total volumes and contained vacuum panels 

having a resistivity of 25 h ft2 OF / (Btu inch) and the dimensions shown in Table 2 were 

also modeled. The 21 and 24 cubic foot units were identical to the 18 with the exception of 

one inch added to the exterior dimensions of the 18 to make a 21 cubic foot unit and 2 

inches added to the 18 to make it into a 24. 

Calculated energy consumption per day decreased by as much as 24 percent for adding 

two inches of foam to the exterior of the 18 cubic foot unit, see Table 23. Similar energy. 

reductions would occur for adding insulation to the exterior of the 21 and 24 cubic foot 

units. 

" 

Incorporating the vacuum panels into the refrigerator produced an average 16 percent 

energy reduction, with the 18 cubic foot unit having a slightly better improvement and the 

24 slightly worse. Since panels sized for the 18 were modeled in all three units, the pariels 

cover less of the area in the larger units and the energy reduction decreases accordingly. 

Finally, comparison of the calculations for the 18 cubic foot unit indicates that addition of 

one inch of foam produces the same energy red.uction as the inclusion of the vacuum panels. Similar results would be expected for the larger units. 

-73-
Table 22

Baseline 1991 Refrigerator

Internal Volume

Recip. Compressor

Refrigerant

18.0 ft3

5.3 EER

CFC12

INSULATION

r-value

Freezer walls

Freezer top

Freezer door

Fresh food walls

Fresh food bottom

Fresh food door

7.9 h ft2 °F/(Btu in)

2.375 inches

2.375 inches

1.75 inches

1.875 inches

2.0 inches

1.75 inches

FANS

Evaporator

Condenser

8W

10W

Table 23

Energy Consumption Analysis Results

MODEL

ENERGY CONSUMPTION

kWh/day % reduction

18 ft3 baseline 1.75

18 ft3 +0.5" foam 1.58 9.7

18 ft3 +1.0" foam 1.46 16.6

18 ft3 +1.5" foam 1.38 21.1

18 ft3 +2.0" foam 1.33 24

18 ft3 +vac. ins. 1.46 16.6

21 ft3 baseline 1.83

21 ft3 +vac. ins. 1.54 15.8

24 ft3 baseline 1.91

24 ft3 +vac. ins. 1.62 15.2

 EE-RM-93-801 COMMENT OR5

Table 22 

Baseline 1991 Refrigerator 

Internal Volume lS.0 ft3 

Recip. Compressor 5.3EER 

Refrigerant CFC12 

.INSULA TION 

r-value 7.9 h ft2 °F/(Btu in) 

Freezer walls 2.375 inches 

Freezer top 2.375 inches 

Freezer door 1.75 inches 

Fresh food walls 1.S75 inches 

Fresh food bottom 2.0 inches 

Fresh food door 1.75 inches 

FANS 

Evaporator SW 

Condenser lOW 

Table 23 

Energy Consumption Analysis Results 

ENERGY CONSUMPTION 

MODEL 

kWh/day % reduction 

IS ft3 baseline 1.75 

IS ft3 +0.5" foam 1.58 9.7 

IS ft3 +1.0" foam 1.46 16.6 

IS ft3 +1.5" foam 1.38 21.1 

IS ft3 +2.0" foam 1.33 24 

IS ft3 +vac. ins. 1.46 16.6 

21 ft3 baseline 1.83 

21 ft3 +vac. ins. 1.54 15.S 

24 ft3 baseline 1.91 

24 ft3 +vac. ins. 1.62 15.2 

-74-

Table 22 

Baseline 1991 Refrigerator 

Internal Volume lS.0 ft3 

Recip. Compressor 5.3EER 

Refrigerant CFC12 

.INSULA TION 

r-value 7.9 h ft2 °F/(Btu in) 

Freezer walls 2.375 inches 

Freezer top 2.375 inches 

Freezer door 1.75 inches 

Fresh food walls 1.S75 inches 

Fresh food bottom 2.0 inches 

Fresh food door 1.75 inches 

FANS 

Evaporator SW 

Condenser lOW 

Table 23 

Energy Consumption Analysis Results 

ENERGY CONSUMPTION 

MODEL 

kWh/day % reduction 

IS ft3 baseline 1.75 

IS ft3 +0.5" foam 1.58 9.7 

IS ft3 +1.0" foam 1.46 16.6 

IS ft3 +1.5" foam 1.38 21.1 

IS ft3 +2.0" foam 1.33 24 

IS ft3 +vac. ins. 1.46 16.6 

21 ft3 baseline 1.83 

21 ft3 +vac. ins. 1.54 15.S 

24 ft3 baseline 1.91 

24 ft3 +vac. ins. 1.62 15.2 

-74-
REFERENCES

Equipment and Material Suppliers

1. Fres-Co System USA, Inc., Telford, Pa., Larry Restivo (form, fill, and seal equipment

and vacuum packaging)

2. T. W. Kutter Inc., Avon, Ma., Fran Ventura & Vinnie Faherty, (form, fill, and seal

equipment and vacuum packaging)

3. Mateer-Burt Co. Inc., Wayne, Pa., Diehl Mateer (auger fillers)

4. North America Silica, Ridgefield Park, N. J. (as of 3/1/92, the Silica Division of

Degussa Corp.) Roger Caffier & Nick Ludovic. (silica material)

5. Nordson Corp., Florence, Ky., John McKenna (hot melt equipment)

6. Fluid Energy Aljet, Plumsteadville, Pa., William Rodzewich (flash driers and

densifiers)

7. Remtec, Inc., Cincinnati, Oh., Charlie Gaynor (robots and assembly stations)

8. Technical Automation, Cincinnati, Oh.,Tom Zito (GMF robots)

9. Roessler Company, Cincinnati, Oh., Ron Roessler (vacuum transfer equipment)

10. Advanced Material Handling/Stewart Glapat, Louisville, Ky., Les Kepley (adjust

oveyors, belt conveyor)

11. Mathews Conveyor, Danville, Ky., Debbie Hoskins (belt and roller conveyor)

12. Unibuilt/Jervis B. Webb, Farmington Hills, Mi., Robert Fredricks (overhead, enclosed

track conveyor)

13. Zellerbach, Louisville, Ky., Chuck Andres, Gary Weil (strapping and bar coding

equipment and strap and cardboard cap material)

14. TapTone, North Falmouth, N. J., Leslie Martin (vacuum test equipment)

15. Oak Ridge National Labs, Oak Ridge, Tn., Tom Kollie (vacuum test equipment)

 EE-RM-93-801 COMMENT OR5

REFERENCES 

Equipment and Material Suppliers 

1. Fres-Co System USA, Inc., Telford, Pa., Larry Restivo (form, fill, and seal equipment 

and vacuum packaging) 

2. T. W. Kutter Inc., Avon, Ma., Fran Ventura & Vinnie Faherty, (form, fill, and seal 

equipment and vacuum packaging) 

3. Mateer-Burt Co. Inc., Wayne, Pa., Diehl Mateer (auger fillers) 

4. North America Silica, Ridgefield Park, N. J. (as of 3/1/92, the Silica Division of 

Degussa Corp.) Roger Caffier & Nick Ludovic. (silica material) 

5. Nordson Corp., Florence, Ky., John McKenna (hot melt equipment) 

6. Fluid Energy Aljet, Plumsteadville, Pa., William Rodzewich (flash driers and 

densifiers) 

7. Remtec, Inc., Cincinnati, Oh., Charlie Gaynor (robots and assembly stations) 

8. Technical Automation, Cincinnati, Oh.,Tom Zito (GMF robots) 

9. Roessler Company, Cincinnati, Oh., Ron Roessler (vacuum transfer equipment> 

10. Advanced Material Handling/Stewart Glapat, Louisville, Ky., tes Kepley (adjust-"" 

oveyors, belt conveyor) 

11. Mathews Conveyor, Danville, Ky., Debbie Hoskins (belt and roller "Conveyor) 

12. Unibuilt/Jervis B. Webb, Farmington Hills, Mi., Robert Fredricks (overhead, enclosed 

track conveyor) 

13. Zellerbach, Louisville, Ky., Chuck Andres, Gary Wei! (strapping and bar coding 

equipment and strap and cardboard cap material) 

14. TapTone, North Falmouth, N. J., Leslie Martin (vacuum test equipment) 

15. Oak Ridge National Labs, Oak Ridge, Tn., Tom Kollie (vacuum test equipment) 

-75-

REFERENCES 

Equipment and Material Suppliers 

1. Fres-Co System USA, Inc., Telford, Pa., Larry Restivo (form, fill, and seal equipment 

and vacuum packaging) 

2. T. W. Kutter Inc., Avon, Ma., Fran Ventura & Vinnie Faherty, (form, fill, and seal 

equipment and vacuum packaging) 

3. Mateer-Burt Co. Inc., Wayne, Pa., Diehl Mateer (auger fillers) 

4. North America Silica, Ridgefield Park, N. J. (as of 3/1/92, the Silica Division of 

Degussa Corp.) Roger Caffier & Nick Ludovic. (silica material) 

5. Nordson Corp., Florence, Ky., John McKenna (hot melt equipment) 

6. Fluid Energy Aljet, Plumsteadville, Pa., William Rodzewich (flash driers and 

densifiers) 

7. Remtec, Inc., Cincinnati, Oh., Charlie Gaynor (robots and assembly stations) 

8. Technical Automation, Cincinnati, Oh.,Tom Zito (GMF robots) 

9. Roessler Company, Cincinnati, Oh., Ron Roessler (vacuum transfer equipment> 

10. Advanced Material Handling/Stewart Glapat, Louisville, Ky., tes Kepley (adjust-"" 

oveyors, belt conveyor) 

11. Mathews Conveyor, Danville, Ky., Debbie Hoskins (belt and roller "Conveyor) 

12. Unibuilt/Jervis B. Webb, Farmington Hills, Mi., Robert Fredricks (overhead, enclosed 

track conveyor) 

13. Zellerbach, Louisville, Ky., Chuck Andres, Gary Wei! (strapping and bar coding 

equipment and strap and cardboard cap material) 

14. TapTone, North Falmouth, N. J., Leslie Martin (vacuum test equipment) 

15. Oak Ridge National Labs, Oak Ridge, Tn., Tom Kollie (vacuum test equipment) 

-75-
16. Babcock/Wllcox, Lynchburg, Va., Kenneth Camplin (vacuum test equipment)

17. Peabody Tec Tank, Parsons Kansas, Sharon Long (silos)

18. JFG Coffee Co., Knoxville, Tn., Brian Morse (user of form, fill, and seal equipment and

vacuum packaging)

19. World Wide Equip./Kenworth, Lexington, Ky., Greg Mills (Kenworth trucks and

Dorsey trailers)

20. Portman Material Handling/Clark, Lexington, Ky., Thomas DeLuca (Clark fork

trucks)

21. Merriam, R. L. 1992. ERA, The EPA Refrigerator Analysis Model and Computer Program. in press, U.S. Environmental Protection Agency, Washington, D.C.

22. Environmental Protection Agency. 1992. Multiple Pathways to Super Efficient Refrigerators, in press, U.S. Environmental Protection Agency, Washington, D.C.

23. Snow Filtration, Cincinnati, Ohio, Dan Wenke (pourous bag material)

 EE-RM-93-801 COMMENT OR5

16. Babcock/Wllcox, Lynchburg, Va., Kenneth Camplin (vacuum test equipment) 

17. Peabody Tee Tank, Parsons Kansas, Sharon Long (silos) 

18. JFG Coffee Co., Knoxville, Tn., Brian Morse (user of form, fill, and seal equipment and 

vacuum packaging) 

19. World Wide Equip./Kenworth, Lexington, Ky., Greg Mills (Kenworth truckS and 

Dorsey trailers) 

20. Portman Material Handling/Clark, Lexington, Ky., Thomas DeLuca (Clark fork 

trucks) 

21. Merriam, R. L. 1992. ERA, The EPA Refrigerator Analysis Model and Computer Program. in press, U.S. Environmental Protection Agency, Washington, D.C. 

22. Environmental Protection Agency. 1992. Multiple Pathways to Super Efficient Refrigerators, in press, U.S. Environmental Protection Agency, Washington, D.C. 

23. Snow Filtration, Cincinnati, Ohio, Dan Wenke (pourous bag material) 

-76-

16. Babcock/Wllcox, Lynchburg, Va., Kenneth Camplin (vacuum test equipment) 

17. Peabody Tee Tank, Parsons Kansas, Sharon Long (silos) 

18. JFG Coffee Co., Knoxville, Tn., Brian Morse (user of form, fill, and seal equipment and 

vacuum packaging) 

19. World Wide Equip./Kenworth, Lexington, Ky., Greg Mills (Kenworth truckS and 

Dorsey trailers) 

20. Portman Material Handling/Clark, Lexington, Ky., Thomas DeLuca (Clark fork 

trucks) 

21. Merriam, R. L. 1992. ERA, The EPA Refrigerator Analysis Model and Computer Program. in press, U.S. Environmental Protection Agency, Washington, D.C. 

22. Environmental Protection Agency. 1992. Multiple Pathways to Super Efficient Refrigerators, in press, U.S. Environmental Protection Agency, Washington, D.C. 

23. Snow Filtration, Cincinnati, Ohio, Dan Wenke (pourous bag material) 

-76-
APPENDICES

A Product-information sheet - FK500IS

B Letter quote - FK500LS

Silica silos

D Volumetric auger filler

E Form, fill, and seal machine

F Tap tone unit

G VIP test chamber

H Strapping machine

I Adjustoveyor

j Bar coding unit

K Material safety data sheet -FK500LS

L Unibuilt enclosed track conveyor

M GMF S-500 robot

N Nordson hot melt equipment

Remtec estimate of adhesive and panel insertion stations

 EE-RM-93-801 COMMENT OR5

APPENDICES 

A ProducHnformation sheet - FK500LS ~ 

B Letter quote - FKSOOLS 

C Silica silos 

D Volumetric auger filler 

E Form, fill, and seal machine 

F Tap tone unit 

G VIP test chamber 

H Strapping machine 

I Adjustoveyor 

J Bar coding unit 

K Material safety data sheet -FK500LS 

L U~built enclosed track conveyor 

M GMF 5-500 robot 

N Nordson hot melt equipment 

0 Remtec estimate of adhesive and panel insertion stations 

-nAPPENDICES 

A ProducHnformation sheet - FK500LS ~ 

B Letter quote - FKSOOLS 

C Silica silos 

D Volumetric auger filler 

E Form, fill, and seal machine 

F Tap tone unit 

G VIP test chamber 

H Strapping machine 

I Adjustoveyor 

J Bar coding unit 

K Material safety data sheet -FK500LS 

L U~built enclosed track conveyor 

M GMF 5-500 robot 

N Nordson hot melt equipment 

0 Remtec estimate of adhesive and panel insertion stations 

-n-
APPENDIX A

425 Metro Place North Dublin, Ohio 43017

PRODUCT: FK500LS

(614) 761-0658

METHOD

If PROPERTIES UNTT

TYPICAL

VALUE

PCM 37U _SURFACE AREA (MICROMERTIICS) sq-=19 475

PCM-23U MOISTURE (1) (DIN 53 198) 16 2.S

PCM 20U pH-VALUE (5%, DIN 53 200) 6.7

PCM 25U TAPPED DENSITY (DIN 53194) g/I 80

PCM-32U-1 A VERAGE AGGLOMERATE SIZE (COULTER) am 3

PCM-41 U DEP ABSORPTION (1) 9/1008

PCM-03U SILICON DIOXIDE (2) 16 99

PCM--1OU 804(2) X 1.0

PCM-51 U A1203 (2) 0 0.2

PCM-SOU Fe2O3 (2) S 0.03

(1) based on material dried for 2 hours @ 105 deg-C

1 (2) based on material ignited for 2 hours Ca) 1000 deg-C

("') currently not a standard method

CAUTION: Inhalation of synthetic amorphous precipitated silica y irritate the respiratory tract.

Adequate ventilation and, where dust occurs, a HIOSH-approved dust respirator is recommended. Material

Safety Data sheets are available on request.

This product is manufactured to comply with FDA requirements for Direct Food Additives Subpart E

--Anticaking Agents (21 C.F.R. § 172,480), and Subpart O--Specific Usage Additives: Defoaaing agents (21

C.F.R. § 173,340).

This product is manufactured to comply with FDA requirements for Indirect Food Additives for Use only as

Components of Adhesives (21 C.F.R. § 175,105), for indirect Food Additives for Use Only as Components of

Paper and Paperboard (21 C.F.R. § 176,200, 21 C.F.R. § 176,210), for Indirect Food Additives.for Use only as

Components of Coatings (21 C.F.R. § 175,300), for use as Basic Components of Single and Repeated Use Food

Contact Surfaces: Cellophane (21 C.F.R. § 177,1200), Rubber articles intended for repeated use (21 C.F.R. §

177,2600), and for indirect Food Additives: Adjuvants and Production Aids in Animal Glue (21 C.F.R. §

178,3120).

information herein is accurate to the best of our knowledge. Suggestions

are made without warranty or guarantee of results . Before using, user

should determine the suitability of the product for his intended use and

user assumes the risk and tiabitity - in connection therewith . we do not

suggest violation of any existing patents or give permission to practice

any patented invention without a license.

CASH: 112926- 00-8; CAS Name; Synthetic Amorphous Precipitated Silica

 EE-RM-93-801 COMMENT OR5

Oegussa .. 

Degussa 

Carpomtion 

425 Metro Place North 

METHOD 

, 

PCM-37U 

PCM-23U 

PCM-20U 

PCM-25U 

~ PCM-32U-1 

PCM-41U 

PCM-D3U 

PCM-lOU 

PCM-51U 

PCM-50U 

APPENDIX A 

Dublin. Ohio 43017 

PRODUCT: FK500LS 

PROPERTIES UNIT 

SURFACE AREA (MlCROMERmCS) arm/g 

MOISTURE (1) (DIN53198) 

pH-VALUE (5~, DIN 53 200) 

TAPPED DENSITY (DIN 53194) 

AVERAGE AGGLOMERATE SIZE (COULTER) 

DBP ABSORPTION (1) gl100g 

SIUCON DIOXIDE (2) 

S04 (2) 

Al203(2) 

Fe20J (2) 

(1) based on material dried for 2 hours @ 105 ~ 

I (2) based on material ignited for 2 hours @ 1000 deg-C 

("" ") currently not a standard method 

TYPICAL 

VALUE 

475 

2.5 

6.7 

80 

3 

32S 

99 

1.0 

0.2 

0.03 

CAlITIOII: Inhalation of synthetic amorphOU$ precipitated silic:a IIIBY irritate the respiratory tract. 

~te ventilation and. where dust occurs, a NIOSH-approved dust respirator is recollDleuded. Material 

Safety Data Sheets are avai lable on r~t. 

(614) 761-0658 

This product is lIIIBrLIfactured to c~ly with FDA requiresIIOInts for Direct Food Additives SUbpart E 

--Antic:aJdng Agents (21 C.F.R. § 172,480), and SUbpart D·-Specific Usage Additives: Defoaaing agents (21 

C.F.R. § 173,340). 

This product is nranufactured to c~ly with FDA requiresIIOInts for Indirect Food Additives for Use Only lIS 

~ts of A<ilesille:S (21 C.f.R. § 175,10S), for Indirect Food Additille:S for Use Only as ~ts of 

Paper and Paperboard (21 C.F.R. § 176,200, 21 C.F.R. § 176.210), for Indirect Food Additille:S.for Use Only as CoaIponents of Coatings (21 C.F.R. § 175,300), for use .. Basic ~ts of Single and Repeated Use Food I 

Contact Surfaces: Cellophane (21 C.F.R. § 177,1200), Rubber articles intended for repeated use (21 C.f .• R. i 

177,2600). and for Indirect Food Additives: Adjuvants and Pro<b:tion Aids in AniNl Glue (21 C.F.R. § 

178,3120). 

Information herein is accurate to the btst of our knowledge. Suggestions 

are made wi thout warr;)nty or guarantee of resul ts. Before using, user 

should determine the suit;)bility ot the product for his intended us~ and 

user assU1>eS the risk and liability:in cornec:tion therewith. lie do not 

suggest viol;)cion ot ;:,ny existing p;:,tents or give penaission to pr:.ccice 

any p;:,tentcd invention without;) license. 

CASII: 112926·00·8; CAS N."IIIC; SYnthetic AmOrphous Precipitated Si I ic;) 

Oegussa .. 

Degussa 

Carpomtion 

425 Metro Place North 

METHOD 

, 

PCM-37U 

PCM-23U 

PCM-20U 

PCM-25U 

~ PCM-32U-1 

PCM-41U 

PCM-D3U 

PCM-lOU 

PCM-51U 

PCM-50U 

APPENDIX A 

Dublin. Ohio 43017 

PRODUCT: FK500LS 

PROPERTIES UNIT 

SURFACE AREA (MlCROMERmCS) arm/g 

MOISTURE (1) (DIN53198) 

pH-VALUE (5~, DIN 53 200) 

TAPPED DENSITY (DIN 53194) 

AVERAGE AGGLOMERATE SIZE (COULTER) 

DBP ABSORPTION (1) gl100g 

SIUCON DIOXIDE (2) 

S04 (2) 

Al203(2) 

Fe20J (2) 

(1) based on material dried for 2 hours @ 105 ~ 

I (2) based on material ignited for 2 hours @ 1000 deg-C 

("" ") currently not a standard method 

TYPICAL 

VALUE 

475 

2.5 

6.7 

80 

3 

32S 

99 

1.0 

0.2 

0.03 

CAlITIOII: Inhalation of synthetic amorphOU$ precipitated silic:a IIIBY irritate the respiratory tract. 

~te ventilation and. where dust occurs, a NIOSH-approved dust respirator is recollDleuded. Material 

Safety Data Sheets are avai lable on r~t. 

(614) 761-0658 

This product is lIIIBrLIfactured to c~ly with FDA requiresIIOInts for Direct Food Additives SUbpart E 

--Antic:aJdng Agents (21 C.F.R. § 172,480), and SUbpart D·-Specific Usage Additives: Defoaaing agents (21 

C.F.R. § 173,340). 

This product is nranufactured to c~ly with FDA requiresIIOInts for Indirect Food Additives for Use Only lIS 

~ts of A<ilesille:S (21 C.f.R. § 175,10S), for Indirect Food Additille:S for Use Only as ~ts of 

Paper and Paperboard (21 C.F.R. § 176,200, 21 C.F.R. § 176.210), for Indirect Food Additille:S.for Use Only as CoaIponents of Coatings (21 C.F.R. § 175,300), for use .. Basic ~ts of Single and Repeated Use Food I 

Contact Surfaces: Cellophane (21 C.F.R. § 177,1200), Rubber articles intended for repeated use (21 C.f .• R. i 

177,2600). and for Indirect Food Additives: Adjuvants and Pro<b:tion Aids in AniNl Glue (21 C.F.R. § 

178,3120). 

Information herein is accurate to the btst of our knowledge. Suggestions 

are made wi thout warr;)nty or guarantee of resul ts. Before using, user 

should determine the suit;)bility ot the product for his intended us~ and 

user assU1>eS the risk and liability:in cornec:tion therewith. lie do not 

suggest viol;)cion ot ;:,ny existing p;:,tents or give penaission to pr:.ccice 

any p;:,tentcd invention without;) license. 

CASII: 112926·00·8; CAS N."IIIC; SYnthetic AmOrphous Precipitated Si I ic;) 
APPENDIX B

1 of 2

North America Silica Company

a joint venture of

Degussa Corporation and PO Corporation

June 11, 1991

Mr. Alan Fine

U.S. ENVIRONMENTAL PROTECTION AGENCY

Technology and Substitutes Branch

Global Change Division

Office of Air and Radiation

401 M Street SW

Washington, DC 20460

Dear Alan:

c7o DEGUSSA CORPORATION

65 Challenger Road

Ridgefield Park , NJ 07660

Phone : (201) 641-6100

Fax: (201) 807-3182

Reference your work with the Center for Robotics and Manufacturing

Systems at the University of Kentucky, I've enclosed two Degussa

Corporation technical bulletins. These brochures "Forms Supplied

and Handling of Synthetic Silicas and Silicates" and "Experience

Gained in the Dust-Free Handling of Solid Materials in Powder Form

with Extremely Low Bulk Densities" may'help you with your University

of Kentucky discussions. -

Regarding the price of our two precipitated silicas that are being

used for the production of vacuum insulation panels, here is some -

general information:

Product Bag

Weight

Bags /

Pallet

Pallet

Stacking

Pallet

Weight

48' Trailer

Quantity

Truckload

Price/Lb.

Sipernat® 22LS 25 30 3X10 750 18,750 $.85

FK 500LS 20 15 3X5 300 15,000 $1.12

Until your organization or one of the appliance manufacturers that

you may be working with, get to a point where they require direct

truckload or bulk delivery of our material, we would like to offer

the following:

We agree to sell Sipernat 22LS and FK 500LS as follows:

Sipernat 22LS $. 65 per pound , any quantity, FOB our Louisville

Distributor William B. Tabler & Company.

FK 500LS $.75 per pound , any quantity, FOB our Louisville

Distributor William B. Tabler & Company.

Once someone moves past the scale-upstages for this application,

we can work out the details of a contract price, stocking point, lead

time, bulk deliveries, etc., etc.

 EE-RM-93-801 COMMENT OR5

North America Silica Company 

a jOint venture of 

Oegussa Corporation and PO Corporation 

June 11, 1991 

Mr. Alan Fine 

APPENDIX B 

1 of 2 

U.S. ENVIRONMENTAL PROTECTION AGENCY 

Technology and Substitutes Branch 

Global Change Division 

O~fice of Air and Radiation 

401 M Street SW 

Washington, DC 20460 

Dear Alan: 

clo DEGUSSA CORPORATION 

6S Challenger Road 

Ridgefield Park, NJ 07660 

Phone: (201) 641-6100 

Fax: (201) 807-3182 

Reference your work with the Center for Robotics and Manufacturing 

Systems at the University of Kentucky, I've enclosed two Degussa 

Corporation technical bulletins. These brochures "Forms Supplied 

and Handling of Synthetic Silicas and Silicates" and "Experience 

Gained in the Dust-Free Handling of Solid Materials in Powder Form 

with Extremely Low Bulk Densities" may "help you with your University 

of Kentucky discussions. 

Regarding the price of our two precipitated silicas that are being 

used for the production of vacuum insulation panels, here is some 

general information: 

Product \ Bag Bags/ Pallet Pallet 48' Trailer Truckload 

Weight Pallet Stacking Weight 2uaritity PriceLLb. 

Sipernat® 22LS 25 30 3XIO 750 18,750 $.85 

FK SOOLS 20 15 3X5 300 15,000 $1.12 

Until your organization or one of the appliance manufacturers that 

you may be working with, get to a point where they require direct 

truckload or bulk delivery of our material, we would like to offer 

the following: 

We agrae to sell Sipernat 22LS and FK 500LS as follows: 

Sipernat 22LS 

FK 500LS 

$.65 per pound, any quantity, FOB our Louisville 

Distributor William B. Tabler & Company. 

$.75 per pound, any quantity, FOB our Louisville 

Distributor William B. Tabler & Company. 

Once someone moves past the scale-up "stages for this application, 

we can work out the details of a contract price, stocking point. lead 

time, bulk deliveries, etc~, etc. 

North America Silica Company 

a jOint venture of 

Oegussa Corporation and PO Corporation 

June 11, 1991 

Mr. Alan Fine 

APPENDIX B 

1 of 2 

U.S. ENVIRONMENTAL PROTECTION AGENCY 

Technology and Substitutes Branch 

Global Change Division 

O~fice of Air and Radiation 

401 M Street SW 

Washington, DC 20460 

Dear Alan: 

clo DEGUSSA CORPORATION 

6S Challenger Road 

Ridgefield Park, NJ 07660 

Phone: (201) 641-6100 

Fax: (201) 807-3182 

Reference your work with the Center for Robotics and Manufacturing 

Systems at the University of Kentucky, I've enclosed two Degussa 

Corporation technical bulletins. These brochures "Forms Supplied 

and Handling of Synthetic Silicas and Silicates" and "Experience 

Gained in the Dust-Free Handling of Solid Materials in Powder Form 

with Extremely Low Bulk Densities" may "help you with your University 

of Kentucky discussions. 

Regarding the price of our two precipitated silicas that are being 

used for the production of vacuum insulation panels, here is some 

general information: 

Product \ Bag Bags/ Pallet Pallet 48' Trailer Truckload 

Weight Pallet Stacking Weight 2uaritity PriceLLb. 

Sipernat® 22LS 25 30 3XIO 750 18,750 $.85 

FK 500LS 20 15 3X5 300 15,000 $1.12 

Until your organization or one of the appliance manufacturers that 

you may be working with, get to a point where they require direct 

truckload or bulk delivery of our material, we would like to offer 

the following: 

We agrae to sell Sipernat 22LS and FK 500LS as follows: 

Sipernat 22LS 

FK 500LS 

$.65 per pound, any quantity, FOB our Louisville 

Distributor William B. Tabler & Company. 

$.75 per pound, any quantity, FOB our Louisville 

Distributor William B. Tabler & Company. 

Once someone moves past the scale-up "stages for this application, 

we can work out the details of a contract price, stocking point. lead 

time, bulk deliveries, etc~, etc. 
APPENDIX B

2 of 2

North America Silica Company

a joint venture of

Degussa Corporation and PO Corporation

cTo DEGUSSA CORPORATION

65 Challenger-Road

Ridgefield Park , NJ 07660

Phone : (201) 641-6100

Fax: (201 ) 807-3182

For planning purposes, these prices of $.6500 and $.7500 can be used

as a guide for the bulk price, FOB. Chester, Pennsylvania, for these

products. Hopefully, our program of subsidizing the use of these

materials and making them readily available through our distributor,

William B. Tabler & Company, Louisville, Kentucky, Phone No. (502)

634-0596, is of benefit to you. Please feel free to use these prices

for engineering purposes. These prices can also be discussed openly

with your associates.

If there are any questions on any of the above matters please give

me a call.

Sincerely,

Kenneth C. Cwick

General Manager

North America Silica Company

A Joint Venture of

`begussa Corporation

and PQ Corporation

KCC:hr

Enclosures -

/026

CC: J. Boggess, William B. Tabler Co.

R. *Caffier, Consultant to Degussa Corporation

J. Nastoff, Degussa Corporation

R. Niccol, Degussa Corporation

R. Reich, NASILCO - PQ-VF

H. Strack, Degussa AG VTC-A

 EE-RM-93-801 COMMENT OR5

North Ameri~ Silica Company 

a/Oint ven.lure of 

Oequssa Corporation and PO Corporalion 

APPENDIX B 

2 of 2 

c/o DEGUSSA CORPORATION 

6S Challenger-load 

Ridgefield Park, BJ 07660 

Phone: (201) 641-6100 

Fax: (201) 807-3182 

Fpr planning purposes, these prices of $.6500 and $.7500 can be used 

as a guide for the bulk price, FOB. Chester, Pennsylvania, for these 

products. Hopefully, our program of subsidizing the use of these 

materials and making them readily available through our distributor, 

William B. Tabler & Company, Louisville, Kentucky, Phone No. (502) 

634-0596, is of benefit to you. Please feel free to use these prices . for engineering purposes. These prices can also be discussed openly 

with your associates. 

If there are any questions on any of the above matters please give 

me a call. 

Sincerely, 

u-",~/.'d:/ Kenneth C. CWick 

General Manager 

North America Silica Company 

A Joint Venture of 

lDegussa Corporation 

and PQ Corporation 

KCC:hr 

Enclosures 

/026 

CC: J. Boggess, William B. Tabler Co. 

R. Caffier, Consultant to Degussa Corporation 

J. Nastoff, Degussa Corporation 

R. Niccol, Degussa Corporation 

R. Reich, NASILCO - PQ-VF 

H. Strack, Degussa AG VTC-A 

North Ameri~ Silica Company 

a/Oint ven.lure of 

Oequssa Corporation and PO Corporalion 

APPENDIX B 

2 of 2 

c/o DEGUSSA CORPORATION 

6S Challenger-load 

Ridgefield Park, BJ 07660 

Phone: (201) 641-6100 

Fax: (201) 807-3182 

Fpr planning purposes, these prices of $.6500 and $.7500 can be used 

as a guide for the bulk price, FOB. Chester, Pennsylvania, for these 

products. Hopefully, our program of subsidizing the use of these 

materials and making them readily available through our distributor, 

William B. Tabler & Company, Louisville, Kentucky, Phone No. (502) 

634-0596, is of benefit to you. Please feel free to use these prices . for engineering purposes. These prices can also be discussed openly 

with your associates. 

If there are any questions on any of the above matters please give 

me a call. 

Sincerely, 

u-",~/.'d:/ Kenneth C. CWick 

General Manager 

North America Silica Company 

A Joint Venture of 

lDegussa Corporation 

and PQ Corporation 

KCC:hr 

Enclosures 

/026 

CC: J. Boggess, William B. Tabler Co. 

R. Caffier, Consultant to Degussa Corporation 

J. Nastoff, Degussa Corporation 

R. Niccol, Degussa Corporation 

R. Reich, NASILCO - PQ-VF 

H. Strack, Degussa AG VTC-A 
APPENDIX C

1 of 3

 EE-RM-93-801 COMMENT OR5

AFFENDIX C 

1 of 3 
APPENDIX C

2 of 3

® PeabodyTecTank

Putting More Into Storage

With Bolted and Welded Tanks for Liquids

and Dry Products

At Peabody TecTank we're putting more into

storage . As a result, more storage is going to

Peabody TecTank. Two modem plants produce

factory coated bolted and factory welded tanks for

both liquid and dry storage applications. The industries we serve often require tanks that most

certain recognized standards and codes . Some of

these, routinely a part of our design and

fabrication , include FDA , BISSC , UBC, AISC,

AWS, API, NFPA, FM, EPA, and AWWA.

To.Meet Industry's Needs

Experienced sales professionals can assist you in

specifying the tank for your needs . Our engineering

staff, utilizing computer aided design , provides

tanks which are engineered to meet your special

requirements . Peabody TecTank's customer

service department can provide help during the

construction phase, including supervision or

complete erection service . This complete service

is at your disposal, whether your tank requirements

ca:" for a large multiple tank installation or only one

tar.

In Demandiny Applications -

A range of sizes and factory coatings are available

to tackle most industrial applications . When storing

bulk solids, interior coatings are selected to protect

against corrosion and abrasion . Exterior coatings

are selected to provide protection against the

effects of weather and the tough environment found

in industrial settings . Tanks may be designed to

accommodate most unloding systems ; they may be

hoppered or flat bottom , skirted or on structure.

They may be designed for tunnel flow or mass flow

and may store a variety of industrial materials such

as minerals, chemicals , plastics, grains, and

processed foods.

Experience , service, quality...the reasons our list

of repeat customers continues to grow. Our

reputation is your guarantee. When you need

storage, let Peabody TecTank put more into

storage for you.

 EE-RM-93-801 COMMENT OR5

• • 

APPENDIX C 

2 of 3 

TecTank 

Putting More Into Storage 

With Bolted and Welded Tanks for Liquids 

and Dry Products 

At PeabodY TecTank we're putting more inlD 

Ilbrage. Iu a result, more .lDrage is going ID 

Peabody TecTank. Two modem plants produce 

faclDry coated bolted and facIDry welded tanka tor 

both ~quid and dry SlDrage applications. The Industries we serve often require tanka that meet 

certain recognized standards and codes. Some of 

these, routinely a part of our design and 

fabrication, include FOA, BISSC, UBC, AISC, 

AWS, API, NFPA, FM, EPA, and AWNA. 

ToMeet Industry's Needs 

Experienced sales professionals can assist you in 

specifying the tank for your needs. Our engineering 

staff, utilizing computer aided design, provides 

tanks which are engineered to meet your special 

requirements. Peabody TecTank's customer 

service department can provide help during !he 

construction phase, including supervision or 

complete erection service. This complete aervice 

is at your disposal, whether your tank requiremenla 

ca': for a large multiple tank installation or only one tar": 

In Demandin~ Applications 

A range of sizes and facIDry coatings are IMliIabie 

ID tackle most industrial applications. When storing 

bulk solids, interior coatings are selected ID proteCt 

against corrosion and abrasion. Exterior c:oatinga 

are selected ID provide protecIion against the 

effects of weather and the IDUgh environment found 

in industrial settings. Tanks may be designed ID 

accommodate most unlading systems; they may be 

hoppered or flat bottom, skirted or on structure. 

They may be designed tor funnel flow or mass flow 

and may slDre a variety of industrial materiaJs such 

as minerals, chemicals, plastics, grains, and 

processed foods. 

Experience, service, quality ..• !he reasons our list 

of repeal customers continues ID grow. Our 

reputation is your guarantee. When you need 

storage,let Peabody TecTank put more inlD 

SlDrage for you. 

• • 

APPENDIX C 

2 of 3 

TecTank 

Putting More Into Storage 

With Bolted and Welded Tanks for Liquids 

and Dry Products 

At PeabodY TecTank we're putting more inlD 

Ilbrage. Iu a result, more .lDrage is going ID 

Peabody TecTank. Two modem plants produce 

faclDry coated bolted and facIDry welded tanka tor 

both ~quid and dry SlDrage applications. The Industries we serve often require tanka that meet 

certain recognized standards and codes. Some of 

these, routinely a part of our design and 

fabrication, include FOA, BISSC, UBC, AISC, 

AWS, API, NFPA, FM, EPA, and AWNA. 

ToMeet Industry's Needs 

Experienced sales professionals can assist you in 

specifying the tank for your needs. Our engineering 

staff, utilizing computer aided design, provides 

tanks which are engineered to meet your special 

requirements. Peabody TecTank's customer 

service department can provide help during !he 

construction phase, including supervision or 

complete erection service. This complete aervice 

is at your disposal, whether your tank requiremenla 

ca': for a large multiple tank installation or only one tar": 

In Demandin~ Applications 

A range of sizes and facIDry coatings are IMliIabie 

ID tackle most industrial applications. When storing 

bulk solids, interior coatings are selected ID proteCt 

against corrosion and abrasion. Exterior c:oatinga 

are selected ID provide protecIion against the 

effects of weather and the IDUgh environment found 

in industrial settings. Tanks may be designed ID 

accommodate most unlading systems; they may be 

hoppered or flat bottom, skirted or on structure. 

They may be designed tor funnel flow or mass flow 

and may slDre a variety of industrial materiaJs such 

as minerals, chemicals, plastics, grains, and 

processed foods. 

Experience, service, quality ..• !he reasons our list 

of repeal customers continues ID grow. Our 

reputation is your guarantee. When you need 

storage,let Peabody TecTank put more inlD 

SlDrage for you. 
3 of 3

Foods -

Our Storage tanks for food products are used

extensively in the milling , baking and food

processing industries . Peabody TecTank's FDA

approved coatings are often specified by major

food companies . Large capacity tanks are

available to store up to 750,000 bushels of

unprocessed grains.

Minerals

Whether it is iron powder at 250 lb/ft3, barite at

160, lime at 80 or silica gel at 6, Peabody TecTank

can provide the storage . Bolted tanks are available

in sizes up to 130 feet in diameter and in heights

up to 129 feet. Welded tanks are available in sizes

to 14 feet in diameter and 85 feet high.

Peabody TecTank's bolted structures allow

access for truck or railcar loadout . Spread leg

welded tanks offer an economical drive through

loadout design . Our experience and engineering

give us the ability to provide special applications for

storage.

Chemicals and Plastics

Our factory applied coatings make our bolted

and welded tanks extremely popular in the

chemical and plastics industries. The high cost of

many of these products and the problems resulting

from contamination make a superior coating

system a must. Extensive use by major producers

and the many processors make this one of our

largest markets. Tanks are often supplied through

systems companies who specialize in a complete

material handling package.

Our capability to design and fabricate a variety

of hoppers and outlets allows our tanks to fit any

material handling system.

 EE-RM-93-801 COMMENT OR5

Foods 

Our Storage tanks lor food prodUCtli are used 

extensively in the miHing, baking and food 

processing iriiustries. Peabody TeeTank's FDA 

approWld coatings are often specified bv major 

food companies. large capacity tanks are 

available to store up to 750,000 busllela of 

unprocessed grains. 

Minerals 

Whether it is iron powder at 250 Iblft3, barite at 

160, Ume at 80 or silica gel at 6, Peabody TeeTank 

can provide the storage. Bolted tanks are available 

in sizes up to 130 feet in diameter and in helghtli 

up to 129 leet. Welded tanks are available in sizes 

to 14 feet in diameter and 85 feet high. 

Peabody TeeT ank's bolted structures allow 

access for truck or railcar Ioadout. Spread leg 

welded tanks offer an economical drive trhough 

Ioadout design. Our experience and engineering 

giYfl us the ability to provide special appUcationa for 

'!Drage. 

Chemicals and Plastics 

Our factory applied coatings make our bolted 

and welded tanks extremely popular in the 

chemical and plastics industries. The high cost 01 

many 01 these products and the problems resulting 

from contamination make a superior coating 

system a must. Extensive use by major producers 

and the many processors make this one 01 our 

largest markets. Tanks are often supplied through 

systems companies who specialize in a complete 

material handling package. 

Our capability to design and fabricate a variety 

01 hoppers and out!etli allows our tanks II) fit any 

material handling system. 

3 of 3 

Foods 

Our Storage tanks lor food prodUCtli are used 

extensively in the miHing, baking and food 

processing iriiustries. Peabody TeeTank's FDA 

approWld coatings are often specified bv major 

food companies. large capacity tanks are 

available to store up to 750,000 busllela of 

unprocessed grains. 

Minerals 

Whether it is iron powder at 250 Iblft3, barite at 

160, Ume at 80 or silica gel at 6, Peabody TeeTank 

can provide the storage. Bolted tanks are available 

in sizes up to 130 feet in diameter and in helghtli 

up to 129 leet. Welded tanks are available in sizes 

to 14 feet in diameter and 85 feet high. 

Peabody TeeT ank's bolted structures allow 

access for truck or railcar Ioadout. Spread leg 

welded tanks offer an economical drive trhough 

Ioadout design. Our experience and engineering 

giYfl us the ability to provide special appUcationa for 

'!Drage. 

Chemicals and Plastics 

Our factory applied coatings make our bolted 

and welded tanks extremely popular in the 

chemical and plastics industries. The high cost 01 

many 01 these products and the problems resulting 

from contamination make a superior coating 

system a must. Extensive use by major producers 

and the many processors make this one 01 our 

largest markets. Tanks are often supplied through 

systems companies who specialize in a complete 

material handling package. 

Our capability to design and fabricate a variety 

01 hoppers and out!etli allows our tanks II) fit any 

material handling system. 

3 of 3 
APPENDIX D

NEOTRON SYSTEM

SERIES 1900

Convenient All-Electric Model

The Neotron Series 1900 filler offers the convenience of an

electromechanical dutch brake without compromising the

high operating standards of Neotron System fillers. The all

electric Series 1900 is ideal as a replacement filling head

on form, fill and seal machines, as standard equipment on

automatic filling machines, or as semiautomatic filling

machines. A high-cycle-life clutch is also availavle as an

option.

NEOTRO SYSTEM

SERIES 1990

Heavy Duty Model For Difficult Fills

The Neotron Series 1990 filler is designed for use in heavy duty

applications where the type of product and/or the fill size offer

unusual diff iculties. The rugged Series 190 is built with a clutch

brake rated at 95 foot pounds of torque and a five-horsepower

drive motor.

 EE-RM-93-801 COMMENT OR5

APPENDIX D 

NEOTRON SYSTEM 

SERIES 1900 

Convenient All-Electric Model 

The Neotron Series 1900 filler offers the convenience of an 

electromechanical clutch brake without compromising the 

high operating standards of Neotron System fillers. The all 

electric Series 1900 is ideal as a replacement filling head 

on form. fill and seal machines. as standard equipment on 

automatic filling machines. or as semiautomatic filling 

machines. A high-cycle-life clutch is also availavle as an 

option. 

NEOTRON SYSTEM 

SERIES 1990 

Heavy Duty Model For Difficult Fills 

The Neotron Series 1990 filler is designed for use in heavy duty 

applications where the type of product and/or the fill size offer 

unusual difficulties. The rugged Series 1990 is built with a clutch 

brake rated at 95 foot pounds of torque and a five-horsepower 

drive motor. 

APPENDIX D 

NEOTRON SYSTEM 

SERIES 1900 

Convenient All-Electric Model 

The Neotron Series 1900 filler offers the convenience of an 

electromechanical clutch brake without compromising the 

high operating standards of Neotron System fillers. The all 

electric Series 1900 is ideal as a replacement filling head 

on form. fill and seal machines. as standard equipment on 

automatic filling machines. or as semiautomatic filling 

machines. A high-cycle-life clutch is also availavle as an 

option. 

NEOTRON SYSTEM 

SERIES 1990 

Heavy Duty Model For Difficult Fills 

The Neotron Series 1990 filler is designed for use in heavy duty 

applications where the type of product and/or the fill size offer 

unusual difficulties. The rugged Series 1990 is built with a clutch 

brake rated at 95 foot pounds of torque and a five-horsepower 

drive motor. 
APPENDIX.E

Automatic Vacuum Packaging System GL-26

Features

'output

Up to 40 bags per minute

'Weight of Bags

2 oz. to 5 lbs.

'Programmable Logic

Controher

'Finished Bag Types

Square bottom qussetted

bags with square or

cathedral top

'Packaging iiaterial

Multi-ply Laminates

'One Machine Operator

*Net Weigh Sceies

fres-co®

Options

'Degassing Valve

'Easy Open

•Reclosure Tape

'Tin Tie

'Top and/or Bottom Flap Hot

Melt

'Double Folding of Bag Top

Flap

'Hot Stamp Imprinter

•Gas Flush

'Vacuum Compensated With

Inert Gas

Dimensions

'23'(L) x 13'(W) x. 14'(H)

' Wieght

17,000 lbs.

SYSTEM USA, INC.

 EE-RM-93-801 COMMENT OR5

APPENDIX E 

Automatic Vacuum Packaging System GL-26 

~~ 

fres-co® 

Features 

-OUtput 

Up to 40 bags per minute 

-Weight ci Bags 

2 oz, to 5 lbs, 

-Programmable Logic 

Controller 

- Finished Bag Types 

Square bottom qussetted 

bags with square or 

cathedral top 

- Packaging Material 

Multi-ply Laminates 

-One Machine Operator 

- Net Weigh SccJes 

SYSTEM USA,INC. 

Options' 

-~assing Valve 

-Easy Open 

-ReclOsure Tape 

-Tin Tie 

-Top and/or Bottom Flap Hot 

Melt 

-!X>uble Folding of Bag Top 

Flap 

-Hot Stamp Imprinter 

-Gas Flush 

- Vacuum Compensated With 

Inert Gas 

Dimensions 

-Z3'(L) x 13'(W) x.14'm) 

-Wieght 

17,000 lbs, 

APPENDIX E 

Automatic Vacuum Packaging System GL-26 

-=lJ 

fres-co® 

Features 

-OUtput 

Up to 40 bags per minute 

-Weight ci Bags 

2 oz, to 5 lbs, 

-Programmable Logic 

Controller 

- Finished Bag Types 

Square bottom qussetted 

bags with square or 

cathedral top 

- Packaging Material 

Multi-ply Laminates 

-One Machine Operator 

- Net Weigh SccJes 

SYSTEM USA,INC. 

Options' 

-~assing Valve 

-Easy Open 

-ReclOsure Tape 

-Tin Tie 

-Top and/or Bottom Flap Hot 

Melt 

-!X>uble Folding of Bag Top 

Flap 

-Hot Stamp Imprinter 

-Gas Flush 

- Vacuum Compensated With 

Inert Gas 

Dimensions 

-Z3'(L) x 13'(W) x.14'm) 

-Wieght 

17,000 lbs, 
Z ;o T

^ es^w..w ^ tv

 EE-RM-93-801 COMMENT OR5
APPENDIX F

2 of 2

MODEL DESCRIPTION APPLICATION

SPEED

PER/MIN OPTIONS

PV2000-CM TRACKER/Conveyor Mount Check vacuum and pressure in cans and jars 500 PV2000-DO Data Output

PV2000-SA TRACKER/Stand Alone without head space. PV2000-PS Pedestal Stand

PV2000-RK Retrofit Kit

SQ-1 PLASTIC BOTTLE Checks leaks in plastic bottles with or without toil 120 Oscilloscope Housing

INSPECTOR inner seal.

4014-PF PUFFER Plastic cups and trays with foil membrane lids. 300 903-Spare Parts Kit

4024-1 LOW SPEED TAPTONE Can or jar lines where headspace is available Max speed '404-CR Crank

and speeds do not exceed 350 cpm. at least 4024-CK Changeover

350 cpm 903-2 Spare Parts

4044-1 HIGH SPEED TAPTONE Can or jar lines where headspace is available 1800 cpm 404-CR Crank

and speeds exceed 350 cpm. 4044-CK Changeover

405-DL Datalogger

903-4 Spare Parts

4044-CB AUTOMATIC LINE Vacuum bagged products from such systems Contact 404-CR Crank

TAPTONE FOR VACUUM as SIG VAC, where a "brick" results. Factory 405-DL Datalogger

TESTING FOIL 903-7 Spare Parts

PACKAGES

4054-2-CB AUTOMATIC CASE Same as 4044-CB. for testing products in the 50 cases 405-SM Spray Marker

TAPTONE FOR VACUUM sealed case. Inspection grade conveyor 405-DL Datalogger

TESTING FOIL included. 405-R Rejector

PACKAGES 903-8 Spare Parts

4054-4 AUTOMATIC CASE Warehouse or distribution center testing of 50 cases 903-5 Spare Parts

TAPTONE product with headspace in the sealed case . 405-SM Spray Marker

Inspection grade conveyor included. 405-DL Datalogger

405-R Rejector

405-SCD Swell Can Det

4054-CK Changeover

4104-4 AUTOMATIC SWELLED Warehouse or distribution center testing of 50 cases 405-SM Spray Marker

CAN DETECTOR product with or without headspace in the sealed 405-R Rejector'

case. Inspection grade conveyor included. 903-6 Spare Parts

4049-4A CASE SCANNER Subjective/manual testing of cans/jars with clear N/A 4049-4H Qase Head

headspace in the case or individually. 4049-S Single Head

4049-A PORTABLE TAPTONE Subjective/manual testing of cans /jars with N/A N/A

clear headspace.

 EE-RM-93-801 COMMENT OR5

MODEL DESCRIPTION 

I PV2000-CM i TRACKEAlConveyor Mount 

1 PV2000-SA TRACKEAlStand Alone I 

SQ-l PLASTIC BOTTLE 

INSPECTOR 

4014-PF I PUFFER I 

4024-1 I LOW SPEED T APTONE 

4044-1 ! HIGH SPEED TAPTONE 

, 

I 

4044-CB AUTOMATIC LINE 

TAPTONE FOR VACUUM 

TESTING FOIL 

PACKAGES 

40S4-2-CB I AUTOMATIC CASE I TAPTONE FOR VACUUM 

TESTING FOIL 

PACKAGES 

40S4-4 AUTOMATIC CASE 

TAPTONE 

i 

4104-4 AUTOMATIC SWELLED 

CAN DETECTOR 

4049-4A I CASE SCANNER 

I 1 

4049-A PORTABLE TAPTONE I 

APPENDIX F 

2 of 2 

APPLICATION 

Check vacuum and pressure in cans and jars 

without head space. 

Checks leaks in plastic bottles with or withoU1 toil 

inner seal. 

Plastic cups and trays with foil membrane lids. 

Can or jar lines where headspace is available 

and speeds do not exceed 3S0 cpm. 

Can or jar lines where headspace is available 

and speeds exceed 3S0 cpm. 

Vacuum bagged products from such systems 

as SIG VAC.!C where a "brick" results. 

Same as 4044-CB. for testing products in the 

sealed case. Inspection grade conveyor 

included. 

Warehouse or distribution center testing of 

product with headspace in the sealed case. 

Inspection grade conveyor included. 

Warehouse or distribution center testing of 

product with or without headspace in the sealed 

case. Inspection grade conveyor included. 

Subjective/manual testing of cans/jars with clear 

headspace in the case or individually. 

Subjective/manual testing of cans/jars with 

clear_lJeadspace. --. -

SPEED 

PER/MIN 

500 

120 

300 

Max speed 

at least 

3S0cpm 

1800cpm 

Contact 

Factory . 

SO cases 

SO cases 

50 cases 

N/A 

NlA 

OPTIONS 

PV2000-DO Data Output 

PV2000-PS Pedestal Stand 

PV2000-RK Retrofit Kit 

Oscilloscope Housing 

903-Spare Parts Kit 

·404-CR Crank 

4024-CK Changeover 

903-2 Spare Parts 

404-CR Crank 

4044-CK Changeover 

405-DL Datalogger 

903-4 Spare Parts 

404-CR Crank 

405-DL Datalogger 

903-7 Spare Parts 

4OS-SM Spray Marker 

40S-DL Datalogger 

40S-R Rejector 

903-8 Spare Parts 

903-S Spare Parts 

40S-SM Spray Marker 

405-DL Datalogger 

40S-R Rejector 

4OS-SCD Swell can Det 

40S4-CK Changeover 

405-SM Spray Marker 

405-R Rejector' 

903-6 Spare Parts 

4049-4H Case Head 

4049-S Single Head 

NlA 

MODEL DESCRIPTION 

I PV2000-CM i TRACKEAlConveyor Mount 

1 PV2000-SA I TRACKEAlStand Alone I 

SQ-l PLASTIC BOTTLE 

INSPECTOR 

4014-PF I PUFFER I 

4024-1 I LOW SPEED T APTONE 

4044-1 ! HIGH SPEED TAPTONE 

, 

I 

4044-CB AUTOMATIC LINE 

TAPTONE FOR VACUUM 

TESTING FOIL 

PACKAGES 

40S4-2-CB I AUTOMATIC CASE I TAPTONE FOR VACUUM 

TESTING FOIL 

PACKAGES 

40S4-4 AUTOMATIC CASE 

TAPTONE 

i 

4104-4 AUTOMATIC SWELLED 

CAN DETECTOR 

4049-4A I CASE SCANNER 

I 1 

4049-A PORTABLE TAPTONE I 

APPENDIX F 

2 of 2 

APPLICATION 

Check vacuum and pressure in cans and jars 

without head space. 

Checks leaks in plastic bottles with or withoU1 toil 

inner seal. 

Plastic cups and trays with foil membrane lids. 

Can or jar lines where headspace is available 

and speeds do not exceed 3S0 cpm. 

Can or jar lines where headspace is available 

and speeds exceed 3S0 cpm. 

Vacuum bagged products from such systems 

as SIG VAC.!C where a "brick" results. 

Same as 4044-CB. for testing products in the 

sealed case. Inspection grade conveyor 

included. 

Warehouse or distribution center testing of 

product with headspace in the sealed case. 

Inspection grade conveyor included. 

Warehouse or distribution center testing of 

product with or without headspace in the sealed 

case. Inspection grade conveyor included. 

Subjective/manual testing of cans/jars with clear 

headspace in the case or individually. 

Subjective/manual testing of cans/jars with 

clear_lJeadspace. --. -

SPEED 

PER/MIN 

500 

120 

300 

Max speed 

at least 

3S0cpm 

1800cpm 

Contact 

Factory . 

SO cases 

SO cases 

50 cases 

N/A 

NlA 

OPTIONS 

PV2000-DO Data Output 

PV2000-PS Pedestal Stand 

PV2000-RK Retrofit Kit 

Oscilloscope Housing 

903-Spare Parts Kit 

·404-CR Crank 

4024-CK Changeover 

903-2 Spare Parts 

404-CR Crank 

4044-CK Changeover 

405-DL Datalogger 

903-4 Spare Parts 

404-CR Crank 

405-DL Datalogger 

903-7 Spare Parts 

4OS-SM Spray Marker 

40S-DL Datalogger 

40S-R Rejector 

903-8 Spare Parts 

903-S Spare Parts 

40S-SM Spray Marker 

405-DL Datalogger 

40S-R Rejector 

4OS-SCD Swell can Det 

40S4-CK Changeover 

405-SM Spray Marker 

405-R Rejector' 

903-6 Spare Parts 

4049-4H Case Head 

4049-S Single Head 

NlA 
APPENDIX G

1 of 3

VACUUM PACK INSPECTION SYSTEM:

The vacuum pack inspection system ( s) were designed and built by

Babcock & Wilcox, CIM Systems , to inspect vacuum packed insulation

panels used in the appliance industry . The system reports the

actual vacuum in the pack on a monitor for operator disposition.

The system utilizes a custom designed vacuum chamber, a high

precision pressure/vacuum transducer , and a optical laser

triangulation sensor in order to measure the vacuum in the packs.

The chamber and sensor mounting design enables many different

sizes of packs to be inspected by the system . The control system

utilizes an IBM compatible computer and B&W software to lead the.

operator through the inspection process . The operator initiates

the inspection process from the main menu and places a pack in the

chamber. Once the lid is closed , a vacuum is pulled on the

chamber. The optical laser sensor , which is contained inside the

vacuum chamber , is focused onto the surface of the insulation

pack. When the vacuum inside the chamber reaches the same vacuum

level of that inside the insulation pack , the insulation pack

wrapper expands . The laser sensor detects the deflection

(expansion ) of the insulation pack and triggers the computer to

read the vacuum transducer at the time of deflection. This

reading is an indication of the actual vacuum level inside the

insulation pack.

ADDED FOR AUTOMATED HANDLING:

The current design is a manual system with respect to the handling

(loading and unloading ) of the insulation panels, and initiation

of the functions via the terminal . The vacuum chamber design

utilizes gas springs to assist the operator in opening and closing

the heavy cover , similar to the liftback of an automobile. This

design can easily be modified to accommodate robotic handling

where the robot would load the panels into the chamber , utilizing

for example , vacuum suction pads for the and effector, and

communicate with the vacuum system computer to start and stop the

processes without operator intervention . The vacuum system

software , with some modification , can than perform the inspection

cycle automatically where the only additional hardware required to

facilitate fully automatic operation would be to replace the gas

springs with solenoid controlled air cylinders.

System throughput is directly dependent on the chamber size

and the percentage of volume that is occupied by the pack

being inspected ( as well as the vacuum pump size). For

"higher" vacuum packs (below 3 torr), the longest step of the

inspection cycle is the time required to pull the vacuum on

 EE-RM-93-801 COMMENT OR5

Q .. 

APPENDIX G 

1 of 3 

VACUUM PACK INSPECTIOn SlSn:M: 

The vacuum paCk inspect;ion system(s) were designed and built by 

Babcock & Wilcox, CIM Sys~ems, to inspec~ vacuum packed insulation 

panels used in the appliance indus~r/. The system reports the ac~ual vacuum in the paCk on a monitor for operator disposition. 

The sys~em u~ilizes a cus~om designed vacuum chamber, a high 

precision pressure/vacuum ~ransducer, and a optical laser 

trianqulation sensor in order to measure the vacuum in the packs. 

The chamber and sensor ~oun~ing design enables many different 

sizes of packs to be inspect;ed by the system. The con~ol system 

utilizes an IBM comoa~ible comDu~er ana B&W software to lead the . opera~or through the inspection process. The opara~or initiates 

the inspection process from the main menu and places a pack in the 

chamber. Once the lid is closed, a vacuum is pulled on the 

chamber. The optical laser sensor, "'hich is contained inside the 

vacuum chamber, is focused on~o the surface of the insulation 

paCk. When the vacuum inside the chamDer reaches the same vacuum 

level of that inside the insulation pack, the insulation pack 

wrapper expands. The laser sensor detects the def laction 

(expansion) of the insulation pack and triggers the computer to 

read the vacuum ~ansducer at the time of defleC'eion. This 

reaaUlg is an indica~ion of the actual vacuum lavel insida the 

insulation pack. 

ADDED FOR AUTOMATED HANDLING: 

The current design is a manual system with respect to tha handling 

(loading and unloading) of the insulation panels, and initiation . of the funct;ions via the terminal. The vacuum c:llamber design 

utilizes gas springs to assist the operator in opening and closing 

the heavy cover, similar to the lif~ack of an automObile. This 

design can easily be modified to accommodate robotic handling 

where the robot would load the panels into the chamber, utilizing 

for example, vacuum suction pads for the end effect;or, and 

communicate with the vacuum sys~em computer to start and stop the 

processes without operator intervention. The vacuum system sof~Jare. with some modification, can then perform the inspection cycle automatically where the only additional hardware required to fac~litate fully automatic operation would be to replace the gas spr~ngs with soleno~d cont~olled air ~llinders. 

System throughput is direct;ly dependent on the chamber size 

and the percentage of volume that is occupied by the pack be~ng inspected <as well as the vacuum pump siZe,. For 

"higher" vacuum packs (·below 3 torr), -:he longest step 'of the 

inspection cycle is the ti~e requ~red to pull the vacuum on 

Q .. 

APPENDIX G 

1 of 3 

VACUUM PACK INSPECTIOn SlSn:M: 

The vacuum paCk inspect;ion system(s) were designed and built by 

Babcock & Wilcox, CIM Sys~ems, to inspec~ vacuum packed insulation 

panels used in the appliance indus~r/. The system reports the ac~ual vacuum in the paCk on a monitor for operator disposition. 

The sys~em u~ilizes a cus~om designed vacuum chamber, a high 

precision pressure/vacuum ~ransducer, and a optical laser 

trianqulation sensor in order to measure the vacuum in the packs. 

The chamber and sensor ~oun~ing design enables many different 

sizes of packs to be inspect;ed by the system. The con~ol system 

utilizes an IBM comoa~ible comDu~er ana B&W software to lead the . opera~or through the inspection process. The opara~or initiates 

the inspection process from the main menu and places a pack in the 

chamber. Once the lid is closed, a vacuum is pulled on the 

chamber. The optical laser sensor, "'hich is contained inside the 

vacuum chamber, is focused on~o the surface of the insulation 

paCk. When the vacuum inside the chamDer reaches the same vacuum 

level of that inside the insulation pack, the insulation pack 

wrapper expands. The laser sensor detects the def laction 

(expansion) of the insulation pack and triggers the computer to 

read the vacuum ~ansducer at the time of defleC'eion. This 

reaaUlg is an indica~ion of the actual vacuum lavel insida the 

insulation pack. 

ADDED FOR AUTOMATED HANDLING: 

The current design is a manual system with respect to tha handling 

(loading and unloading) of the insulation panels, and initiation . of the funct;ions via the terminal. The vacuum c:llamber design 

utilizes gas springs to assist the operator in opening and closing 

the heavy cover, similar to the lif~ack of an automObile. This 

design can easily be modified to accommodate robotic handling 

where the robot would load the panels into the chamber, utilizing 

for example, vacuum suction pads for the end effect;or, and 

communicate with the vacuum sys~em computer to start and stop the 

processes without operator intervention. The vacuum system sof~Jare. with some modification, can then perform the inspection cycle automatically where the only additional hardware required to fac~litate fully automatic operation would be to replace the gas spr~ngs with soleno~d cont~olled air ~llinders. 

System throughput is direct;ly dependent on the chamber size 

and the percentage of volume that is occupied by the pack be~ng inspected <as well as the vacuum pump siZe,. For 

"higher" vacuum packs (·below 3 torr), -:he longest step 'of the 

inspection cycle is the ti~e requ~red to pull the vacuum on 
APPENDIX G

2 of 3

the vacant portion of the chamber . Therefore , this time can

be greatly - reduced (approaching the 10 second range) if the

chamaer(s) can be sized to be only slightly larger than the

packs to be inspected . Loading , closing , bleeding , opening,

and unloading- ( the remaining steps of the cycle ) only require

a cumulative of about 10 additional seconds). In order to

support higher throughput requirements , several vacuum pack

inspection systems can be utilized per robot.

Babcock & Wilcox is experienced with custom automated robotic

handling and inspection systems , and can provide both the

automated version of the vacuum pack inspection systems or the

entire turnkey system , inclusive of the robot, to the and users.

 EE-RM-93-801 COMMENT OR5

APPENDIX G 

2 of 3 

the vacan~ poreion of the chamber. Therefore, this time can 

be grea~ly-reduced (approaching the 10 second range, if the 

chamDer(s) can be sized ~o be only slightly larger than the 

packs ~o be inspe~ed. Loading, closing, bleeding, opening, 

and unloadin~ (the remaining steps of the ~lcle) only require 

a cumulative of abou~ lO additional seconds). In order to 

support higher througnpu~ requiremen~s, several vacuum pack inspec~~on systems can be u~ilized per robo~. 

Babcock & Wilcox is experienced with cus~om automated robotic 

handling and inspec~ion sys~ems, and can provide both the au~oma~ed vers~on of ~~e vacuum pack inspec~~on systems or the en~ire ~urnkey sys~em. inClusive of the robo~, to the end users. 

APPENDIX G 

2 of 3 

the vacan~ poreion of the chamber. Therefore, this time can 

be grea~ly-reduced (approaching the 10 second range, if the 

chamDer(s) can be sized ~o be only slightly larger than the 

packs ~o be inspe~ed. Loading, closing, bleeding, opening, 

and unloadin~ (the remaining steps of the ~lcle) only require 

a cumulative of abou~ lO additional seconds). In order to 

support higher througnpu~ requiremen~s, several vacuum pack inspec~~on systems can be u~ilized per robo~. 

Babcock & Wilcox is experienced with cus~om automated robotic 

handling and inspec~ion sys~ems, and can provide both the au~oma~ed vers~on of ~~e vacuum pack inspec~~on systems or the en~ire ~urnkey sys~em. inClusive of the robo~, to the end users. 
 EE-RM-93-801 COMMENT OR5
APPENDIX H

Automatic, All-Electric

Plastic Strapping Machines for a

Variety of Bundling, Carton Closing

and Unitizing Applications

IT"S PORTABLE!

The ASM Series feature swivel

casters for machine portability

and a jacking leg for operational

stability. Combined with its "plug

in and operate" electrical requirements, the machines can be easily moved about your production

area as needs change.

SIMPLE JAM CLEARING

Unlike most competitive models,

the ASM's feature a simple, very

accessible jam clearing system.

A pushbuttom opens the strap

track allowing the operator to

remove trapped strap. Another

pushbutton cycles the sealer, cuts

off the old strap and re-feeds.

DUAL PRESS BAR OPTION

A pneumatically powered dual

press bar option for some track

sizes is available with up to 120

lbs. of compression to help presettle package contents, close

telescoping cartons and stabilize

packages during the strapping

operation.

POWERED CONVEYOR

AVAILABLE

The ASM-1 A features powered

belt conveyor with hinged top

plates and photo-eye controls for

PC controlled application of one

or two straps. The ASM-1 AA with

adjustable table top and external

dispenser is available with either

roller top or belt conveyor.

 EE-RM-93-801 COMMENT OR5

APPENDIX H 

Automatic, All-Electric 

Plastic Strapping Machines for a 

Variety of Bundling, Carton Closing 

and Unitizing Applications 

IT'S PORTABLE! 

The ASM Series feature swivel 

casters for machine portability 

and a jacking leg for operational 

stability. Combined with its "plug 

in and operate" electrical requirements, the machines can be easily moved about your production 

area as needs change. 

SIMPLE JAM CLEARING 

Unlike most competitive models, 

the ASM's feature a simple, very 

accessible jam clearing system. 

A pushbuttom opens the strap 

track allowing the operator to 

remove trapped strap. Another 

pushbutton cycles the sealer, cuts 

off the old strap and re-feeds. 

DUAL PRESS BAR OPTION 

A pneumatically powered dual 

press bar option for some track 

sizes· is available with up to 120 

Ibs. of compression to help presettle package contents, close 

telescoping cartons and stabilize 

packages during the strapping 

operation. 

POWERED CONVEYORAVAILABLE 

The ASM-1 A features powered 

belt conveyor with hinged top 

plates and photo-eye controls for 

PC controlled application of one 

or two straps. The ASM-1AA with 

adjustable table top and external 

dispenser is available with either 

roller top or belt conveyor. 

APPENDIX H 

Automatic, All-Electric 

Plastic Strapping Machines for a 

Variety of Bundling, Carton Closing 

and Unitizing Applications 

IT'S PORTABLE! 

The ASM Series feature swivel 

casters for machine portability 

and a jacking leg for operational 

stability. Combined with its "plug 

in and operate" electrical requirements, the machines can be easily moved about your production 

area as needs change. 

SIMPLE JAM CLEARING 

Unlike most competitive models, 

the ASM's feature a simple, very 

accessible jam clearing system. 

A pushbuttom opens the strap 

track allowing the operator to 

remove trapped strap. Another 

pushbutton cycles the sealer, cuts 

off the old strap and re-feeds. 

DUAL PRESS BAR OPTION 

A pneumatically powered dual 

press bar option for some track 

sizes· is available with up to 120 

Ibs. of compression to help presettle package contents, close 

telescoping cartons and stabilize 

packages during the strapping 

operation. 

POWERED CONVEYORAVAILABLE 

The ASM-1 A features powered 

belt conveyor with hinged top 

plates and photo-eye controls for 

PC controlled application of one 

or two straps. The ASM-1AA with 

adjustable table top and external 

dispenser is available with either 

roller top or belt conveyor. 
Adjustoveyor

extendable conveyors offer

many MONEY-SAVING benefits

When you use the job-proven Adjustoveyor you can expect these

benefits to your dock and wharehouse operations:

• Labor productiviy improvement of 500 % in most applications

• Reduced turnaround time for trucks, improving their on-the-road

productivity

• Reduced product damage, resulting in fewer claims and improved

product quality

• Improved dock space utilization through the avoidance of staging areas

• Smooth uninterupted flow to or from the truck

These operating benefits translate directly to cost reductions which easily

allow the Adjustoveyor to leap over those 40% after-tax corporate hurdle

rates used for capital bugeting decisions. In fact, many applications result in

a payback of less than one year! If the productivity improvement of your

overall system is one of your objectives, the Adjustoveyor is your best

investment.

 EE-RM-93-801 COMMENT OR5

APPENDIX I 

1 of 2 

Adjustoveyor 

extendable conveyors offer 

many MONEY-SAVING ben"efits 

When you use the job-proven Adjustoveyor you can expect these 

benefits to your dock and wharehouse operations: 

- Labor productiviy improvement of 500% in most applications 

- Reduced turnaround time for trucks, improving their on-the-road 

productivity 

- Reduced product damage, resulting in fewer claims and improved 

product quality 

-Improved dock space utilization through the avoidance of staging areas 

- Smooth uninterupted flow to or from the truck 

These operating benefits translate directly to cost reductions which easily 

allow the Adjustoveyor to leap over those 40% after-tax corporate hurdle 

rates used for capital bugeting decisions. In fact, many applications result in 

a payback of less than one year! If the productivity improvement of your 

overall system is one of your objectives, the Adjustoveyor is your best 

investment. 

APPENDIX I 

1 of 2 

Adjustoveyor 

extendable conveyors offer 

many MONEY-SAVING ben"efits 

When you use the job-proven Adjustoveyor you can expect these 

benefits to your dock and wharehouse operations: 

- Labor productiviy improvement of 500% in most applications 

- Reduced turnaround time for trucks, improving their on-the-road 

productivity 

- Reduced product damage, resulting in fewer claims and improved 

product quality 

-Improved dock space utilization through the avoidance of staging areas 

- Smooth uninterupted flow to or from the truck 

These operating benefits translate directly to cost reductions which easily 

allow the Adjustoveyor to leap over those 40% after-tax corporate hurdle 

rates used for capital bugeting decisions. In fact, many applications result in 

a payback of less than one year! If the productivity improvement of your 

overall system is one of your objectives, the Adjustoveyor is your best 

investment. 
BELT# BOOM MTRS.'

MID. UNDERNEATH

(OPTION: MTRS CAN

BE SIDE MTD.)

OPTIANAI TPArK

(FLOOR MTD)

EXTENDED LENGTH

CLOSED LENGTH CANTILEVER LENGTH

M TMA1 COWAOM N TM{ NYMATK01 w OS

T{M@ I O CAUV AMI CWYOM acvir MO TOM

SUMMA OV MI OIO OTdI PAT SOY. TMOMOAA AM

W Cf AO10 IrT Mil TM 0010 N TIQMIYT

MOMW OF IN PIWW.C YAT COY. AIM ATO

AVAAANZ YOO MW TARMTT OO T PAiT O WT W A0O

AIMT TM11N T111 RAAf.O A?AT COY.

STEWART.GLAPAT CORPORATION

ZANESVt1E, ONO, USA

SA-14-9-.1 0--U4

TRIPLE BOOM

ADJUS'0VEYOR

(SELF -PROPELLED) SKS40910 C

 EE-RM-93-801 COMMENT OR5

CLOSED LENGTH 

WIDTH (B.W) 

1 TR~VERSE: 30 FPM 

[

POWER: SPECIFY FINISH: 

EXTENDED lENGTH 

RIGHT SIDE VIEW 

fLUSH TRACK SHOWN (SEE OPTIONAL TRACK) 

SPECIFY BElT DIRECTION: 

TOP VIEW 

OPTIONAL TRACK (FLOOR MT 0.) 

CANTILEVER LENGTH 

o 

SAFETY 

ROLLERS 

BOOM SPEED: 30 FPM . 

TRIPLE BOOM 

OA" .. , - .. 

ADJUS~OVEYOR • 0 (SELF -~;:;OPElL£D) 51<8.071 c 

CLOSED LENGTH 

WIDTH (B.W) 

1 TR~VERSE: 30 FPM 

[

POWER: SPECIFY FINISH: 

EXTENDED lENGTH 

RIGHT SIDE VIEW 

fLUSH TRACK SHOWN (SEE OPTIONAL TRACK) 

SPECIFY BElT DIRECTION: 

TOP VIEW 

OPTIONAL TRACK (FLOOR MT 0.) 

CANTILEVER LENGTH 

o 

SAFETY 

ROLLERS 

BOOM SPEED: 30 FPM . 

TRIPLE BOOM 

OA" .. , - .. 

ADJUS~OVEYOR • 0 (SELF -~;:;OPElL£D) 51<8.071 c 
APPZNDD14 0

1 of 2

LPA/80T LPA/86T

THERMAL LABEL PRINTER/APPLICATOR

The LPA/80T and LPA/86T are heavy duty industrial direct thermal

printer/applicators which create high quality barcodes and variable

text on demand. The LPA/80T can process up to a 4" wide label and the

LPA186T up to 6" in width. Labels are smudge proof and oil and water

resistant. Print rate is up to 4" per second. The thermal printing process uses no ink or ribbon. Images are produced on temperature sensitive label material as it moves past a stationary print head. Dual

microprocessors control printing and labling functions. Advanced

programming includes graphic data base systems, free format

systems and custom software packages . Each printer/applicator includes stand, control box and product detection devices. Already proven by years of service, the LPA/80T printer/applicators provide a standard in high speed in line thermal label applications.

0

LORD LABEL SYSTEMS, INC.

- (214) 647-2504

 EE-RM-93-801 COMMENT OR5

APP.t:N,UJ.A u 

1 of 2 

LPAl80T LPAl86T 

THERMAL LABEL PRINTER/APPLICATOR 

The LPAl80T and LPAl86T are heavy duty industrial direct thermal 

printer/applicators which create high quality barcodes and variable 

text on demand. The LPAl80T can process up to a 4" wide label and the 

LPAl86T up to 6" in width. Labels are smudge proof and oil and water 

resistant. Print rate is up to 4" per second. The thermal printing process uses no ink or ribbon. Images are produced on temperature sensitive label material as it moves past a stationary print head. Dual 

microprocessors control printing and labling functions. Advanced 

programming includes graphic data base systems, free format 

systems and custom software packages. Each printer/applicator includes stand, control box and product detection devices. Already proven by years of service, the LPAl80T printer/applicators provide a standard in high speed in line thermal label applications. 

LORD LABEL SYSTEMS, INC. 

(214) 647-2504 

APP.t:N,UJ.A u 

1 of 2 

LPAl80T LPAl86T 

THERMAL LABEL PRINTER/APPLICATOR 

The LPAl80T and LPAl86T are heavy duty industrial direct thermal 

printer/applicators which create high quality barcodes and variable 

text on demand. The LPAl80T can process up to a 4" wide label and the 

LPAl86T up to 6" in width. Labels are smudge proof and oil and water 

resistant. Print rate is up to 4" per second. The thermal printing process uses no ink or ribbon. Images are produced on temperature sensitive label material as it moves past a stationary print head. Dual 

microprocessors control printing and labling functions. Advanced 

programming includes graphic data base systems, free format 

systems and custom software packages. Each printer/applicator includes stand, control box and product detection devices. Already proven by years of service, the LPAl80T printer/applicators provide a standard in high speed in line thermal label applications. 

LORD LABEL SYSTEMS, INC. 

(214) 647-2504 
APPENDIX J

2 of 2

lPf^/80T & lPf^/86T SPE^IfICf^TIONS

El

A

73" 22%

(185) (57) L

18"

- (45.7)

(ADJUSTABLE

7'h

(19)

Head Diminsion

Length 15 5/16°(40)

Width 131h (35)

Height 22% (57)

Applicator.

• Drive Motor: '/ta HP gear motor, 115 VAC

• Label Control: Photoelectric sensing, electric brake

and clutch

• Application Method: Air cylinder actuated tamp pad or

high pressure air blast

• Construction: Anodized aluminum and stainless steel

Label Sizes:

LPA/80T 4 '/a" wide x 4" repeat (111mm x 102mm) maximum standard size. Larger sizes available at extra cost.

LPA/86T 61/2" wide x 4" repeat (165mm x 102mm) maximum standard size. Larger sizes available at extra cost.

Printer.

• Method: Ceramic thick film thermal print modules.

• Print Pattern: LPA/80T single row of 300 print points,

approximately 76 dots per inch. Dot dimension 0.013"

(0.33mm). Print field width 3.9" (99mm).

LPA/86T single row of 450 print. points, approximately

.76 dots per inch. Dot dimension 0.013" (0.33mm). Print

field width 5.9" (150mm).

• Rate: 3" (76mm) per second standard. Rate may vary

depending on application.

Electronics: .

• Enclosure: NEMA 12, water resistant; may be remote

mounted.

• Control: Z80 Microprocessor CPU with solid state

memory and control chips. Label format, character

generator, fixed label data and print routine are stored

- in plug-in EPROM's.

LORD LABEL SYSTEMS, INC.

1200 Ave. H East

Arlington, TX. 76011

(214) 647-2504

1-800-433-5310

MiMHI

MEMBER COK4*Ny

1111141AtM

8 J \1E^"T7

(94) (ADJUSTABLE)

9

42

(107)

• Display: 16 Character LED display indicates the status

of the printer/applicator. Test functions are

commanded from a 16 button keypad and read out on

the display. In addition, error messages are displayed

to pinpoint mechanical malfunctions or input data

faults to minimize troubleshooting time.

Data Input:

The unit may operate as a stand-alone printer/applicator .

by means of the integral keypad or an optional. terminal

using on-board programming. Data input can come from

any computer output device with an RS232 serial interface, such as an electronic scale, barcode reader or host

computer.

Label Material: -

Thermal sensitive paper: smudge proof, oil and water

resistant. Paper is available for infrared scannable barcodes (900 nanometers).

Label Formatting:

Available barcodes are interleaved 2 of 5, Code 39, UPC

and EAN. Other barcode structures can be provided. Formats are designed to suit the application. Several variable

fields can be provided within a format. Character sizes

can be up to 1.0".

Power Required:

115 VAC, 10 amp circuit

Air Required:

60 to 80 psi filtered (15 micron), dry air at '/3 CFM

AutbonZed Dlatnbutor

Recomrnend d and dut bu d by

2 Zellelrbach

A ra.,

1101 Indupnal Blvd

Louisville KentuCkv 40219

Tatennorn 502-964.6451

 EE-RM-93-801 COMMENT OR5

APPENDIX J 

2 of 2 

lPA/80T & lPA/86 T SPECIFICATIONS 

Head Dlmlnsion 

Length 155/16" (40) 

Width 13'12 (35) 

Height 22% (57) 

73" 

(185) 

Applicator: 

46'12" 

22% 

(57) 

(1 19) -----~ 

• Drive Motor: 'I,. HP gear motor, 115 VAC • Label Control: Photoelectric sensing, electric brake 

and clutch • Application Method: Air cylinder actuated tamp pad or 

high pressure air blast • Construction: Anodized aluminum and stainless steel 

Label Sizes: 

LPA/80T 4 'I," wide x 4" repeat (111mm x 102mm) maximum standard size. Larger sizes available at extra cost. 

!.PAl86T 6Y2" wide x 4" repeat (165mm x 102mm) maximum standard size. Larger sizes available at extra cost. 

Printer: 

• Method: Ceramic thick film thermal print modules. • Print Pattern: LPA/80T single row of 300 print points, 

approximately 76 dots per inch. Dot dimension 0.013" 

(0.33mm). Print field width 3.9" (99mm). LPA/86T single row of 450 print. pOints, approximately 

.76 dots per inch. Dot dimension 0.013" (0.33mm). Print 

field width 5.9" (150mm). • Rate: 3" (76mm) per second standard. Rate may vary 

depending on application. 

Electronics: . • Enclosure: NEMA 12, water reSistant; may be remote 

mounted. • Control: Z80 Microprocessor CPU with solid state 

memory .and control chips. Label format. character 

generator, fixed label data and print routine are stored . in plug-in EPROM's. 

LOAD LABEL SYSTEMS, INC. 

1200 Ave. H East 

Arlington. TX. 76011 

(214) 647·2504 

1-800·433-5310 

~.JMHI 

1IIIIIlIUM 

7'12 

(19) 

• Display: 16 Character LED display indicates the status 

of the printer/applicator. Test functions are 

commanded from a 16 button keypad and read out on 

the display. In addition, error messages are displayed 

to pinpoint mechanical malfunctions or input data 

faults to minimize troubleshooting time. 

Data Input: 

The unit may operate as a stand-alone printerlapplicator . by means of the integral keypad or an optional. terminal 

using on-board programming. Data input can come from 

any computer output device with an RS232 serial interface, such as an electronic scale, barcode reader or host 

computer. 

Label Material: 

Thermal sensitive paper: smudge proof, oil and water 

resistant. Paper is available for infrared scannable barcodes (900 nanometers). 

Label Formatting: 

Available barcodes are interleaved 2 of 5, Code 39, UPC 

and EAN. Other barcode structures can be provided. Formats are designed to suit the application. Several variable 

fields can be provided within a format. Character sizes 

can be up to 1.0". 

Power Required: 

115 VAC, 10 amp circuit 

Air Required: 

60 to 80 psi filtered (15 micron), dry air at 'I, CFM 

AulhOrtZe(J Olatnbutcr 

'101 Indultnel Blvd 

lOUIsville KentUCky .t.02H~ 

Telepl1One. 502~1 

APPENDIX J 

2 of 2 

lPA/80T & lPA/86 T SPECIFICATIONS 

Head Dlmlnsion 

Length 155/16" (40) 

Width 13'12 (35) 

Height 22% (57) 

73" 

(185) 

Applicator: 

46'12" 

22% 

(57) 

(1 19) -----~ 

• Drive Motor: 'I,. HP gear motor, 115 VAC • Label Control: Photoelectric sensing, electric brake 

and clutch • Application Method: Air cylinder actuated tamp pad or 

high pressure air blast • Construction: Anodized aluminum and stainless steel 

Label Sizes: 

LPA/80T 4 'I," wide x 4" repeat (111mm x 102mm) maximum standard size. Larger sizes available at extra cost. 

!.PAl86T 6Y2" wide x 4" repeat (165mm x 102mm) maximum standard size. Larger sizes available at extra cost. 

Printer: 

• Method: Ceramic thick film thermal print modules. • Print Pattern: LPA/80T single row of 300 print points, 

approximately 76 dots per inch. Dot dimension 0.013" 

(0.33mm). Print field width 3.9" (99mm). LPA/86T single row of 450 print. pOints, approximately 

.76 dots per inch. Dot dimension 0.013" (0.33mm). Print 

field width 5.9" (150mm). • Rate: 3" (76mm) per second standard. Rate may vary 

depending on application. 

Electronics: . • Enclosure: NEMA 12, water reSistant; may be remote 

mounted. • Control: Z80 Microprocessor CPU with solid state 

memory .and control chips. Label format. character 

generator, fixed label data and print routine are stored . in plug-in EPROM's. 

LOAD LABEL SYSTEMS, INC. 

1200 Ave. H East 

Arlington. TX. 76011 

(214) 647·2504 

1-800·433-5310 

~.JMHI 

1IIIIIlIUM 

7'12 

(19) 

• Display: 16 Character LED display indicates the status 

of the printer/applicator. Test functions are 

commanded from a 16 button keypad and read out on 

the display. In addition, error messages are displayed 

to pinpoint mechanical malfunctions or input data 

faults to minimize troubleshooting time. 

Data Input: 

The unit may operate as a stand-alone printerlapplicator . by means of the integral keypad or an optional. terminal 

using on-board programming. Data input can come from 

any computer output device with an RS232 serial interface, such as an electronic scale, barcode reader or host 

computer. 

Label Material: 

Thermal sensitive paper: smudge proof, oil and water 

resistant. Paper is available for infrared scannable barcodes (900 nanometers). 

Label Formatting: 

Available barcodes are interleaved 2 of 5, Code 39, UPC 

and EAN. Other barcode structures can be provided. Formats are designed to suit the application. Several variable 

fields can be provided within a format. Character sizes 

can be up to 1.0". 

Power Required: 

115 VAC, 10 amp circuit 

Air Required: 

60 to 80 psi filtered (15 micron), dry air at 'I, CFM 

AulhOrtZe(J Olatnbutcr 

'101 Indultnel Blvd 

lOUIsville KentUCky .t.02H~ 

Telepl1One. 502~1 
APPENDIX K

1 of 3

Degussa

Degussa

Corporation

Material Safety Data Sheet

1. PRODUCT INFORMATION

Trade Name: FKe 50OLS Precipitated Silica

Chemical Name : Synthetic amorphous silicon dioxide hydrate

CAS Registry No.: 112926-00-8

Ii. SUMMARY OF HAZARDS

May cause eye and skin irritation . Causes irritation to lungs and

respiratory tract. If inhaled , immediately remove to fresh air . In case

of eve contact, immediately flush eyes with plenty of water for at least 15

mi:,utes , call a physician . Flush skin with water. See Section V for

additional information on health hazards.

III. HAZARDOUS INGREDIENTS

A new CAS registry number has been assigned to Amorphous Precipitated

Silica which will differentiate it from crystalline forms of silica. -The

-new CAS number is as shown , 112926 -00-8, changed from 7631-86-9.

Name CAS No. % TLV®

Amorphous silica 112926-00-8 91% l0mg/m3

Not listed by OSHA, NTP, or IARC as a carcinogen.

IV. CHEMICAL AND PHYSICAL PROPERTIES

APPEARANCE : Dry, white powder SPECIFIC GRAVITY: N/A

SOL. IN WATER: Negligable VAPOR PRESSURE: N/A

EVAPORATION RATE: N/A BOILING POINT: N/A

VAPOR DENSITY: N/A pH: N/A

150 Spraeside Drive Suite 110 Aeacn OH 44333 216-668-2235 FAX 216-668-3846

 EE-RM-93-801 COMMENT OR5

Degussa .. 

Degussa 

Corporation 

I. PRODUCT INFORMATION 

APPENDIX K 

1 of 3 

Material Safety Data Sheet 

Trade Name: F~ SOOLS Precipitated Silica 

Chemical Name: Synthetic amorphous silicon dioxide hydrate 

CAS Registry No.: 112926-00-8 

II. SUMMARY OF HAZARDS 

May cause eye and skin irritation. Causes irritation to lungs and 

respiratory tract. If inhaled, immediately remove to fresh air. In case 

of eye contact, immediately flush eyes with plenty of water for at least 15 

mL~utes, call a physician. Flush skin with water. See section V for 

additional information on health hazards. 

III. HAZARDOUS INGREDIENTS 

A new CAS registry number has been assigned to Amorphous Precipitated 

Silica which will differentiate it from crystalline forms of silica. The 

new CAS number is as shown, 112926-00-8, changed from 7631-86-9. 

CAS No. 

Amorphous silica 112926-00-8 91% 

TL~ 

1 o mgjm3 

Not listed by OSHA, NTP, or IARC as a carcinogen. 

IV. CHEMICAL AND PHYSICAL PROPERTIES 

APPEARANCE: Dry, white powder 

SOL. IN WATER: Negligable 

EVAPORATION RATE: NjA 

VAPOR DENSITY: NjA 

SPECIFIC GRAVITY: 

VAPOR PRESSURE: 

BOILING POINT: 

pH: 

150 SpnngSlde Dnve SUlte 11[' Aacn OH 44333216'-668-2235 FAX 216-668-3846 

N/A 

N/A 

NjA 

NjA 

Degussa .. 

Degussa 

Corporation 

I. PRODUCT INFORMATION 

APPENDIX K 

1 of 3 

Material Safety Data Sheet 

Trade Name: F~ SOOLS Precipitated Silica 

Chemical Name: Synthetic amorphous silicon dioxide hydrate 

CAS Registry No.: 112926-00-8 

II. SUMMARY OF HAZARDS 

May cause eye and skin irritation. Causes irritation to lungs and 

respiratory tract. If inhaled, immediately remove to fresh air. In case 

of eye contact, immediately flush eyes with plenty of water for at least 15 

mL~utes, call a physician. Flush skin with water. See section V for 

additional information on health hazards. 

III. HAZARDOUS INGREDIENTS 

A new CAS registry number has been assigned to Amorphous Precipitated 

Silica which will differentiate it from crystalline forms of silica. The 

new CAS number is as shown, 112926-00-8, changed from 7631-86-9. 

CAS No. 

Amorphous silica 112926-00-8 91% 

TL~ 

1 o mgjm3 

Not listed by OSHA, NTP, or IARC as a carcinogen. 

IV. CHEMICAL AND PHYSICAL PROPERTIES 

APPEARANCE: Dry, white powder 

SOL. IN WATER: Negligable 

EVAPORATION RATE: NjA 

VAPOR DENSITY: NjA 

SPECIFIC GRAVITY: 

VAPOR PRESSURE: 

BOILING POINT: 

pH: 

N/A 

N/A 

NjA 

NjA 

150 SpnngSlde Dnve SUlte 11[' Aacn OH 44333216'-668-2235 FAX 216-668-3846 ----------
APPENDIX K

2 of 3

Degussa

Degussa

Corporation

am ¢::ara:za^zrr ...

V HEALTH HAZARD DATA & FIRST AID PROCEDURES

Amorphous silica , unlike crystalline silica, is considered biologically

benign.

EYE CONTACT:

SKIN CONTACT:

INHALATION:

CHRONIC HAZARDS:

SIGN AND SYMPTOMS

OF EXPOSURE:

May cause eye irritation.

May cause skin irritation.

Causes irritation to lungs and respiratory tract.

No known chronic hazards.

Sneezing and dryness mucous membranes (inhalation).

May cause dry, chapped skin ( skin exposure). May

cause redness and tearing ( eye exposure).

MEDICAL CONDITIONS

AGGRAVATED BY EXPOSURE: Skin diseases (dermatitis ), asthma and lung

diseases.

VI. EXPOSURE CONTROL MEASURES

GLOVES: Tightly woven cotton, plastic, or rubber.

EYE PROTECTION : Chemical goggles are recommended.

RESPIRATORY PROTECTION : Use NIOSH approved dust respirator where dust.

occurs.

ENGINEERING CONTROL: Use with adequate ventilation.

OTHER PROTECTIVE

EQUIPMENT : Safety shower and eyewash fountain should be within

direct access.

PERSONAL HYGIENE: Avoid breathing dust. Wash thoroughly after

handling.

VII. REACTIVITY DATA

STABILITY: Stable

CONDITIONS TO AVOID: N/A

INCOMPATIBILITY: N/A

HAZARDOUS -

DECOMPOSITION PRODUCTS: None

1 50 Soringsde Dnve Suite 110 Akron OH 44333 216-668.2235 FAX 216-668-3846

 EE-RM-93-801 COMMENT OR5

Degussa • 

. Degussa 

Corporation 

APPENDIX R 

2 of 3 

V. HEALTH HAZARD DATA & FIRST AID PROCEDURES 

Amorphous silica, unlike crystalline silica, is considered biologically 

benign. 

EYE CONTACT: 

SKIN CONTACT: 

INHALATION: 

CHRONIC HAZARDS: 

SIGN AND SYMPrOMS 

OF EXPOSURE: 

MEDICAL CONDITIONS 

May c?use eye irritation. 

May cause skin irritation. 

Causes irritation to lungs and respiratorY tract. 

No known chronic hazards. 

Sneezing and dryness mucous membranes (inhalation). 

May cause dry, chapped skin (skin exposure). May 

cause redness and tearing (eye exposure). 

AGGRAVATED BY EXPOSURE: Skin diseases (dermatitis), asthma and lung 

diseases. 

VI. EXPOSURE CONTROL MEASURES 

GLOVES: Tightly woven cotton, plastic, or rubber. 

EYE PROTECTION: Chemical goggles are recommended. 

RESPIRATORY PROTECTION: Use NIOSH approved dust respirator where dust 

occurs. 

ENGINEERING CONTROL: 

OTHER PROTECTIVE 

EQUIPMENT: 

PERSONAL HYGIENE: 

VII. REACTIVITY DATA 

STABILITY: 

CONDITIONS TO AVOID: 

INCOMPATIBILITY: 

HAZARDOUS 

DECOMPOSITION PRODUCTS: 

Use with adequate ventilation. 

Safety shower and eyewash fountain shoul~ be within 

direct access. 

Avoid breathing dust. Wash thoroughly after 

handling. 

Stable 

NjA 

NjA 

None 

150 SpnngSlde Dnve- SUlte 110 Akron OH 44333 216-668:2235 FAX 216-668-3846 

Degussa • 

. Degussa 

Corporation 

APPENDIX R 

2 of 3 

V. HEALTH HAZARD DATA & FIRST AID PROCEDURES 

Amorphous silica, unlike crystalline silica, is considered biologically 

benign. 

EYE CONTACT: 

SKIN CONTACT: 

INHALATION: 

CHRONIC HAZARDS: 

SIGN AND SYMPrOMS 

OF EXPOSURE: 

MEDICAL CONDITIONS 

May c?use eye irritation. 

May cause skin irritation. 

Causes irritation to lungs and respiratorY tract. 

No known chronic hazards. 

Sneezing and dryness mucous membranes (inhalation). 

May cause dry, chapped skin (skin exposure). May 

cause redness and tearing (eye exposure). 

AGGRAVATED BY EXPOSURE: Skin diseases (dermatitis), asthma and lung 

diseases. 

VI. EXPOSURE CONTROL MEASURES 

GLOVES: Tightly woven cotton, plastic, or rubber. 

EYE PROTECTION: Chemical goggles are recommended. 

RESPIRATORY PROTECTION: Use NIOSH approved dust respirator where dust 

occurs. 

ENGINEERING CONTROL: 

OTHER PROTECTIVE 

EQUIPMENT: 

PERSONAL HYGIENE: 

VII. REACTIVITY DATA 

STABILITY: 

CONDITIONS TO AVOID: 

INCOMPATIBILITY: 

HAZARDOUS 

DECOMPOSITION PRODUCTS: 

Use with adequate ventilation. 

Safety shower and eyewash fountain shoul~ be within 

direct access. 

Avoid breathing dust. Wash thoroughly after 

handling. 

Stable 

NjA 

NjA 

None 

150 SpnngSlde Dnve--:S~U1-te--:-11:-::0:---:-A-:-kr-o-n -=O-H-4-4333 216-668:2235 FAX 2:-::16;-;-6:-:::6=-8-::::38:-:4-;::6 ----------
APPENDIX K

3 of 3

Degussa

Degussa

Corporation

VIII. FIRE AND EXPLOSION HAZARD DATA

FLASH POINT: Noncombustible

FLAMMABLE LIMITS: N/A

EXTINGUISHING METHOD: N/A

FIRE FIGHTING

INSTRUCTIONS:

UNUSUAL FIRE AND

EXPLOSION HAZARDS:

N/A

None

IX. ENVIRONMENTAL & DISPOSAL INFORMATION

ENVIRONMENTAL HAZARDS: No known adverse effects. Not a listed

toxic chemical under SARA Title III, §302,

§304, or §313.

SPILLAGE : Sweep, scoop, or vacuum discharged

material.

WASTE DISPOSAL METHOD : Lindfill according to local , state, and

-federal regulations . Not a hazardous

waste under RCRA regulations.

X. SUBSTANCES FOR WHICH STANDARDS HAVE BEEN SET

COMPONENT : Amorphous Silica/ Percent : 91% as SiO2

OSHA Exposure Limit: 20mppcf ( 5mg/m3 ) Si02 Respirable dust. 8 hour

time weighted average.

TLV®: 10mg/m3 Total dust; 5mg/m3 respirable.

EXPOSURE ANALYSIS METHODS : NIOSH Manual of Analytical Methods, 3rd ed.,

Method 7501, ( 1984).

XI. SOURCE OF INFORMATION

John G. Blumberg, Product Safety Coordinator, 10/19/89

150 Spnngside Drive Suite 110 Alum, OH 44333 216-668-2235 FAX 216-668 3846

 EE-RM-93-801 COMMENT OR5

Oegu.ssa .. 

Degussa 

Corporation 

AFF~NDJ:X K 

3 of 3 

VIII. FIRE AND EXPLOSION HAZARD DATA 

FLASH POINT: 

FLAMMABLE LIMITS: 

EXTINGUISHING METHOD: 

FIRE FIGHTI.NG 

INSTRUCTIONS: 

UNUSUAL FIRE AND 

EXPLOSION HAZARDS: 

Noncombustible 

N/A 

N/A 

N/A 

None 

IX. . ENVIRONMENTAL & DISPOSAL INFORMATION 

ENVIRONMENTAL HAZARDS: 

SPILLAGE: 

WASTE DIS~OSAL METHOD: 

No known adverse effects. Not a listed 

toxic chemical under SARA Title III, §302, 

§304, or §313. 

Sweep, scoop, or vacuum discharged 

material. 

~ndfill according to local, state, and 

·federal regulations. Not a hazardo~s 

waste under RCRA regulations. 

X. SUBSTANCES FOR WHICH STANDo\RDS HAVE BEEN SET 

COMPONENT: 

OSHA Exposure Limit: 

Amorphous Silica/Percent: 91% as SiOz 

20mppcf (5mg/m3 ) SiOz Respirable dust. 8 hour 

time weighted average. 

TL~: 10mg/m3 Total dust; 5mg/m3 respirable. 

EXPOSURE ANALYSIS METHODS: NIOSH Manual of Analytical Methods, 3rd ed., 

Method 7501, (1984). 

XI. SOURCE OF INFORMATION 

John G. Blumberg, Product Safety Coordinator, 10/19/89· 

150 SpnngSlde Dnve SUlte 110 Akron OH 44333 216·668·2235 FAX 216·668·3846 

Oegu.ssa .. 

Degussa 

Corporation 

AFF~NDJ:X K 

3 of 3 

VIII. FIRE AND EXPLOSION HAZARD DATA 

FLASH POINT: 

FLAMMABLE LIMITS: 

EXTINGUISHING METHOD: 

FIRE FIGHTI.NG 

INSTRUCTIONS: 

UNUSUAL FIRE AND 

EXPLOSION HAZARDS: 

Noncombustible 

N/A 

N/A 

N/A 

None 

IX. . ENVIRONMENTAL & DISPOSAL INFORMATION 

ENVIRONMENTAL HAZARDS: 

SPILLAGE: 

WASTE DIS~OSAL METHOD: 

No known adverse effects. Not a listed 

toxic chemical under SARA Title III, §302, 

§304, or §313. 

Sweep, scoop, or vacuum discharged 

material. 

~ndfill according to local, state, and 

·federal regulations. Not a hazardo~s 

waste under RCRA regulations. 

X. SUBSTANCES FOR WHICH STANDo\RDS HAVE BEEN SET 

COMPONENT: 

OSHA Exposure Limit: 

Amorphous Silica/Percent: 91% as SiOz 

20mppcf (5mg/m3 ) SiOz Respirable dust. 8 hour 

time weighted average. 

TL~: 10mg/m3 Total dust; 5mg/m3 respirable. 

EXPOSURE ANALYSIS METHODS: NIOSH Manual of Analytical Methods, 3rd ed., 

Method 7501, (1984). 

XI. SOURCE OF INFORMATION 

John G. Blumberg, Product Safety Coordinator, 10/19/89· 

150 SpnngSlde Dnve SUlte 110 Akron OH 44333 216·668·2235 FAX 216·668·3846 
APPENDIX L

UNIBILT4ENCLOSED TRACK CONVEYORS

The Unibilt Division of the Jervis B. Webb Company was created in the early 1960s to provide

manufactureres of all types with a multi-purpose

enclosed track conveyor. Designed and built

upon the principles of increasing productivity,

Unibilt"Enclosed Track Conveyors incorporate

reliability, economy, flexibility and simple installation either by weldng or bolting.

Unibilt Enclosed Track Conveyors contain many

features normally associated with conventional

I-Beam conveyors, plus features that are unique

to this type of system, such as:

1

Completely enclosed chain helps prevent accidental contact with moving parts.

2

An enclosed track helps prevent contmination

from reaching the chain or track bearing surfaces.

3

The universal link chain is designed to provide

maximum flexibility in all directions, featuring

easy assembly or disassembly with simple

hand tools.

4

The enclosed track design helps provide protection from the elements for the chain and

other moving parts.

5

Shorter radius curves and closer spacing of

curve tangents are possible due to the universal link chain.

6

Easier installation.. .no bulky roller turns or traction wheels to erect.

7

Caterpillar-type drive units provide flexility for

all enclosed track power requirements in a

single compact package.

Qualified local distributors and regional Unibilt

representatives are available to assist you'in all

phases of a conveying system: design/

engineering, plan layout, installation and

application.

Unibilt Enclosed Track conveyors offer a system that has applications in both simple and

complex handling problems.

 EE-RM-93-801 COMMENT OR5

APPENDIX L 

UNlBIL~ENCLOSED TRACK CONVEYORS 

The Unibilt Division of the Jervis B. Webb Company was created in the early 1960s to provide 

manufactureres of all types with a multi-purpose 

enclosed track conveyor. Designed and built 

upon the principles of increasing productivity. 

Unibilt®Enclosed Track Conveyors incorporate 

reliability. economy. flexibility and simple installation either by weldng or bolting. 

Unibilt Enclosed Track Conveyors contain many 

features normally associated with conventional 

I-Beam conveyors. plus features that are unique 

to this type of system. such as: 

1 

Completely enclosed chain helps prevent accidental contact with moving parts. 

2 

An enclosed track helps prevent contmination 

from reaching the chain or track bearing surfaces. 

3 

The universal link chain is deSigned to provide 

maximum flexibility in all directions. featuring 

easy assembly or disassembly with simple 

hand tools. 

4 

The enclosed track design helps provide protection from the elements for the chain and 

other moving parts. 

" 5 

Shorter radius curves and closer spacing of 

curve tangents are possible due to the universal link chain. 

6 

Easier installation ... no bulky roller turns or traction wheels to erect. 

7 

Caterpillar-type drive units provide flexility for 

all enclosed track power requirements in a" 

single compact package. 

Qualified local distributors and regional Unibilt 

representatives are available to assist you "in all 

phases of a conveying system: deSign! 

engineering. plan layout. installation and 

application. 

Unibilt Enclosed Track conveyors offer a system that has applications in both simple and 

complex handling problems. 

APPENDIX L 

UNlBIL~ENCLOSED TRACK CONVEYORS 

The Unibilt Division of the Jervis B. Webb Company was created in the early 1960s to provide 

manufactureres of all types with a multi-purpose 

enclosed track conveyor. Designed and built 

upon the principles of increasing productivity. 

Unibilt®Enclosed Track Conveyors incorporate 

reliability. economy. flexibility and simple installation either by weldng or bolting. 

Unibilt Enclosed Track Conveyors contain many 

features normally associated with conventional 

I-Beam conveyors. plus features that are unique 

to this type of system. such as: 

1 

Completely enclosed chain helps prevent accidental contact with moving parts. 

2 

An enclosed track helps prevent contmination 

from reaching the chain or track bearing surfaces. 

3 

The universal link chain is deSigned to provide 

maximum flexibility in all directions. featuring 

easy assembly or disassembly with simple 

hand tools. 

4 

The enclosed track design helps provide protection from the elements for the chain and 

other moving parts. 

" 5 

Shorter radius curves and closer spacing of 

curve tangents are possible due to the universal link chain. 

6 

Easier installation ... no bulky roller turns or traction wheels to erect. 

7 

Caterpillar-type drive units provide flexility for 

all enclosed track power requirements in a" 

single compact package. 

Qualified local distributors and regional Unibilt 

representatives are available to assist you "in all 

phases of a conveying system: deSign! 

engineering. plan layout. installation and 

application. 

Unibilt Enclosed Track conveyors offer a system that has applications in both simple and 

complex handling problems. 
APPENDIX M

1 of 2

GMFanuc Robotics

Basic Descrition

The GMFanuc Model S-500 is a six-axis,

simultaneously controlled, articulated coordinate, electro-mechanically operated robot. It is

controlled by the KAREL®Robot Controller

which features user-friendly programming

language and built-in card slots for MAP and

integrated Vision Boards. The S-500 has an

exceptionally large work envelope allowing it to

handle many applications::.::

Features

• 6 axes of motion.

• 15 kg (33 lbs.) payload.

• Excellent path repeatability ±0.25mm (±0.010").

• 300° base rotation.

• 2700mm (106.3") horizontal travel.

• 4000mm (157.5") vertical travel.

• 1500mm/sec (59"/sec) max. sealing speed.

• Slender arm design.

• High speed option on axis 6 of 600°/sec.

• Analog output signal proportional to tool

tip velocity.

• Precision gears and sealed-for-life bearings.

• Compact FANUC AC servo motor with

absolute pulse coders.

• High efficiency, compact drive train.

• Maintenance dust covers and external

lube fittings.

S-500 Applications

• Sealing • Machine Load/Unloading

• Material Handling • Parts Transfer

• Deburing • Welding

Customer Benefits

• Large work envelope for wide

application range.

• Precise path control and

repeatability allow consistent

and predictable sealing beads.

• High speed wrist option to further

minimize cycle times.

• Analog control output signal

allows consistent bead

widths throughout varying

path geometries.

• Reliable and precision

electronic and mechanical

components mean longer

MTBF and lower production

downtime.

• Maintenance is quick and

easy with dust covers and

external lubrication on

fittings.

• Safety limit switches provide overtravel protection

and a safe environment for

workers.

 EE-RM-93-801 COMMENT OR5

APPENDIX M 

1 of 2 

GMranuc Robotics 

Basic Descrition 

. The GM~anuc Model S-500 is a six-axis, 

simultaneously controlled, articulated coordinate, electro-mechanically operated robot. It is 

controlled by the KAREL®Robot Controller 

which features user-friendly programming 

language and built-in card slots for MAP and 

integrated Vision Boards. The S-500 has an 

exceptionally large work envelope allowing it to 

handle many applications. 

Features 

• 6 axes of motion. 

• 15 kg (33 Ibs.) payload. 

• Excellent path repeatability ±O.25mm (±O.010"). 

• 300° base rotation. 

• 2700mm (106.3") horizontal travel. 

• 4000mm (157.5") vertical travel. 

• 1500mm/sec (59"/sec) max. sealing speed. 

• Slender arm design. 

• High speed option on axis 6 of 6000

/sec. 

• Analog output signal proportional to tool 

tip velocity. 

• Precision gears and sealed-for-life bearings. 

• Compact FANUC AC servo motor with 

absolute pulse coders. 

• High efficiency, compact drive train. 

• Maintenance dust covers and external 

lube fittings. 

8-500 Applications 

• Sealing 

• Material Handling 

• Deburing 

Customer Benefits 

• Large work envelope for wide 

application range. 

• Precise path control and 

repeatability allow consistent 

and predictable sealirig beads. 

• Machine Load/Unloading 

• Parts Transfer 

• Welding 

allows consistent bead 

widths throughout varying 

path geometries. 

• High speed wrist option to further 

minimize cycle times. 

• Reliable and precision 

electronic and mechanical 

components mean longer 

MTBF and lower production 

• Analog control output signal downtime. 

5-500 

• Maintenance is quick and 

easy with dust covers and 

external lubrication on 

fittings. 

• Safety limit switches provide overtravel protection 

and a safe environment for 

workers. 

APPENDIX M 

1 of 2 

GMranuc Robotics 

Basic Descrition 

. The GM~anuc Model S-500 is a six-axis, 

simultaneously controlled, articulated coordinate, electro-mechanically operated robot. It is 

controlled by the KAREL®Robot Controller 

which features user-friendly programming 

language and built-in card slots for MAP and 

integrated Vision Boards. The S-500 has an 

exceptionally large work envelope allowing it to 

handle many applications. 

Features 

• 6 axes of motion. 

• 15 kg (33 Ibs.) payload. 

• Excellent path repeatability ±O.25mm (±O.010"). 

• 300° base rotation. 

• 2700mm (106.3") horizontal travel. 

• 4000mm (157.5") vertical travel. 

• 1500mm/sec (59"/sec) max. sealing speed. 

• Slender arm design. 

• High speed option on axis 6 of 6000

/sec. 

• Analog output signal proportional to tool 

tip velocity. 

• Precision gears and sealed-for-life bearings. 

• Compact FANUC AC servo motor with 

absolute pulse coders. 

• High efficiency, compact drive train. 

• Maintenance dust covers and external 

lube fittings. 

8-500 Applications 

• Sealing 

• Material Handling 

• Deburing 

Customer Benefits 

• Large work envelope for wide 

application range. 

• Precise path control and 

repeatability allow consistent 

and predictable sealirig beads. 

• Machine Load/Unloading 

• Parts Transfer 

• Welding 

allows consistent bead 

widths throughout varying 

path geometries. 

• High speed wrist option to further 

minimize cycle times. 

• Reliable and precision 

electronic and mechanical 

components mean longer 

MTBF and lower production 

• Analog control output signal downtime. 

5-500 

• Maintenance is quick and 

easy with dust covers and 

external lubrication on 

fittings. 

• Safety limit switches provide overtravel protection 

and a safe environment for 

workers. 
wee,

Conbvftd Am

Sy

r Ebor--cr pnast ab o

^ d

r--_

Moon tend A)ft .+elt

P :. ^• " ^. Spwd

axis 1 -4 3D0._. f>c#x f90YeeG

S )de 2 1B0' --•` 90Ywaids 3 16+r 90'lsec

atos4 .320"sec.

a1a5

Staetdatd -

am 6

900' z ;, ..

axm=6

gDa. 'Mi

Payiosd - 15kg-.e : ...^

pepsatsb hty a025MM440010 )

l)$e 1T ethod AC setw arotlor --: -

Posbon 0ebctlon Atteokne Arias Goder

Weigtrt-Meehar jcd UM AM= 900 k9(1.985 bs")

S-500 Dimensions

2739mrn

(3L0-) (10'I9'1

,^ t epOrm+ _ _ teon.n

(62$) (7.11

^,,,r, I

I (11.x1

Axs 3

rear sae

rcnenerance

Specifications subject to (Marge without notice

GW, ran=

Robotics

::ec-Cfl' CIS s c•ec:fo cca'roe:.!^o,.t "oi ce

APPENDIX M

2 of 2

Capacities

GMFanuc Robotics Corporation GMFanuc Robotics Canada. Ltd. GMFanuc Robotics Europe GmbH

2000 South Adams Roan 6395 Kestrel Road Heinrich- Hertz-Strasse 16

Auburn Hills. MI 48326-2800 Mississauca . Ontario P.O. Box 3345

Literature Reouest 1 -800-47-ROBOT Canada LST 1Z5 D-4006 Erkrath 1. West Germany

Phone (313) 377-7000 Fax (313) 377-7366 Main Othce (416) 670-5755 Main Office 211-20060

 EE-RM-93-801 COMMENT OR5

5·500 Dimensions 

8!IOmm 1 2739nwTI ___ _ 

(35.0") 1-('0781 

I~II '~ _____ ;1~ 

! (1181 Tj 

! I 

! ' 

APPENDIX M 

2 of 2 

Grid Sc:aJo: 1 bkx::k:: l00mm (3.Sj 

Capacities 

111m 

AxIa 

IIlda 1 

axla2 

1Ilda3 

axis 4 

1IlCis5 

'+' 

...... tt 

-t 

..... 

~;. 

-" ~= 

150' 

,..; 

FIcor-1l'~ also 

~l:IhWIiniIed 

n.iQB v1d 8PIIII1 .",<. 

A.x~3 

,3238mm 

1(127.51 ! 512mm __ IIOOn'm + 

r!{ 

~ 

f: c tear SlOe 1,-:- lTllerterence : \. 

area ." 

(211.1") --4+~-- (111.0") (3~S) 

~ 

"Qmm 

'-(16.1") 

GMi=anuc 

Roboncs 

721 ..... (28.3") , 810mm 

(31.9"1 

GMFanuc Robotics Coroorallon 

2000 South Adams Roac 

Auburn Hllis, MI 48326-2800 

Literature Reouest 1-800-47-ROBOT 

Phone (3t3l377-7000 Fax (313l377-7366 

:::::e:::' .:a: ::'"'S s ... c'ec: !c :r,~"ae ... ·,...,0:....1 ""C'l ce :; 39 ~~:: _1-.... 0 ''\ '-.; 5 :.. 

GMFanuc RObotiCS Canada, Ltd, 

6395 Kestrel Road 

Mississauca. Ontario 

Canaca LST 1 Z5 

. Main OHlce '416l670-5755 

0::: 

GMFanuc Roboncs Europe GmbH 

Helnnch-Her1z-Strasse 16 

P.O, Bex 3345 

0-4006 Erkrath ,. West Germany 

Main Office 2" -20060 

5·500 Dimensions 

8!IOmm 1 2739nwTI ___ ..-; 

(35.0") 1-('0781 

I~II '~ ____ .... ;1~ 

! (1181 Tj 

! I 

! ' 

APPENDIX M 

2 of 2 

Grid Sc:aJo: 1 bkx::k:: l00mm (3.Sj 

Capacities 

111m 

AxIa 

IIlda 1 

axla2 

1Ilda3 

axis 4 

1IlCis5 

"'tt I" 

~ 

..... 

~;. 

-" ~= 

~ 

FIcor-1l'~ also 

~l:IhWIiniIed 

n.iQB v1d 8PIIII1 .",<. 

A.x~3 

,3238mm 

1(127.51 ! 512mm __ .J.." ~ 

15n: c tear SlOe 1,-:- lTllerterence : \. 

area ." 

(211.1") "':'--I+~~- (111.0") (3~S) ~ 

"Qmm 

'-(16." 

GMi=anuc 

Roboncs 

721 ..... (28.3") , 810mm 

(31.!1") 

GMFanuc Robotics Coroorallon 

2000 South Adams Roac 

Auburn Hllis, MI 48326-2800 

Literature Reouest 1-800-47-ROBOT 

Phone (3t3l377-7000 Fax (313l377-7366 

:::::e:::' .:a: ::'"'S s ... c'ec: !c :r,~"ae ... ·,...,0:....1 ""C'l ce :; 39 ~~:: _1-.... 0 ''\ '-.; 5 :.. 

GMFanuc RObotiCS Canada, Ltd. 

6395 Kestrel Road 

Mississauca. Ontario 

Canaca LST 1 Z5 

. Main OHlce '416l670-5755 

"" 

GMFanuc Roboncs Europe GmbH 

Helnnch-Her1z-Strasse 16 

P.O. Box 3345 

0-4006 Erkrath " West Germany 

Main Office 2" -20060 
AYYXNL)1X N

1 of 3

Automatic Density Control

The Nordson 170 Series

Processors feature a simple, repeatable one-step setting for

maintaining consistent foamed

material density. A density sensor

is located in the fitter/density controller, which automatically monitors and adjusts the gas /adhesive

mix. It is capable of achieving

density reduction to within ±2.5

percentage points of the predetermined value.

Sequential Startup

In sequential startup, the hose heaters are activated only after the processor approaches operating temperature , and the gun heaters are

phased in when the hose channels

are nearing their setpoints. This

staged warmup process minimizes

char formation, lowers energy consumption, and reduces maintenance

costs by minimizing stress on seals

and other sytem components.

Wide Selection Of Guns And

Hoses

Fully compatible with over 100

Nordson RTD-controlled guns,

Series 170 Processors can meet the

requirements of almost any application. In addition to standard singlemodule and mufti module guns, 170

units can be equipped with low-profile guns, zero-cavity guns, waterresistant guns, spray guns, and a

variety of handguns. Both automatic

and manual hoses are available for

the 170 Processors, including standard hoses, water-resistant hoses,

and the new Nordson biaxial hoses.

in hadgun applications.

With the supply

and return passages combined

in the same

bundle, biaxial

hoses are very

cost eff ective,

and their

superior maneuverability

makes them

especially useful

Additional Features

Many other beneficial features are

standard on Foam Melt 170 Processors. They include:

• Quiet, variable-speed DC motor

• System Ready Delay to prevent

pump operation before material in

the applicator reaches operating

temperature

• O-ring fittings on manifold, hoses,

and guns

• Filter/density controller, drain

valve, and pressure control valve

front mounted for easy access

• Contacts for customer-supplied

inputs and outputs

• Quick electrical disconnects on

hoses and guns

• Comprehensive overtemperature

protection with continuous monitoring of temperatures on all zones

• Advanced self-diagnostic capability

 EE-RM-93-801 COMMENT OR5

Automatic Density Control 

The Nordson 170 Series 

Processors feature a simple, repeatable one-step setting for 

maintaining consistent foamed 

material density. A density sensor 

is located in the filter/density controller, which automaticallY monitors and adjusts the gas/adhesive 

mix. It is capable of achieving 

density reduction to within ±2.5 

percentage points of the predetermined value. 

Wide Selection Of Gun. And 

Hose8 

Fully compatible with over 1 ()() 

Nordson RTD-controlled guns, 

Series 170 Processors can meet the 

requirements of almost any application. In addition to standard singlemodule and multi module guns, 170 

units can be equipped with Iow-profile guns, zero-cavity guns, waterresistant guns, spray guns, and a 

variety of handguns. Both automatic 

and manual hoses are available for 

the 170 Processors, including standard hoses, water-resistant hoses, 

and the new Nordson biaxial hoses. 

With the supply 

and return passages combined 

in the same 

bundle, biaxial 

hoses are very 

cost effective, 

and their 

superior maneuverability 

makes them 

especially useful 

in hadgun applications. 

Additional Feature. 

Many other beneficial features are 

Sequential Startup standard on FoamMelt 170 ProcIn sequential startup, the hose heat- essors. They include: 

ers are activated only after the pro- • Quiet, variable-speed DC motor 

cessor approaches operating temp- • System Ready Delay to prevent 

erature, and the gun heaters are pump operation before material in 

phased in when the hose channels the applicator reaches .operating 

are nearing their setpoints .. !h~s temperature 

staged warmup process minimizes • O-ring fittings on manifold, hoses, 

char formation, lowers energy con- and guns 

sumption, and reduces maintenance. Filter/density controUer, drain 

costs by minimizing stress on seals valve, and pressure control valve 

and other sytem components. front mounted for easy access 

• Contacts for customer-supplied 

inputs and outputs . 

• Quick electrical disconnects on 

hoses and guns 

• Comprehensive overtemperature 

protection with continuous monitoring of temperatures on all zones 

• Advanced self-diagnostic capability 

Automatic Density Control 

The Nordson 170 Series 

Processors feature a simple, repeatable one-step setting for 

maintaining consistent foamed 

material density. A density sensor 

is located in the filter/density controller, which automaticallY monitors and adjusts the gas/adhesive 

mix. It is capable of achieving 

density reduction to within ±2.5 

percentage points of the predetermined value. 

Wide Selection Of Gun. And 

Hose8 

Fully compatible with over 1 ()() 

Nordson RTD-controlled guns, 

Series 170 Processors can meet the 

requirements of almost any application. In addition to standard singlemodule and multi module guns, 170 

units can be equipped with Iow-profile guns, zero-cavity guns, waterresistant guns, spray guns, and a 

variety of handguns. Both automatic 

and manual hoses are available for 

the 170 Processors, including standard hoses, water-resistant hoses, 

and the new Nordson biaxial hoses. 

With the supply 

and return passages combined 

in the same 

bundle, biaxial 

hoses are very 

cost effective, 

and their 

superior maneuverability 

makes them 

especially useful 

in hadgun applications. 

Additional Feature. 

Many other beneficial features are 

Sequential Startup standard on FoamMelt 170 ProcIn sequential startup, the hose heat- essors. They include: 

ers are activated only after the pro- • Quiet, variable-speed DC motor 

cessor approaches operating temp- • System Ready Delay to prevent 

erature, and the gun heaters are pump operation before material in 

phased in when the hose channels the applicator reaches .operating 

are nearing their setpoints .. !h~s temperature 

staged warmup process minimizes • O-ring fittings on manifold, hoses, 

char formation, lowers energy con- and guns 

sumption, and reduces maintenance. Filter/density controUer, drain 

costs by minimizing stress on seals valve, and pressure control valve 

and other sytem components. front mounted for easy access 

• Contacts for customer-supplied 

inputs and outputs . 

• Quick electrical disconnects on 

hoses and guns 

• Comprehensive overtemperature 

protection with continuous monitoring of temperatures on all zones 

• Advanced self-diagnostic capability 
APPENDIX N

2 of 3

Vlorsom FoamMelf

1 70 Series processors

a

Specifications

Type of System

Holding Capacity

Melt Rate'

Model 170T

Circulating , gear pump

35 lb

27 lb/hr

Continuous Delivery Rate2 55 lb/hr

independent Temperature Control Tank, manifold, 6 hoses,

4 guns

Temperature Control Stability f1°F

Temperature Control Method PID3

Temperature Range (All Channels) 150°F-450°F

Electrical Service 220-240 VAC, 50/60 Hz, 1 /3 0

380Y/220 VAC, 50 Hz, 3/1 0

Amperage4 50 A max.

Maximum Power Requirements 5,000 watts

Viscosity Range 1,000 to 50,000 cps

Model 170H

Circulating , gear pump

60 lb

Exceeds CDR (see next line)

55 lb/hr

Reservoir, grid, hopper, manifold,

6 hoses, 4 guns

t1°F

PID3

150°F-450°F

220-240 VAC, 50/60 Hz, 1/3 0

380Y/220 VAC, 50 Hz, 3/1 0

50 A max.

11,000 watts

1,000 to 50,000 cps

Gas Supply Industrial grade carbon dioxide

or nitrogen (30-50 psi)

Industrial grade carbon dioxide

or nitrogen (30-50 psi)

Weight 350 lb 350 lb

Hose Ports 4 4

Air Supply 90-150 psi of dry, filtered air 90-150 psi of dry, filtered air

Note 1: Actual rates can vary depending on adhesive

viscosity and other characteristics.

Note 2: Based upon a 50% density reduction.

Note 3: PID stands for proportional /integral/derivative.

Note 4: Includes applicator and total allowable hoses,

guns and auxiliary devices.

Note 5: Does not include power requirement of

guns and hoses.

f n

B Rf

MOCRitY

On Selected Components

Nordson Corporation

350 Research Court

Technology Park/Atlanta

Norcross, Georgia 30092

Toll Free (800) 241-8777

'1990 Noraso' Corporalwn 306-18 -777 issues 8190

 EE-RM-93-801 COMMENT OR5

APPENDIX N 

2 of 3 

Nordson® FoamMelt® 

170 Series Processors 

Specifications 

Type of System 

Holding Capacity 

Melt Ratel 

Continuous Delivery Rate2 

Jndependent Temperature Control 

Temperature Control Stability 

Temperature Control Method 

Temperature Range (All Channels) 

Electrical Service 

Maximum Power RequirementS 

Viscosity Range 

Gas Supply 

Weight 

'Hose Ports 

Air Supply 

Model 170T 

Circulating. gear pump 

3SIb 

27lb/hr 

SSlb/hr 

Tank. manifold. 6 hoses. 

4 guns 

·220-240 VAC. SO/60 Hz. 1/3" 

380Y/220 VAC. SO Hz. 3/1" 

SOAmax. 

S.ooowatts 

1.000 to SO.OOO cps 

Industrial g-rade carbon dioxide 

or nitrogen (30-S0 psi) 

3S0lb 

4 

9O-1S0 psi of dry. filtered air 

Note 1: Actual rates can vary depending on adhesive 

viSCOSity and other characteristics. 

Note 2: Based upon a 50% density reduction. 

Note 3: PID stands for prOPOrtional/integral/derivative. 

Note 4: Includes applicator and total allowable hoses. 

guns and auxiliary devices. 

Note 5: Does not include power reQuirement of 

guns and hoses. 

60.8 in. 

lL:~,.d!L 

Model 170H 

Circulating. gear pump 

60lb 

Exceeds CDR (see next line) 

S5lb/hr 

Reservoir. grid. hopper. manifold. 

6 hoses. 4 guns 

220-240 VAC. SO/60 Hz. 1/3 " 

380Y/220 VAC. SO Hz. 3/1" 

SOAmax. 

11,000 watts 

. 1,000 to SO,OOO cps 

Industrial grade carbon dioxide 

or nitrogen (30-S0 psi) . 

3S0lb 

4 

90-150 psi of dry. filtered air 

~rds?3J. 

Nordson Corporation 

350 Research Court 

Technology Park/Atlanta 

Norcross, Georgia 30092 

Toll Free (800) 241-Sm 

~1990 Noroson Corper.llon 3ClfH8-777 Is.suecl 6190 

APPENDIX N 

2 of 3 

Nordson® FoamMelt® 

170 Series Processors 

Specifications 

Type of System 

Holding Capacity 

Melt Ratel 

Continuous Delivery Rate2 

Jndependent Temperature Control 

Temperature Control Stability 

Temperature Control Method 

Temperature Range (All Channels) 

Electrical Service 

Maximum Power RequirementS 

Viscosity Range 

Gas Supply 

Weight 

'Hose Ports 

Air Supply 

Model 170T 

Circulating. gear pump 

351b 

27lb/hr 

55lb/hr 

Tank. manifold. 6 hoses. 

4 guns 

·220-240 VAC. 50/60 Hz. 1/3" 

380Y/220 VAC. 50 Hz. 3/1" 

50Amax. 

5.000 watts 

1.000 to 50.000 cps 

Industrial g-rade carbon dioxide 

or nitrogen (30-50 psi) 

350lb 

4 

90-150 psi of dry. filtered air 

Note 1: Actual rates can vary depending on adhesive 

viSCOSity and other characteristics. 

Note 2: Based upon a 50% density reduction. 

Note 3: PID stands for prOPOrtional/integral/derivative. 

Note 4: Includes applicator and total allowable hoses. 

guns and auxiliary devices. 

Note 5: Does not include power reQuirement of 

guns and hoses. 

60.8 in. 

lL:~,.d~L 

Model 170H 

Circulating. gear pump 

60lb 

Exceeds CDR (see next line) 

55lb/hr 

Reservoir. grid. hopper. manifold. 

6 hoses. 4 guns 

220-240 VAC. 50/60 Hz. 1/3 " 

380Y/220 VAC. 50 Hz. 3/1" 

50Amax. 

11,000 watts 

. 1,000 to 50,000 cps 

Industrial grade carbon dioxide 

or nitrogen (30-50 psi) . 

350lb 

4 

90-150 psi of dry. filtered air 

c§.rds?}j. 

Nordson Corporation 

350 Research Court 

Technology Park/Atlanta 

Norcross, Georgia 30092 

Toll Free (800) 241-Sm 

~1990 Noroson Corper.llon 3ClfH8-777 Is.suecl 6190 
APPENDIX N

3 of 3

Unsurpassed Design,

Unmatched Performance

Advanced

Application

Technology

FoamMeft®170

Processors

employ the most

advanced hot

melt application technology

available - the patented Nordson®

FoamMeft Process . First Introduced in 1981, the FoamMeft

Process dramtically improves the

performance of most hot melt adhesives by mixing them with an

inert gas . Typical benefits include:

• Increased adhesive mileage

• Longer open times

• Faster set times

• Increased penetration

• Improved gap-filling capabilities

• Increased bond strength

The degree of improvement in

adhesive performance will depend

upon application conditions and the

adhesive used. While all of the

benefits of foamed adhesives will

not be experienced in every

application , the benefits in most

applications will be significant.

The FoamMeft 170 Processors

The 170 Series Foam Melt Processors are designed to provide advanced automation and pinpoint

temperature control in a system that

can melt and deliver up to 55 Ib/hr of

high-viscosity foamed material. The

series includes two types of processors, a unit with a tank (the 170T),

and a unit with a heated hopper

and grid for high performance adhesives (the 170H).

The patented gear pump contains two stages. The first stage

(the top gear set) pumps only

melted adhesive. The second

stage, which contains larger

gears, forces inert gas into solution with the adhesive.

Highly Automated Control

System

W

A sophisticated microprocessorbased controller directs the operation of FoamMeft 170 Processors.

Among the functions that take place

automatically after initial setup are

sequential startup, temperature

control, density reduction, system

monitoring, self-diagnosis , and system shutdown when fault conditions

are not corrected.

State-Of-The-Art

Temperature

Control

RTD temperature

sensors and a PID

(proportion/

integral/

derivative) control system

combine to maintain the

temperature of s•'stem components

within ±1 ° F of setpoint. With 16

individual- heating channels,

FoamMelt 170 units can control the

temperature of up to four singlemodule or multi-module guns, six

hoses, the manifold, the reservoir,

the grid, and the hopper. On 170T

units the tank is controlled instead

of the reservoir, grid, and hopper.

Mounted on a swivel arm at optimum

viewing height, the 170 Series control

panel is designed to cut training time,

reduce operating errors , and minimize

downtime. All controls and indicators

are clearly labled and grouped according to function. Separate digital display

windows provide quick access to system

pressure, gas pressure , pump RPMs,

and temperatures on all zones. The

temperature window also displays error

messages that aid in troubleshooting

the unit.

The temperature

control section

of the operator

panel incorpo°°

rates a variety of

useful features:

• Digital Readout

• Ability to scan the

temperatures on all zones in

sequence (SCAN ) or on one zone

continuously (FREEZE)

• Capability of displaying actual or setpoint temperatures on all zones

• Ability to display temperatures in either

OF or °C

• Ability to set all temperatures to the

same setpoint simultaneously (SET

ALL) or-enter different setpoints on

each zone

Integrated Run-Up Control

By automatically adjusting system

pressure as production speed varies,

Run-Up control keeps bead thickness constant. With Run-Up Control,

Nordson FoamMelt 170 units produce

more un iform bonds, minimize

product waste, and further reduce

adhesive consumption.

Large-Bore Manifold

Large-diameter flow pathways

permit the use of high-viscosity

materials and allow higher flow rates

with reduced fluctuations in line

pressure during demand cycles.

Larger diameter hoses may be used

with the 170 Series units to improve

material flow and reduce system

pressure drops.

 EE-RM-93-801 COMMENT OR5

APPENDJ:X N 

3 of 3 

Unsurpassed Design, 

Unmatched Performance 

Advanced 

Application 

Technology 

FoamMelt® 170 

Processors 

employ the most 

advanced hot 

melt application technology 

available - the patented Nordson® 

FoamMelt Process. First Introduced in 1981. the FoamMelt 

Process dramtically improves the 

performance of most hot melt adhesives by mixing them with an 

inert gas. Typical benefits include: 

• Increased adhesive mileage 

• Longer open times 

• Faster set times 

• Increased penetration 

• Improved gap-filling capabilities 

• Increased bond strength 

The degree of improvement in 

adhesive performance will depend 

upon application conditions and the 

adhesive used. While all of the 

benefits of foamed adhesives will 

not be experienced in every 

application, the benefits in most 

applications will be significant. 

The FoamMelt 170 Processors 

The 170 Series Foam Melt Processors are designed to provide advanced automation and pinpoint 

temperature control in a system that 

can melt and deliver up to 55 IbIhr of 

high-viscosity foamed material. The 

series includes two types of processors, a unit with a tank (the 170T). 

. and a unit with a heated hopper 

and grid for high performance adhesives (the 170H). 

The patented gear pump contains two stages. The first stage 

(the top gear set) pumps only 

melted adhesive. The second 

stage, which contains larger 

gears, forces inert gas into solution with the adhesive. 

Highly Automated Control J\II{]>'Jr"HC' on a arm at optimum 

System .VI~'loVlrln height. the 170 Series control 

A sophisticated microprocessor- panel is designed to cut training time. 

based controller directs the opera- reduce operating errors, and minimize 

tion of FoamMelt 170 Processors. downtime. All controls and indicatol'l? 

Among the functions that take are clearly Iabled and grouped accordautomatically after initial setup are ing to function. Seperate digital display 

sequential startup. temperature windows provide quick access to system 

control. density reduction. system pressure. gas pressure. pump RPMs, 

monitoring, self-diagnosis. and sys- and temperatures on all zones. The 

tem shutdown when fault COl1CfiliorlS temperature window also displays error 

are not corrected. messages that aid in troubleshooting 

the unit. 

State-Of-The-Art 

Temperature 

Control 

RTD temperature 

sensors and a PID 

(proportion! 

integral! 

derivative) control system 

combine to maintain the 

temperature of s"stem components 

within ±1 0 F of setpoint. With 16 

individua~ heating channels, 

FoamMett 170 units can control the 

temperature of up to four singlemodule or multi-module guns, six 

hoses, the manifold, the reservoir, 

the grid, and the hopper. On 170T 

units the tank is controlled instead 

of the reservoir, grid, and hopper. 

The temperature 

control section 

of the operator 

panel incorpo" 

rates a variety of 

useful features: 

• Digital Readout 

• Ability to scan the 

temperatures on all zones in 

sequence (SCAN) or on one zone 

continuously (FReEZE) 

• Capability of displaying actual or setpoint temperatures on all zones 

• Ability to display temperatures in either 

OF or °C . 

• Ability to set all temperatures to the 

same setpoint simultaneously (SET 

ALL) or.enter different setpoints on 

each zone . 

Integrated Run-Up Control 

By automatically adjusting system 

pressure as production speed varies, 

Run-Up control keeps bead thick- . 

ness constant. With Run-Up Control, 

Nordson FoamMelt 170 units produce 

more uniform bonds, minimize 

product waste, and further reduce 

adhesive consumption. 

Large-Bore Manifold 

Large-diameter flow pathways 

permit the use of high-viscosity 

materials and allow higher flow rates 

with reduced fluctuations in line 

pressure during demand cycles. 

Larger diameter hoses may be used 

with the 170 Series units to improve 

material flow and reduce system 

pressure drops. 

APPENDJ:X N 

3 of 3 

Unsurpassed Design, 

Unmatched Performance 

Advanced 

Application 

Technology 

FoamMelt® 170 

Processors 

employ the most 

advanced hot 

melt application technology 

available - the patented Nordson® 

FoamMelt Process. First Introduced in 1981. the FoamMelt 

Process dramtically improves the 

performance of most hot melt adhesives by mixing them with an 

inert gas. Typical benefits include: 

• Increased adhesive mileage 

• Longer open times 

• Faster set times 

• Increased penetration 

• Improved gap-filling capabilities 

• Increased bond strength 

The degree of improvement in 

adhesive performance will depend 

upon application conditions and the 

adhesive used. While all of the 

benefits of foamed adhesives will 

not be experienced in every 

application, the benefits in most 

applications will be significant. 

The FoamMelt 170 Processors 

The 170 Series Foam Melt Processors are designed to provide advanced automation and pinpoint 

temperature control in a system that 

can melt and deliver up to 55 IbIhr of 

high-viscosity foamed material. The 

series includes two types of processors, a unit with a tank (the 170T). 

. and a unit with a heated hopper 

and grid for high performance adhesives (the 170H). 

The patented gear pump contains two stages. The first stage 

(the top gear set) pumps only 

melted adhesive. The second 

stage, which contains larger 

gears, forces inert gas into solution with the adhesive. 

Highly Automated Control J\II{]>'Jr"HC' on a arm at optimum 

System .VI~'loVlrln height. the 170 Series control 

A sophisticated microprocessor- panel is designed to cut training time. 

based controller directs the opera- reduce operating errors, and minimize 

tion of FoamMelt 170 Processors. downtime. All controls and indicatol'l? 

Among the functions that take are clearly Iabled and grouped accordautomatically after initial setup are ing to function. Seperate digital display 

sequential startup. temperature windows provide quick access to system 

control. density reduction. system pressure. gas pressure. pump RPMs, 

monitoring, self-diagnosis. and sys- and temperatures on all zones. The 

tem shutdown when fault COl1CfiliorlS temperature window also displays error 

are not corrected. messages that aid in troubleshooting 

the unit. 

State-Of-The-Art 

Temperature 

Control 

RTD temperature 

sensors and a PID 

(proportion! 

integral! 

derivative) control system 

combine to maintain the 

temperature of s"stem components 

within ±1 0 F of setpoint. With 16 

individua~ heating channels, 

FoamMett 170 units can control the 

temperature of up to four singlemodule or multi-module guns, six 

hoses, the manifold, the reservoir, 

the grid, and the hopper. On 170T 

units the tank is controlled instead 

of the reservoir, grid, and hopper. 

The temperature 

control section 

of the operator 

panel incorpo" 

rates a variety of 

useful features: 

• Digital Readout 

• Ability to scan the 

temperatures on all zones in 

sequence (SCAN) or on one zone 

continuously (FReEZE) 

• Capability of displaying actual or setpoint temperatures on all zones 

• Ability to display temperatures in either 

OF or °C . 

• Ability to set all temperatures to the 

same setpoint simultaneously (SET 

ALL) or.enter different setpoints on 

each zone . 

Integrated Run-Up Control 

By automatically adjusting system 

pressure as production speed varies, 

Run-Up control keeps bead thick- . 

ness constant. With Run-Up Control, 

Nordson FoamMelt 170 units produce 

more uniform bonds, minimize 

product waste, and further reduce 

adhesive consumption. 

Large-Bore Manifold 

Large-diameter flow pathways 

permit the use of high-viscosity 

materials and allow higher flow rates 

with reduced fluctuations in line 

pressure during demand cycles. 

Larger diameter hoses may be used 

with the 170 Series units to improve 

material flow and reduce system 

pressure drops. 
APPENDIX 0

1 of 4

Vmm^ A .r1 __ TAP"I

Sir N* 1®/N ® a 1 IL1 11

CINCINNATI, OH

2.

February 20, 1992

University of Kentucky

Center for Robotics and Manufacturing Systems

College of Engineering

Lexington ,KY 40506-0108

Attention : Mr James M . Waldron P.E.

Subject : Advanced Refrigerator Manufacturing System

Dear Jim:

This letter is in response to your request for our review of'A

portion of your advanced manufacturing system for the

production of.a new low energy refrigerator.

We are responding to the portion of the project that has to do

with the application of "new age " it ulating panels to the

inside of the case and doors, and the back side of the plastic

liner. Our comments and responses will address those separate

areas.

1. Aolication of hot melt spray adhesive

We feel that two (2) robots will be adequate to spray the

required areas at the anticipated line rate of 200 cases

per hour - 18 seconds.

The equipment required in this area is as follows:

Each Total

2-GMFanuc S500 robots $ 100,000 3 200,000

2-2'risers 2,000 4,000

2-adhesive dispensing systems 15,000 30,000

incl dual nozzle setups

2-stop,square and meter stations 3,000 6,000

in the case line conveyor

Total .$ 240, 000

Installation of liners into cases

We feel that three (-) robots will be sufficient to insert

the different panel sizes into the case as it

4858 Provident Drive Phone: (513) 860-4299

Cincinnati, OH 45246 Fax: (513 ) 860-4587

 EE-RM-93-801 COMMENT OR5

APPENDIX 0 

1 of 4 

.... 1IIIIIIl;... • F 

• .,.., II--( 1". • ...... '.1.. Y'" .... .JI ...... 

CINCINNATI.OH 

~eb~ua~y 20, 1992 

Unive~sity of Kentucky 

Cente~ fo~ Robotics and ~anufactu~ing Systems 

College of Enginee~ing 

Lexington,KY 40506-0108 

Attention: M~ James M. Waldron P.E. 

Subject: Advanced Ref~igerato~ Manufacturing System 

Dea~ Jim: 

This lette~ is in ~esponse to you~ request for ou~ ~eview of "a:. 

portion of you~ advanced manufactu~ing system fo~ the 

p~oduction of,a new low ene~gy ~ef~ige~ato~. 

We a~e ~esponding to the po~tionof the p~oje~t that has to do 

with the application of "new age" ir~ulating panels to the 

inside of the case and doo~s, and the back side of the plastic 

line~. Qu~ comments and ~esponses will add~ess those sepa~ate 

areas. 

1. Application of hot melt spray adhesive 

We feel that two (2) robots will be adequate to Spray the 

required areas at the antlcipated line rate bf 200 cas~~ 

per hour - 18 seconds. 

The eqUipment required in this area is as follows: 

2-GMFanuc S500 ~obots 

2-2'risers 

2-adhesive dispensing systems 

incl dual nozzle setups 

2-stop,square and meter stations 

in the case line conveyor 

Total 

2. Installation of liners into· cases 

Each 

$ 100,000 

2,000 

15,000 

3,000 

Total 

$ 200,000 

4,000 

30,000 

6,000 

$ 240.,000 

We feel that three (3) robots will be sufficient to insert 

the different panel sizes into the case as it 

.4858 Provident Drive 

Cincinnati. OH 45246 

Phone: (513) 860-4299 

Fax: (513) 860-4587 

APPENDIX 0 

1 of 4 

.... 1IIIIIIl;... • F 

• .,.., II--( 1". • ...... '.1.. Y'" .... .JI ...... 

CINCINNATI.OH 

~eb~ua~y 20, 1992 

Unive~sity of Kentucky 

Cente~ fo~ Robotics and ~anufactu~ing Systems 

College of Enginee~ing 

Lexington,KY 40506-0108 

Attention: M~ James M. Waldron P.E. 

Subject: Advanced Ref~igerato~ Manufacturing System 

Dea~ Jim: 

This lette~ is in ~esponse to you~ request for ou~ ~eview of "a:. 

portion of you~ advanced manufactu~ing system fo~ the 

p~oduction of,a new low ene~gy ~ef~ige~ato~. 

We a~e ~esponding to the po~tionof the p~oje~t that has to do 

with the application of "new age" ir~ulating panels to the 

inside of the case and doo~s, and the back side of the plastic 

line~. Qu~ comments and ~esponses will add~ess those sepa~ate 

areas. 

1. Application of hot melt spray adhesive 

We feel that two (2) robots will be adequate to Spray the 

required areas at the antlcipated line rate bf 200 cas~~ 

per hour - 18 seconds. 

The eqUipment required in this area is as follows: 

2-GMFanuc S500 ~obots 

2-2'risers 

2-adhesive dispensing systems 

incl dual nozzle setups 

2-stop,square and meter stations 

in the case line conveyor 

Total 

2. Installation of liners into· cases 

Each 

$ 100,000 

2,000 

15,000 

3,000 

Total 

$ 200,000 

4,000 

30,000 

6,000 

$ 240.,000 

We feel that three (3) robots will be sufficient to insert 

the different panel sizes into the case as it 

.4858 Provident Drive 

Cincinnati. OH 45246 

Phone: (513) 860-4299 

Fax: (513) 860-4587 
APPENDIX 0

2 of 4

University of Kentucky

Page 2

progresses down the line . We anticipate handling two

parts at a time with the panel delivery conveyors arranged

a little bit differently than your concept. Rather than

having a conveyor at the 3 o'clock and the 9 o'clock

position for parts i and 7,we would propose that those two

conveyors lie along side of each other at the 3 o'clock

position.The long arm of the S500 robot could reach over

both conveyors to access both parts in less time than

swinging over to the 9 o'clock position for each cycle.

We have not done any conceptualizing on the material

handling that could be used to carry the panels from the

delivery trucks or warehouse to the part delivery

conveyors. We are assuming that the panels will be

unbanded and placed onto the panel delivery conveyors

manually. We are assuming a stack height of 2-3'.

The equipment required to install all 6 panels (four

different sizes ) at three work stations is:

Each Total

3-GMFanuc S500 robots $ 100,000 $ 300,000

3-2'risers 2,000 6,000

3-dual end-eff-,tors 6,000 18,000

3-stop,square a-id meter stations

in the case conveyor

3,000 9,000

1-central vacuum system 5,000 5,000

6-panel delivery conveyors8'roller

3,000 18,000

6-stop,square,and meter stations

in the panel conveyors

2,000 12,000

Total $ 368,000

Affix ing panel to back side of plastic liner

This operation is to be done on another separate but

merging line . Since only one panel is being applied.' it

is envisaged that a single robot fitted with a special

dual purpose end -effector could do the application of the

adhesive as well as present the panel to the liner.

The equipment required here is as follows:

Each Total

1-GMFanuc S500 robot $ 100 ,000 $ 100.000

1-2' riser 2, 000 2, 000

1-dual purpose end-effector , 6,000 6,000

spray and mat'l handling

1-adhesive dispensing system 15 ,000 15,000

 EE-RM-93-801 COMMENT OR5

APPENDIX 0 

2 of 4 

University of Kentucky 

Page 2 

progresses down the line. We anticipate handling two 

parts at a time with the panel delivery conveyors arranged 

a little bit differently than your concept. Rather than 

having a conveyor at the 3 o'clock and the 9 o'clock 

position for parts 1 and 7,we would propose that those two 

conveyors lie along side of each other at the 3 o'clock 

position. The long arm of the 5500 robot ~ould reach over 

both conveyors to access both parts in less time than 

swinging over to the 9 o'clock position for each cycle. 

We have not done any conceptualizing on the material 

handling that could be used to carry the panels from the 

delivery trucks or warehouse to the part delivery 

conveyors. We are assuming that the panels will be 

unbanded and placed onto the panel delivery conveyors 

manually. We are assuming a stack height of 2-3'. 

The equipment required to install all 6 panels (four 

different sizes) at three work stations is: 

3-GMFanuc 8500 robots 

3-2' t~isers 

3~dual end-efff"-tors 

3-stop,square ~ld meter stations 

in the case conveyor 

I-central vacuum system 

6-panel delivery conveyors- 8't~011er 

6-stop,square,and meter stations 

in the panel conveyors 

Total 

~ 

• 100,000 

2,000 

6,000 

3,000 

5,000 

3,000 

2,000 

3. Affixing panel to back side of plastic liner 

Total 

• 300,000 

6,000 

18,000 

9,000 

5,000 

18,000 

12,000 

S 368,000 

This operation is to be done on another separate but 

merging line. Since only one panel is being applied; it 

is envisaged that a single robot fitted with a speCial 

dual purpose end-effector could do the application of the 

adhesive as well as present the panel to the liner. 

The equipment required here is as follows: 

I-GMFanuc 5500 robot 

1-2' t'i set' 

1-dual purpose end-effecto~, 

spray and mat'l handling 

1-adhesive dispensing system 

S 

Each 

100,000 

2.000 

6,000 

15,000 

Total 

$ 100,000 

2,000 

6,000 

15,000 

APPENDIX 0 

2 of 4 

University of Kentucky 

Page 2 

progresses down the line. We anticipate handling two 

parts at a time with the panel delivery conveyors arranged 

a little bit differently than your concept. Rather than 

having a conveyor at the 3 o'clock and the 9 o'clock 

position for parts 1 and 7,we would propose that those two 

conveyors lie along side of each other at the 3 o'clock 

position. The long arm of the 5500 robot ~ould reach over 

both conveyors to access both parts in less time than 

swinging over to the 9 o'clock position for each cycle. 

We have not done any conceptualizing on the material 

handling that could be used to carry the panels from the 

delivery trucks or warehouse to the part delivery 

conveyors. We are assuming that the panels will be 

unbanded and placed onto the panel delivery conveyors 

manually. We are assuming a stack height of 2-3'. 

The equipment required to install all 6 panels (four 

different sizes) at three work stations is: 

3-GMFanuc 8500 robots 

3-2' t~isers 

3~dual end-efff"-tors 

3-stop,square ~ld meter stations 

in the case conveyor 

I-central vacuum system 

6-panel delivery conveyors- 8't~011er 

6-stop,square,and meter stations 

in the panel conveyors 

Total 

~ 

• 100,000 

2,000 

6,000 

3,000 

5,000 

3,000 

2,000 

3. Affixing panel to back side of plastic liner 

Total 

• 300,000 

6,000 

18,000 

9,000 

5,000 

18,000 

12,000 

S 368,000 

This operation is to be done on another separate but 

merging line. Since only one panel is being applied; it 

is envisaged that a single robot fitted with a speCial 

dual purpose end-effector could do the application of the 

adhesive as well as present the panel to the liner. 

The equipment required here is as follows: 

I-GMFanuc 5500 robot 

1-2' t'i set' 

1-dual purpose end-effecto~, 

spray and mat'l handling 

1-adhesive dispensing system 

S 

Each 

100,000 

2.000 

6,000 

15,000 

Total 

$ 100,000 

2,000 

6,000 

15,000 
APPENDIX 0

3 of 4

University of Kentucky

Page 3

1-stop,square and meter station 3,000 3,000

in the liner conveyor

1-panel delivery conveyor 3,000 3,000

8' roller

1-stop,square and meter station 2 ,000 2,000

in the panel conveyor

Total $ 131,000

4. Assembly of panels to freezer door and main door

We are assuming that the door set is moving down the

assembly line in matched sets and is properly fixtured

when it is stopped at the robot assembly station. Since

the door panels are expected to be the same size (two for

the main door and one for the freezer door ) only one panel

delivery conveyor will be needed. Two robots ought to. be

sufficient to do both the spray adhesive and material

handling if special dual purpose end -effectors are used.

The two robots would share the same panel delivery

conveyor but each would have the ability to spray adhesive

as well as handle the panels; i.e. the panel ( s) will

already have been picked up by the end effector and be

moving with the end -effector while the adhesive is being

applied . Once applied the end-effector is turned over and

the panel(s) are applied.

The equipment required her is expected to'be as follows:

Each Total

2-GMF S-500 robots $ 100,000 $ 200,000

2-Dual purpose end-effectors 6,000 12,000

spray and mat 'l handling

2-Adhesive systems 15,000 30,000

1-Panel delivery conveyor-S ft 3,000 3,000

1-Stop, square and meter station 2.000 2.000

Total $ 247,000

Summary:

The total estimated cost is:

1. Application of hot melt spray adhesive $ 243,000

2. Installation of 6 panels into case 368,000

Affix ing panel to back side of liner 131,000

4. Affixing 3 panels to freezer and main 247,000

5.

door sets _

Project management and installation 50,000

supervision

Grand Total $ 1,039,000

 EE-RM-93-801 COMMENT OR5

APPENDIX 0 

3 of 4 

University of Kentucky 

Page 3 

1-5top,s~uare and meter station 

in the liner conveyor 

l-panel delivery conveyor 

S' roller 

1-stop,s~uare and meter station 

in the panel conveyor 

Total 

3,000 3,000 

3,000 3,000 

2,000 2,000 

• 131,000 

4. Assembly of panels to freezer door and main door 

We are assuming that the door set is moving down the 

assembly line in matched sets and is properly fixtured 

when it is stopped at the robot assembly station~ Since 

the door panels are expected to be the same size (two tor 

the main door and one for the freezer door) only one panel 

delivery conveyor will be needed. Two robots ought to. be 

sufficient to do both the spray adhesive and material 

handling if special dual purpose end-effectors are used. 

The two robots would share the same panel delivery 

conveyor but each would have the ability to spray adhesive 

as well as handle the panels; i.e. the panel(s) will 

already have been picked up by the end" "effector and be 

moving with the end-effector while the adhesive i5 being 

applied. Once applied the end-effector is turned over and 

the panel(s) are applied. 

The equipment required her is expected to@be as follows: 

2-GMF 5-500 robots 

2-Dual purpose end-effectors 

spray and mat'l handling 

2-Adhesive systems 

$ 

1-Panel delivery conveyor-8 ft 

1-Stop,square and meter station 

Total 

"Each 

100,000 

6,000 

15,000 

3,000 

2.000 

Summary: 

The total estimated cost is: 

1. 

2. 

4. 

5. 

Application of hot melt spray adhesive 

Installation of 6 panels into case 

Affixing panel to back side of liner 

Affixing 3 panels to freezer and main 

door sets 

Project management and installation 

super'vis ion 

Total 

$ 200,000" 

12,000 

30,000 

3,000 

2.000 

$ 247,000 

$ 243,000 

368,000 

131,000 

247,000 

50,000 

Gr'and Total $ 1,039,000 

APPENDIX 0 

3 of 4 

University of Kentucky 

Page 3 

1-5top,s~uare and meter station 

in the liner conveyor 

l-panel delivery conveyor 

S' roller 

1-stop,s~uare and meter station 

in the panel conveyor 

Total 

3,000 3,000 

3,000 3,000 

2,000 2,000 

• 131,000 

4. Assembly of panels to freezer door and main door 

We are assuming that the door set is moving down the 

assembly line in matched sets and is properly fixtured 

when it is stopped at the robot assembly station~ Since 

the door panels are expected to be the same size (two tor 

the main door and one for the freezer door) only one panel 

delivery conveyor will be needed. Two robots ought to. be 

sufficient to do both the spray adhesive and material 

handling if special dual purpose end-effectors are used. 

The two robots would share the same panel delivery 

conveyor but each would have the ability to spray adhesive 

as well as handle the panels; i.e. the panel(s) will 

already have been picked up by the end" "effector and be 

moving with the end-effector while the adhesive i5 being 

applied. Once applied the end-effector is turned over and 

the panel(s) are applied. 

The equipment required her is expected to@be as follows: 

2-GMF 5-500 robots 

2-Dual purpose end-effectors 

spray and mat'l handling 

2-Adhesive systems 

$ 

1-Panel delivery conveyor-8 ft 

1-Stop,square and meter station 

Total 

"Each 

100,000 

6,000 

15,000 

3,000 

2.000 

Summary: 

The total estimated cost is: 

1. 

2. 

4. 

5. 

Application of hot melt spray adhesive 

Installation of 6 panels into case 

Affixing panel to back side of liner 

Affixing 3 panels to freezer and main 

door sets 

Project management and installation 

super'vis ion 

Total 

$ 200,000" 

12,000 

30,000 

3,000 

2.000 

$ 247,000 

$ 243,000 

368,000 

131,000 

247,000 

50,000 

Gr'and Total $ 1,039,000 
APPENDIX 0

4 of 4

University of Kentucky

Page 4

We have reviewed these numbers with Tom Zito of Technical

Equipment in Cincinnati , OH, and Bob Borgmann of Nordson in

Florence, KY, who feel that they are adequate enough to be

included in your report. Needless to say Jim, we are all

looking forward to working with you and others on this project

in the future.

I should point out Jim, that although we have followed a

robotic scenario in this proposal, it is possible to come up

with other automation alternatives in areas where the prices

might be a little high for justification. This could be the

case at the liner area and the door area.

Thanks again for giving us the opportunity to participate

in your project.

Sincerely,

REMTEC, INC.

Charlie Gayr.^r

Vice Presid^-t

Sales & Marketing

CG/k. jh

 EE-RM-93-801 COMMENT OR5

APPENDIX 0 

4 of 4 

University of Kentucky 

Page 4 

We have reviewed these numbers with Tom Zito of Technical 

Equlpment in Cincinnati, OH, and Bob Borgmann of Nordson in 

Floren;e, KY, who feel that they are adequate enough to be 

included in your report. Needless to say Jim, we are all 

looking forward to working with you and others on this project 

in the future. 

I should point out Jim, that although we have followed a 

robotic scenario in this proposal, it is possible to come up 

with other automation alternatives in areas where the prices 

might be a little high for justification. This could be the 

case at the liner area and the door area. 

Thanks again for giving us the opportunity to participate 

in your project. 

Sincerely, 

REMTEC, INC. 

Charlie 

~~ Gayr.::>r 

Vice Presid;:-t 

Sales & Marketing 

CG/kjh 

APPENDIX 0 

4 of 4 

University of Kentucky 

Page 4 

We have reviewed these numbers with Tom Zito of Technical 

Equlpment in Cincinnati, OH, and Bob Borgmann of Nordson in 

Floren;e, KY, who feel that they are adequate enough to be 

included in your report. Needless to say Jim, we are all 

looking forward to working with you and others on this project 

in the future. 

I should point out Jim, that although we have followed a 

robotic scenario in this proposal, it is possible to come up 

with other automation alternatives in areas where the prices 

might be a little high for justification. This could be the 

case at the liner area and the door area. 

Thanks again for giving us the opportunity to participate 

in your project. 

Sincerely, 

REMTEC, INC. 

Charlie 

~~ Gayr.::>r 

Vice Presid;:-t 

Sales & Marketing 

CG/kjh