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 

# &EPA United States Environmental Protection Agency Air and Radiation (ANR-445) EPA/430/R-92/110 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) EPA/430/R-92/110 October 1992 

# Vacuum Panel and Thick Wall Foam Insulation for Refrigerators: Cost Estimates for Manufacturing and Installation

@ Printed on Recycled PaperUnited 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 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 

## 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 ofAtmospheric and IndoorAir Programs Office ofAir 

### and Radiation U. S. EPA Project No. X818749-01-O

by James M. Waldron Center for Robotics and Manufacturing Systems
_ University of Kentucky College ofEngineering Lexington, Kentucky40506-0108

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 ofAtmospheric and IndoorAir Programs Office ofAir 

### and Radiation U. S. EPA Project No. X818749-01-O

by James M. Waldron Center for Robotics and Manufacturing Systems
_ University of Kentucky College ofEngineering Lexington, Kentucky40506-0108

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

## VACUUM PANEL AND THICK WALL FOAM INSULATION FOR REFRIGERATORS: Cost Estimates for Manufacturing and Installation
ABSTRACT**~proved** 

### insulationbetween the outer case and the inner liner is among the technologies
.

.available to refrigerator manufacturers to achieve significantreductions in energy consumption and the pollution associated with its generation. One approach is to add more insulation to the refrigerator cabinet. A second, "superinsulation", is a developing technology which would allow refrigerator manufacturers to significantly improveenergyefficiency without compromising the internal to external volume ratio ofthe :efrigerator. One approach to superinsulation is the useofvacuum 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 equipmentrequirements 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 requiredforreceiving, 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 plantbelocated adjacent to the silica plant to minimize transportation cost. Silica processing mustbeoptimized between the silica· plant and the VIP plant to minimize the required investmentin plant and equipment. Trade-offs between VIP plantefficiency and refrigerator energy efficiency mustbemade during development to determine the best mix ofpanel dimensions. Existing refrigerator assembly plants can be 

### retrofit to receive and install VIPs, but some
-ii

## VACUUM PANEL AND THICK WALL FOAM INSULATION FOR REFRIGERATORS: Cost Estimates for Manufacturing and Installation
ABSTRACT**~proved** 

### insulationbetween the outer case and the inner liner is among the technologies
.

.available to refrigerator manufacturers to achieve significantreductions in energy consumption and the pollution associated with its generation. One approach is to add more insulation to the refrigerator cabinet. A second, "superinsulation", is a developing technology which would allow refrigerator manufacturers to significantly improveenergyefficiency without compromising the internal to external volume ratio ofthe :efrigerator. One approach to superinsulation is the useofvacuum 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 equipmentrequirements 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 requiredforreceiving, 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 plantbelocated adjacent to the silica plant to minimize transportation cost. Silica processing mustbeoptimized between the silica· plant and the VIP plant to minimize the required investmentin plant and equipment. Trade-offs between VIP plantefficiency and refrigerator energy efficiency mustbemade during development to determine the best mix ofpanel 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. 

### mayrequire significant rearrangement. The technology to install VIPs into refrigerator cases and doors exists nowin some plants: Thickening thefoam insulation maybemore cost effective on smallerrefrigerators «20') wherekitchen dimensions are less limiting and where internal/external volume ratios are less important.

-iii

### mayrequire significant rearrangement. The technology to install VIPs into refrigerator cases and doors exists nowin some plants: Thickening thefoam insulation maybemore cost effective on smallerrefrigerators «20') wherekitchen dimensions are less limiting and where internal/external volume ratios are less important.

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### SIN31NOO 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-...... }uvTd dIA - aeanj dn-i eiS ....... alnPatpS pafo. dIA .................................................................... ShcA 4 IM POW uzeo;-a zd 1000 St................................................................. sdlA IPIM sea-IV =o;-aid caul pue aseD .....................................................................1ueTd 101e.021.'ag - ea.IV 2UTAlaJag dIA S£ ................................................................................................OUT Is Pue ^IIt3'uuo3 ££ ..................................................... autl IeaS pue 'Ot3 'uz zo3 - suopeatjpadS ssaao zd t£ .................................................................................................... uot^eIpisul ssasdnaeA

................................................................................iatsuaQ ssaidnaeA. ............................................................................... . IauQ used iau-p-la j :........................................................................................}wqj MOU Buisswozd Palms ........................................ uof^eznreS1O Weld laUed ............................................................................. }noAuj }UTd IaUd Ot ........................................................................................ suoT^e1 laued io}era2u;ag
.............................:............................" eaw ur o;-ard IOOQ ...................................................... seaay Umoj-ald aauri pue aseD ................................................................................... suOT^elnsul Jualenmbg


### e68d iegwnN



# s3an2EI 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 

### 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 lineChangeovers and Scheduling
.......................:....................28 8 Average Daily Panel Requirements for RefrigeratorAssembly line
......................40 9 48 FootTrailer Loading
..................................................................................................42 10 Flow 

### Thru Rack Requirements
......................................................................................45 11**Refrigeratc~'** 

### Plant Equipment
.......................................................................................52 12 Additional Operating Cost-RefrigeratorPlant
........................................................:53 13 Vacuum Insulated Panel Manufacturing Program Cost
........................................:..55 14 ProductCostfor VIP Manufacturing and Installation
........................**~**

### .....................57 15 VIP Product Cost SensitivityAnalysis
.....................:...................................................58 16 Thick InsulationAlternatives External Dimensions
..................................................64 17 Carton Sizes for 18' Refrigerators with 

### Thicker Insulation
..............:..............:.........66 ' 18 Thick FoamAlternatives Retooling Requirements
....................................................68 19 Cost to Increase Insulation Thickness on 18' Refrigerators
......................................69 20 Thick Wall Product Cost SensitivityAnalysis
.............................................................70 21 Cost to Increase Insulation Thickness on 18' Refrigerator Doors Only
.......**~**

### ..........71 22 Baseline 1991 Refrigerator
..............................................................................................74 23 Energy ConsumptionAnalysis Results
........................................................................74

-vi

### 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 lineChangeovers and Scheduling
.......................:....................28 8 Average Daily Panel Requirements for RefrigeratorAssembly line
......................40 9 48 FootTrailer Loading
..................................................................................................42 10 Flow 

### Thru Rack Requirements
......................................................................................45 11**Refrigeratc~'** 

### Plant Equipment
.......................................................................................52 12 Additional Operating Cost-RefrigeratorPlant
........................................................:53 13 Vacuum Insulated Panel Manufacturing Program Cost
........................................:..55 14 ProductCostfor VIP Manufacturing and Installation
........................**~**

### .....................57 15 VIP Product Cost SensitivityAnalysis
.....................:...................................................58 16 Thick InsulationAlternatives External Dimensions
..................................................64 17 Carton Sizes for 18' Refrigerators with 

### Thicker Insulation
..............:..............:.........66 ' 18 Thick FoamAlternatives Retooling Requirements
....................................................68 19 Cost to Increase Insulation Thickness on 18' Refrigerators
......................................69 20 Thick Wall Product Cost SensitivityAnalysis
.............................................................70 21 Cost to Increase Insulation Thickness on 18' Refrigerator Doors Only
.......**~**

### ..........71 22 Baseline 1991 Refrigerator
..............................................................................................74 23 Energy ConsumptionAnalysis 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 

### ABBREVIATIONS
AGV-Automatic Guided Vehicle
Board Foot-Avolume element l' 

### x l' 

### x 1"
CFC-Chlorofluorocarbons [x)E-DepartmentofEnergy
K-A specific property of a conducting material defined as the quantity ofheat 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-NationalAppliance Energy Conservation Act
ORNL-DakRidge National Laboratory Torr-pressureequal to a column ofmercury one millimeter high.
VIP-Vacuum insulation panel

-vii

### ABBREVIATIONS
AGV-Automatic Guided Vehicle
Board Foot-Avolume element l' 

### x l' 

### x 1"
CFC-Chlorofluorocarbons [x)E-DepartmentofEnergy
K-A specific property of a conducting material defined as the quantity ofheat 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-NationalAppliance Energy Conservation Act
ORNL-DakRidge National Laboratory Torr-pressureequal to a column ofmercury 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 asthe 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 - 

## ACKNOWLEDGEMENTS
This studywas.completed with the assistance ofa technical consultant,LouisW. Dawson, whohas more than 30 years ofexperience inmajor appliances-primarilyinrefrigerator manufacturing.
General Electric Appliances (GEA) provided samples of 18 cubicfoot refrigerator cabinets and liners and samples ofprototypeVIPs. Refrigerator specifications and costinformation were made available, through a non-disclosure agreement, to support the study. Ken Downs, GEA, assisted inthe development ofVIP 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 ofKentucky (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 atUK, provided capable CAD assistance in preparing figures and tables. Also, con"siderable technical and costinformation on raw materials and manufacturing equipmentwas provided by many companies which arelisted as references on page75. Two companies in particular; Fres-Co SystemUSA, Inc. (Larry Restivo) and Degussa Corporation (Roger Caffier & 

### Nick Ludovic) were especially helpful inproviding key inputs.

-viii

## ACKNOWLEDGEMENTS
This studywas.completed with the assistance ofa technical consultant,LouisW. Dawson, whohas more than 30 years ofexperience inmajor appliances-primarilyinrefrigerator manufacturing.
General Electric Appliances (GEA) provided samples of 18 cubicfoot refrigerator cabinets and liners and samples ofprototypeVIPs. Refrigerator specifications and costinformation were made available, through a non-disclosure agreement, to support the study. Ken Downs, GEA, assisted inthe development ofVIP 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 ofKentucky (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 atUK, provided capable CAD assistance in preparing figures and tables. Also, con"siderable technical and costinformation on raw materials and manufacturing equipmentwas provided by many companies which arelisted as references on page75. Two companies in particular; Fres-Co SystemUSA, Inc. (Larry Restivo) and Degussa Corporation (Roger Caffier & 

### Nick Ludovic) were especially helpful inproviding 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) andthicker 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 keyin 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. Imcan be made to the hermetic system, control systems, such as the defrost sysprovementstem, 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 ofa thermoformed plasticinnerliner and a steel outer case with CFC blownpolyurethane foam insulationinbetween. The doors usually are of similar construction. Twotechnologies, vacuuminsulationpanels (VIPs) and thicker foam insulation, havebeenproposed to reduce the thermal load through therefrigerator cabinet wall and theresulting powerrequirement. The current design evolved from the use offiberglass insulation during the sixties and
. brought significant energyefficiency improvements. The use offoam insulation allowed refrigerator manufacturers to increase the food storage capacity of a given refrigerator while maintaining the sameexternal dimensions. This "thin wall" concept hasbeen a key in refrigerator design. Increasing the thickness ofthe walls could require consumer compromises in food storage capacity for available kitchen space for consumers oflarger (> 

### 18') refrigerators. CFCs used in the foam insulation havebeenbanned by theMontreal Protocol and the Clean Air Act Amendments of 1990. Furthermore, President Bush has mandated that their
usebe completely eliminated after 1995. The DepartmentofEnergy (DOE), authorized by the National ApplianceEnergy Conservation Act (NAECA) of 1987, has issued stringentrefrigerator energy standards tobe metfor 1993 production. These standards require, on the average, a 30 percent additional effi**ci~ncy** 

### increase over 1990 requirements; and possible further efficiency increases for 1998
.. Many tedmologies canbe used to reduce the energy consumption ofrefrigerators. 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 ofa thermoformed plasticinnerliner and a steel outer case with CFC blownpolyurethane foam insulationinbetween. The doors usually are of similar construction. Twotechnologies, vacuuminsulationpanels (VIPs) and thicker foam insulation, havebeenproposed to reduce the thermal load through therefrigerator cabinet wall and theresulting powerrequirement. The current design evolved from the use offiberglass insulation during the sixties and
. brought significant energyefficiency improvements. The use offoam insulation allowed refrigerator manufacturers to increase the food storage capacity of a given refrigerator while maintaining the sameexternal dimensions. This "thin wall" concept hasbeen a key in refrigerator design. Increasing the thickness ofthe walls could require consumer compromises in food storage capacity for available kitchen space for consumers oflarger (> 

### 18') refrigerators. CFCs used in the foam insulation havebeenbanned by theMontreal Protocol and the Clean Air Act Amendments of 1990. Furthermore, President Bush has mandated that their
usebe completely eliminated after 1995. The DepartmentofEnergy (DOE), authorized by the National ApplianceEnergy Conservation Act (NAECA) of 1987, has issued stringentrefrigerator energy standards tobe metfor 1993 production. These standards require, on the average, a 30 percent additional effi**ci~ncy** 

### increase over 1990 requirements; and possible further efficiency increases for 1998
.. Many tedmologies canbe used to reduce the energy consumption ofrefrigerators. 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 installvacuum insulation panels into refrigerators. It also estimates the manufacturing and product costs of adding more foam to thicken the urethane foam insulation. 

### While buyers of smaller capacity units «21') maybe

### willing to accept some compromises .to avoid additional cost, buyers oflarger 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 otherfuture requirements for energy efficiency improvements without CFCs maynecessitate the use ofnewthermal insulation technologies. One approach to improved thermal insulation is 

### the use ofvacuuminsulation panels in conjunction with a non-CFC blownfoam. These panels maybe 

### manufactured byfilling a porous.bagwith a micro-grained powder, placing thebag into an envelope impervious to water and gases, and evacuating and sealing the envelope. The evacuated spaceprovides a barrier to the transfer ofheat which is 

### moreeffective than any modern dayinsulation. 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 costfor actual production and applicauon continues to be 

### debated.**Ot~ler** 

### Important issues such as the long term degradation ofthe vacuum and the impactofCFC substitutes, are being addressed elsewhere. This study evaluates the manufacturing feasibility and estimates cost to produce and install vacuuminsulation panels into refrigerators. It

### also estimates the manufacturing and PFoduct costs ofadding morefoam to thicken the urethane foam insulation.

-2- 

### While buyers of smaller capacity units «21') maybe

### willing to accept some compromises .to avoid additional cost, buyers oflarger 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 otherfuture requirements for energy efficiency improvements without CFCs maynecessitate the use ofnewthermal insulation technologies. One approach to improved thermal insulation is 

### the use ofvacuuminsulation panels in conjunction with a non-CFC blownfoam. These panels maybe 

### manufactured byfilling a porous.bagwith a micro-grained powder, placing thebag into an envelope impervious to water and gases, and evacuating and sealing the envelope. The evacuated spaceprovides a barrier to the transfer ofheat which is 

### moreeffective than any modern dayinsulation. 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 costfor actual production and applicauon continues to be 

### debated.**Ot~ler** 

### Important issues such as the long term degradation ofthe vacuum and the impactofCFC substitutes, are being addressed elsewhere. This study evaluates the manufacturing feasibility and estimates cost to produce and install vacuuminsulation panels into refrigerators. It

### also estimates the manufacturing and PFoduct costs ofadding morefoam 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 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 processingsteps 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 flashdrying 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 

### FINDINGS

• It

### is feasible, with existingtechnology, to manufacture vacuum insulationpanels (VIPs) in sufficient volume and with sufficient qualityfor installation intohousehold refrigerators.

CD 

### Existing refrigerator plants canbe retrofit to installVIPs-butmayrequire significant rearrangement and cost.

• This technology will allow significant reduction inrefrigerator energy usage without increasing the external dimensions ofthe refrigerator.

• Replacing urethane foam with VIPs will significantly increase the variable manufacturing cost and thus the retail price ofrefrigerators. The increase in variable manufacturing cost ofthe refrigerator is estimated to be $1.39 perboard foot ofVIPs 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, otherfiller materials, such as aluminum silicate, inplace ofor in 

### combination withprecipitated silica mayprovemore cost effective. A goal of$1.00 perboard foot is probably attainable within three tofive years ofinitial production.


## • Investment and expenserequired toimplement the production and application of
_ VIPs for three hundred thousand 21 or 24 cubicfoot refrigerators per yearis estimated to be about $24 million. This cost can probablybereducedby optimization oftheflash drying and densification processes between theVIP plant and the silica**~lant.** 

### Increased costs to the consumer will beminimized if

### the total systems cost, from the manufacture of silica to the final panel installation, is optimized.

• As the cost ofurethanefoam increases, the cost difference between foam and VIPs**~l** 

### decreaseby about $O.02/board foot for every 10% increase infoam cost. This

-4- 

### FINDINGS

• It

### is feasible, with existingtechnology, to manufacture vacuum insulationpanels (VIPs) in sufficient volume and with sufficient qualityfor installation intohousehold refrigerators.

CD 

### Existing refrigerator plants canbe retrofit to installVIPs-butmayrequire significant rearrangement and cost.

• This technology will allow significant reduction inrefrigerator energy usage without increasing the external dimensions ofthe refrigerator.

• Replacing urethane foam with VIPs will significantly increase the variable manufacturing cost and thus the retail price ofrefrigerators. The increase in variable manufacturing cost ofthe refrigerator is estimated to be $1.39 perboard foot ofVIPs 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, otherfiller materials, such as aluminum silicate, inplace ofor in 

### combination withprecipitated silica mayprovemore cost effective. A goal of$1.00 perboard foot is probably attainable within three tofive years ofinitial production.


## • Investment and expenserequired toimplement the production and application of
_ VIPs for three hundred thousand 21 or 24 cubicfoot refrigerators per yearis estimated to be about $24 million. This cost can probablybereducedby optimization oftheflash drying and densification processes between theVIP plant and the silica**~lant.** 

### Increased costs to the consumer will beminimized if

### the total systems cost, from the manufacture of silica to the final panel installation, is optimized.

• As the cost ofurethanefoam increases, the cost difference between foam and VIPs**~l** 

### decreaseby about $O.02/board foot for every 10% increase infoam 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 heightwidth: 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.



### assumes thatVIP 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 areless limiting. Maintaining the same approximateheight: width: depthratios will benecessary to avoid significant kitchen fit problems (reduced market) when adding more insulation.

• AddingVIPs will notincrease refrigerator shipping costbecause even with the added weight ofVIPs, the weightofa 48 foot trailer remains less than one half the gross weight limit. Shipping cost will increase for thicker insulation, even with a onehalf inch increase in insulation thickness, because the number ofrefrigerators per trailer will be 

### reduced.

• The product and transportation cost increase to add one inch offoam to an 18' cabinet will be 

### about 50% ofthe cost of adding vacuum insulation panels to a 21' cabinet and will give comparable energy improvement.



### RECOMMENDATIONS 1. A prototype facility shouldbebuiltby an appliance manufacturer or an independent company to develop and optimize VIP manufacturing. Ajoint venture with either a silica manufacturer or a form, fill, and seal equipmentmanufacturer is an alternative. 2. Long term vacuum and insulation degradation should be evaluated via accelerated life tests and field trials, so thatrefrigerator life cycle benefits and liabilities (in warranty and outofwarranty costs) arebetter understood.

-5- 

### assumes thatVIP 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 areless limiting. Maintaining the same approximateheight: width: depthratios will benecessary to avoid significant kitchen fit problems (reduced market) when adding more insulation.

• AddingVIPs will notincrease refrigerator shipping costbecause even with the added weight ofVIPs, the weightofa 48 foot trailer remains less than one half the gross weight limit. Shipping cost will increase for thicker insulation, even with a onehalf inch increase in insulation thickness, because the number ofrefrigerators per trailer will be 

### reduced.

• The product and transportation cost increase to add one inch offoam to an 18' cabinet will be 

### about 50% ofthe cost of adding vacuum insulation panels to a 21' cabinet and will give comparable energy improvement.



### RECOMMENDATIONS 1. A prototype facility shouldbebuiltby an appliance manufacturer or an independent company to develop and optimize VIP manufacturing. Ajoint venture with either a silica manufacturer or a form, fill, and seal equipmentmanufacturer is an alternative. 2. Long term vacuum and insulation degradation should be evaluated via accelerated life tests and field trials, so thatrefrigerator life cycle benefits and liabilities (in warranty and outofwarranty costs) arebetter 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. 

### GENERIC REFRIGERATOR ASSEMBLY LINE As 

### a basisfor this study a generic**refrigerato~** 

### line and factory has been defined. Product assumptions for this line are: 1.**~ee** 

### cabinet sizes maybeproduced: 18 cubicfoot, 21 cubic foot and 24 cubic foot. 2. Steel case and plasticliner construction. Steel doors also haveplasticinnerliners. 3. Urethanefoam insulation in

### boththe'cabinet and door. 4. Foamblowing agent 

### willbe R-ll or a suitable substitute. Foam, in conjunction with
vacuuminsulation panels, will 

### provide a mechanical structureequivalent to the currentdesign. 5. Productredesign changes to accommodate VIPs will be

### minimal
.

. Process assumptions are: 1. Thefabrication and assembly line will operate two 7.6 hour shifts, five days/week, 220 days/year. 2. lheline will produceone. unit every

## 20 seconds. 3. At 85% efficiency the line will have a capacity ofabout500,000 units per year. (180 units/hour x 7.6 hours/shiftx 2 shifts/dayx 220 days/year x .85) 4. Outputwill average 1,163 units per 7.6 hour shift. The areas ofthe plantwhich are examined inthis study are case and liner pre-foam and door pre-foam. The case and liner pre-foam area is shown inFigure 2. The door**pr~foam** 

### area is shownin Figure 3. The layouts ofthe affected areas will bedifferentin each refrigeratorplant and the actual rearrangement and costs required toinstall VIPs will varyfrom this study and from one manufacturer to another.

-6- 

### GENERIC REFRIGERATOR ASSEMBLY LINE As 

### a basisfor this study a generic**refrigerato~** 

### line and factory has been defined. Product assumptions for this line are: 1.**~ee** 

### cabinet sizes maybeproduced: 18 cubicfoot, 21 cubic foot and 24 cubic foot. 2. Steel case and plasticliner construction. Steel doors also haveplasticinnerliners. 3. Urethanefoam insulation in

### boththe'cabinet and door. 4. Foamblowing agent 

### willbe R-ll or a suitable substitute. Foam, in conjunction with
vacuuminsulation panels, will 

### provide a mechanical structureequivalent to the currentdesign. 5. Productredesign changes to accommodate VIPs will be

### minimal
.

. Process assumptions are: 1. Thefabrication and assembly line will operate two 7.6 hour shifts, five days/week, 220 days/year. 2. lheline will produceone. unit every

## 20 seconds. 3. At 85% efficiency the line will have a capacity ofabout500,000 units per year. (180 units/hour x 7.6 hours/shiftx 2 shifts/dayx 220 days/year x .85) 4. Outputwill average 1,163 units per 7.6 hour shift. The areas ofthe plantwhich are examined inthis study are case and liner pre-foam and door pre-foam. The case and liner pre-foam area is shown inFigure 2. The door**pr~foam** 

### area is shownin Figure 3. The layouts ofthe affected areas will bedifferentin each refrigeratorplant and the actual rearrangement and costs required toinstall VIPs will varyfrom 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

I -..J I 

### liners FroM 

## V

o.eUUM ForM 

## C Figure 2 . , Iner Pre-foam 

## A ' reas ase and 

# L-

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 [Jperators ' I -..J I 

### liners FroM 

## V

o.eUUM ForM 

## C Figure 2 . , Iner Pre-foam 

## A ' reas ase and 

# L-

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 [Jperators '

# 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 

## 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. 

### · VACUUM INSULATION PANEL REQUIREMENTS This study assumes that all 21 and 24 cubic foot refrigerators made onthis generic line will receiv·e vacuum insulation panels and the total annual volumeofthese models is 300,000 peryear. Eighteen cubic foot models arenotincluded since this size is morePri:ce sensitive and wouldbeless likely to useVIPs. A thicker insulation alternative for smaller, moreprice sensitive models is discussed in "ThickWall Alternatives". All ofthe 21 and 24 cubic foot models will beproduced on the line with an annual capacity of500,000, thus using 60% ofthat line's capacity. The other40% wouldbeused for 18' models. Whenrunning models with vacuuminsulation panels, the 20 second cycle time will still bemaintained. It

### is assumed that the refrigerator line will schedule the models which will receive VIPs an equivalent ofthree days or six shifts eachweek, or a maximum of6,978 refrigerators with VIPs per week. These models normally wr:be 60% ofeach 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 ofpanels, giving slightly less coverage'for the24 foot as a trade offfor increased manufacturing efficiency in thepanel plant. The 18 foot model also could use these same panels. As the volume ofmodels with VIPs increas.es,justifying a second panel line, panel sizes couldbefurther tailored to specific models to attain greater energyimprovement. Through analysis of an actual 18 cubic foot cabinet, optimum**panellocatio~s** 

### and sizes
were developed. All ofthese panels would, ofcourse, fit into a 21 cubic foot and a 24 cubic foot cabinet since all ofthe dimensions are the same or slightly larger. A 21 cubicfoot 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 onthis generic line will receiv·e vacuum insulation panels and the total annual volumeofthese models is 300,000 peryear. Eighteen cubic foot models arenotincluded since this size is morePri:ce sensitive and wouldbeless likely to useVIPs. A thicker insulation alternative for smaller, moreprice sensitive models is discussed in "ThickWall Alternatives". All ofthe 21 and 24 cubic foot models will beproduced on the line with an annual capacity of500,000, thus using 60% ofthat line's capacity. The other40% wouldbeused for 18' models. Whenrunning models with vacuuminsulation panels, the 20 second cycle time will still bemaintained. It

### is assumed that the refrigerator line will schedule the models which will receive VIPs an equivalent ofthree days or six shifts eachweek, or a maximum of6,978 refrigerators with VIPs per week. These models normally wr:be 60% ofeach 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 ofpanels, giving slightly less coverage'for the24 foot as a trade offfor increased manufacturing efficiency in thepanel plant. The 18 foot model also could use these same panels. As the volume ofmodels with VIPs increas.es,justifying a second panel line, panel sizes couldbefurther tailored to specific models to attain greater energyimprovement. Through analysis of an actual 18 cubic foot cabinet, optimum**panellocatio~s** 

### and sizes
were developed. All ofthese panels would, ofcourse, fit into a 21 cubic foot and a 24 cubic foot cabinet since all ofthe dimensions are the same or slightly larger. A 21 cubicfoot refrigerator with VIP locations is shown in Figure 4.

-9-

# Figure 4

Refrigerator Panel Locations 21ft3 Refrigerator with 10 Panels 

# 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. 

### There are ten panels ineach refrigerator. The panels will be

### produced infive 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 wouldbe 

### attached. Table 2 showsthe sizes for thebaIJ'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 ductnecessitated a small panel which was deemed ineffective.

A productredesign to relocate some ofthese could allow a freezer back panel to be

### large enough to be

### justified.

-11- 

### There are ten panels ineach refrigerator. The panels will be

### produced infive 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 wouldbe 

### attached. Table 2 showsthe sizes for thebaIJ'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 ductnecessitated a small panel which was deemed ineffective.

A productredesign to relocate some ofthese 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 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 ofpanels = 

### 35.5 square feet Total weightofpanels 

## =29 pounds Total boardfeet = 

### 29 LOCATION INSTALLATION AREA

FreezerTop CasePre-Foam Freezer Sides CasePre-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 ofpanels = 

### 35.5 square feet Total weightofpanels 

## =29 pounds Total boardfeet = 

### 29 LOCATION INSTALLATION AREA

FreezerTop CasePre-Foam Freezer Sides CasePre-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 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

### VACUUM INSULATION PANEL MANUFACTURING

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

### VACUUM INSULATION PANEL MANUFACTURING This 

### section describes the facility, organization, materials, and equipmentrequired to**produ~** 

### three million VIPs peryear for three hundred thousand 21 or24 cubic foot refrigerators. When selecting the location for thefacility**~th** 

### regard to the appliance assemblyplant, several elements mustbe 

### considered. Rawmaterial sources and transportation, the possible requirement to make VIPs for multiple assemblyplants, and the trend away from vertical integration and toward "assemblyonly" plants are all 

### items which mustbefactored into this decision. M9.terials for VIPs were selected from those currentlybeing used for R&D, and costs were obtained from the materials manufacturers ortheir representatives. The VIP manufacturing process was defined and the equipment selected after numerous discussions with several**partie~** 

### 'N'h.J haveproduced VIPs for R&D; manufacturers of form, fill, and seal equipment who incorporatevacuumpackaging in 

### their equipment; users ofform, fill, and seal equipmentfor vacuum packed products such as coffee; manufacturers ofsilica andbag materials; and many equipmentmanufacturers who supply equipmentwhich has the capability to perform portions ofthe VIP manufacturing process. Some equipmentmanufacturers whose equipment was considered butnotincluded in the final design areincluded inthereferences. VIP**manufa~ing** 

### is discussed in the following sections. A. Facility and equipment B. Panel plantorganization 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 equipmentrequired to**produ~** 

### three million VIPs peryear for three hundred thousand 21 or24 cubic foot refrigerators. When selecting the location for thefacility**~th** 

### regard to the appliance assemblyplant, several elements mustbe 

### considered. Rawmaterial sources and transportation, the possible requirement to make VIPs for multiple assemblyplants, and the trend away from vertical integration and toward "assemblyonly" plants are all 

### items which mustbefactored into this decision. M9.terials for VIPs were selected from those currentlybeing used for R&D, and costs were obtained from the materials manufacturers ortheir representatives. The VIP manufacturing process was defined and the equipment selected after numerous discussions with several**partie~** 

### 'N'h.J haveproduced VIPs for R&D; manufacturers of form, fill, and seal equipment who incorporatevacuumpackaging in 

### their equipment; users ofform, fill, and seal equipmentfor vacuum packed products such as coffee; manufacturers ofsilica andbag materials; and many equipmentmanufacturers who supply equipmentwhich has the capability to perform portions ofthe VIP manufacturing process. Some equipmentmanufacturers whose equipment was considered butnotincluded in the final design areincluded inthereferences. VIP**manufa~ing** 

### is discussed in the following sections. A. Facility and equipment B. Panel plantorganization 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 areabout 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 tenmillion 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. 

### F. Flash drying G.

- Silostorage 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 panelplantwouldbe

### built 100 miles from the refrigerator plant and next to the silica plant, and that the silica plantwouldbe

### next to the silicate plant. Sodium silicate and sulfuric acid are theraw materials for the production ofprecipitated silica. A major consideration for the location ofthe complex would be transportation means and routes for sand and soda ash, which are the raw materials for sodium silicate. About three pounds ofsodium silicate arerequired to produce one poundofsilica; 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 maybe less expensive than shipping silica orits rawmaterials. Thebuilding would be 

### sized to accommodate threepanellines for future expansion to ten million panels (one millionrefrigerators) peryear. Cost for onlyonepanelfine and supporting equipmentis included in this study. Building cost was estimatedbased on actual cost of a recent plant and includes normal power distribution, lighting, offices, heating and air conditioning, and other utility equipmentplus truck docks, parking lot, landscaping, roads, etc.

-15- 

### F. Flash drying G.

- Silostorage 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 panelplantwouldbe

### built 100 miles from the refrigerator plant and next to the silica plant, and that the silica plantwouldbe

### next to the silicate plant. Sodium silicate and sulfuric acid are theraw materials for the production ofprecipitated silica. A major consideration for the location ofthe complex would be transportation means and routes for sand and soda ash, which are the raw materials for sodium silicate. About three pounds ofsodium silicate arerequired to produce one poundofsilica; 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 maybe less expensive than shipping silica orits rawmaterials. Thebuilding would be 

### sized to accommodate threepanellines for future expansion to ten million panels (one millionrefrigerators) peryear. Cost for onlyonepanelfine and supporting equipmentis included in this study. Building cost was estimatedbased on actual cost of a recent plant and includes normal power distribution, lighting, offices, heating and air conditioning, and other utility equipmentplus 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 operatorsare 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. 

### - 

### The building**wo~d** 

### be air 

### conditioned toprovide therequired humidity control as well as . employee comfort. There wouldbe

### one sheltered, two trailerreceiving dock and one sheltered, twotrailer shipping dock. A layoutofthe panelplantis showninFigure 5. Thepanel plantequipment, which will be 

### discussed in detail later, is summarized inTable 3, along withtheestimated costs. A 25% contingency, commonly used bymanufacturers for feasibility studyestimates, hasbeen included. B. Plant organization and operation 

### The plant will have nine salaried and 22 hourlypersonnel, as shownon the organization chart in 

### Figure 6. Hourlypersonnel will be

### paid on a day work plan. Position descriptions**f~r** 

### all personnel will allow them to do anyjob which they are capable ofperforming. Cross training andjob flexibility will be

### rewarded withhigher hourly rates. Quality control personnel will be

### responsible for inspection work as well as qualityengineering andprocess 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 offequipment, minor maintenance and unjamming, preventive maintenance, andhousekeeping in their area. Shipping material handlers will be

### responsible for loading trailers and keeping the line stocked with material, which will be

### doneprimarily during changeovers. Three oPerators areplanned on each shift so that adequatereliefto trailer loaders can beprovidedby assigtUl}ent rotation. Panel plantoperatingpersonnel and costs are summarized in Table 4.

-16- 

### - 

### The building**wo~d** 

### be air 

### conditioned toprovide therequired humidity control as well as . employee comfort. There wouldbe

### one sheltered, two trailerreceiving dock and one sheltered, twotrailer shipping dock. A layoutofthe panelplantis showninFigure 5. Thepanel plantequipment, which will be 

### discussed in detail later, is summarized inTable 3, along withtheestimated costs. A 25% contingency, commonly used bymanufacturers for feasibility studyestimates, hasbeen included. B. Plant organization and operation 

### The plant will have nine salaried and 22 hourlypersonnel, as shownon the organization chart in 

### Figure 6. Hourlypersonnel will be

### paid on a day work plan. Position descriptions**f~r** 

### all personnel will allow them to do anyjob which they are capable ofperforming. Cross training andjob flexibility will be

### rewarded withhigher hourly rates. Quality control personnel will be

### responsible for inspection work as well as qualityengineering andprocess 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 offequipment, minor maintenance and unjamming, preventive maintenance, andhousekeeping in their area. Shipping material handlers will be

### responsible for loading trailers and keeping the line stocked with material, which will be

### doneprimarily during changeovers. Three oPerators areplanned on each shift so that adequatereliefto trailer loaders can beprovidedby assigtUl}ent rotation. Panel plantoperatingpersonnel 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

# IRest

Utilities ROOM

I



## ....

....... I

100'



# t MOintenonce Q C lI' 

## Lob'

# ~Ilr~ U



### 11



### 6 

## FigureS Panel Plant Layout 

## (441

## 400 

# 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 

## (441

## 400 

# 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' I 

# ... Q) I EQUIPMENT Silos Pneumatic system Flash dryer Densifier Augerfiller Fonn,fill, and seal Hotbarreseal Vacuumcheck Bundle stacking Auto pack Barcode Adjustoveyor Tractors Trailers QC lab equipment Maintenanceequipment Fork/coil truck Spareparts Building Land Office equipment Total equipmentcost 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 StewartGlapat 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% ofselected eq. 250,000 44,400 sq. ft. $85/sq. ft. 3,774,000 100,000 $25,000 SI-llPPING INSTALLAnON $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 Augerfiller Fonn,fill, and seal Hotbarreseal Vacuumcheck Bundle stacking Auto pack Barcode Adjustoveyor Tractors Trailers QC lab equipment Maintenanceequipment Fork/coil truck Spareparts Building Land Office equipment Total equipmentcost 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 StewartGlapat 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% ofselected eq. 250,000 44,400 sq. ft. $85/sq. ft. 3,774,000 100,000 $25,000 SI-llPPING INSTALLAnON $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 P secretary 

### 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

I

..... CD I 

# Figure 6 Panel Plant Organization 

# IPLANT 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 I**~** o I 

## Table 4 

# Annual Operatir'l 

# Cost - Panel.Plant

NUMBER HOURLY RATE ANNUAL WAGE BENEFITS 

### SALARIED PERSONNEL (40%) 

### Plantmanager 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 

### Shippingand materials handlers 9 8.00 16,640 

### Control men 6 12.00 24,960 

### Total HourlyWages TRANSPORTATION COST Truckdrivers 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%) 

### Plantmanager 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 

### Shippingand materials handlers 9 8.00 16,640 

### Control men 6 12.00 24,960 

### Total HourlyWages TRANSPORTATION COST Truckdrivers 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 suppliedby 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%. 

# c. Silica material

. 

### The silica used for filling thepanel is FK500lS, suppliedby Degussa [4]. A productinformation sheet is.shown in Appendix A. Material cost is assumed to be $O.75/pound, as stated in a letter from Degussa (formerly NorthAmerica Silica) to Mr. 

### Alan Fine, EPA, on June 11,1991 (Appendix B). Flash drying and densifying equipmentprovidedinthis 

### plant would most likely facilitate the use ofa 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 ornotthis is feasible would have to be determined through R & 

### D and pilot operations where trade-offs between panelunit cost andinsulation efficiency couldbeevaluated. D. Bag materials 

### The microporous bag, which will contain the silica during compaction and evacuation, is TYVEK suppliedby Snow Filtration, Cincinnati, Ohio [23]. This material is quoted at $0.036/ square foot in the volumes assumed for this study. Thebarrierbag, which retains the vacuum, is VECAT. A multi-layered material supplied byFres-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 panelplant,into a flash drier located in the panel plant and then into a silo, as shown in the flow chart inFigure 7. Silica coming into the panel plant has an average particle size of3.5 microns, a density offour pounds per cubic foot, and a moisture content of3-4%.

-21- 

# c. Silica material

. 

### The silica used for filling thepanel is FK500lS, suppliedby Degussa [4]. A productinformation sheet is.shown in Appendix A. Material cost is assumed to be $O.75/pound, as stated in a letter from Degussa (formerly NorthAmerica Silica) to Mr. 

### Alan Fine, EPA, on June 11,1991 (Appendix B). Flash drying and densifying equipmentprovidedinthis 

### plant would most likely facilitate the use ofa 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 ornotthis is feasible would have to be determined through R & 

### D and pilot operations where trade-offs between panelunit cost andinsulation efficiency couldbeevaluated. D. Bag materials 

### The microporous bag, which will contain the silica during compaction and evacuation, is TYVEK suppliedby Snow Filtration, Cincinnati, Ohio [23]. This material is quoted at $0.036/ square foot in the volumes assumed for this study. Thebarrierbag, which retains the vacuum, is VECAT. A multi-layered material supplied byFres-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 panelplant,into a flash drier located in the panel plant and then into a silo, as shown in the flow chart inFigure 7. Silica coming into the panel plant has an average particle size of3.5 microns, a density offour pounds per cubic foot, and a moisture content of3-4%.

-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. \ 

## 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 to4Ib/ft3 Transfer to densifier 

# I Densify 8 - 10 lb/ft:i 

# I Transfer to VIP line 

# J ProductVIPs <1% final density 121b/ft3

Silica will flow from the silica plant to the VIP plant at a rate of2000 to 2200 pounds perhour.
VIPs will beproduced at a rate of900 perhourless losses for downtime, rejects, etc., and changeovers ofone to three hoursbetween 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 to4Ib/ft3 Transfer to densifier 

## I Densify 8 - 10 lb/ft:i 

# I Transfer to VIP line 

# I ProductVIPs <1% final density 121b/ft3

Silica will flow from the silica plant to the VIP plant at a rate of2000 to 2200 pounds perhour.
VIPs will beproduced at a rate of900 perhourless losses for downtime, rejects, etc., and changeovers ofone to three hoursbetween 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-Drierby 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 rotaryvane. 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- 

### Silica usage will average 16,000 to 18,000 P9unds per eighthour 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) 

### willbe 31,536 poundsper eighthour shift. F. Flash 

### Drying Silica coming into the panel plantfrom the silica plantwould first beprocessed through a flash drierbefore entering a silo. Experimentalpanelmanufacturing processes have dried the silica in an oven after it

### has beenputinto the porous bag. This process is acceptablefor R&Dbutwasjudgedtoo expensive for high volumeproduction. The flash drier is designed to reduce the moisture content ofthe silica from 3 to 4% to less than 1%. 

### The equipment selected for this application is a Jet-O-Drier® produced byFluid Energy Aljet [6].**~e** 

### Jet-O-Drier is a flash/spray drier with a material retention timeofless than one second. This equipment can accommodate veryhigh inlet temperatures without causing product degradation while still maintaining a low outlet temperature. Aljet's description oftheJet-O-Drier operatingprincipleis: "Drying gas, usually air, is pressurized, heated, and introduced into theJet-O-Drier by specially designed nozzles. The energy ofthe pressurized hotfluid (or wetpowder) is converted into velocity. The directional flow from the nozzles develops a controlled high velocity drier circuit. The system velocity is balancedby mass flow and evaporativerate which maintains a system pressureinside the drierslightly above atmospheric. Wet solids areintroduced pneumatically orbyIl)eans ofa rotary vane. The violent action in the drying chamber deagglomerates the individualparticles, thereby exposing enormously large drying surfaces. At the.drier outletthe finely dispersed dryparticles are removed by the frictional dragofthe 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 eighthour 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) 

### willbe 31,536 poundsper eighthour shift. F. Flash 

### Drying Silica coming into the panel plantfrom the silica plantwould first beprocessed through a flash drierbefore entering a silo. Experimentalpanelmanufacturing processes have dried the silica in an oven after it

### has beenputinto the porous bag. This process is acceptablefor R&Dbutwasjudgedtoo expensive for high volumeproduction. The flash drier is designed to reduce the moisture content ofthe silica from 3 to 4% to less than 1%. 

### The equipment selected for this application is a Jet-O-Drier® produced byFluid Energy Aljet [6].**~e** 

### Jet-O-Drier is a flash/spray drier with a material retention timeofless than one second. This equipment can accommodate veryhigh inlet temperatures without causing product degradation while still maintaining a low outlet temperature. Aljet's description oftheJet-O-Drier operatingprincipleis: "Drying gas, usually air, is pressurized, heated, and introduced into theJet-O-Drier by specially designed nozzles. The energy ofthe pressurized hotfluid (or wetpowder) is converted into velocity. The directional flow from the nozzles develops a controlled high velocity drier circuit. The system velocity is balancedby mass flow and evaporativerate which maintains a system pressureinside the drierslightly above atmospheric. Wet solids areintroduced pneumatically orbyIl)eans ofa rotary vane. The violent action in the drying chamber deagglomerates the individualparticles, thereby exposing enormously large drying surfaces. At the.drier outletthe finely dispersed dryparticles are removed by the frictional dragofthe 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. I I\,) .Ilo I 

## 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 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 arebeing 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 PANELS/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 arebeing run. 2497



## . 1695 1695 2681 2497 2681 594 1132 1132 1132

17736Immediately 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 footas 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 onthe 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. 

### Immediately after beingprocessed through the flash drier the silica would have 

## a density" "" ofaboutone pound per cubic foot. It

### would redensify to about four poundsper cubic foot as it 

### settled in the silo. Air 

### wouldbe removed from thetop ofthe silo to speed up densification. Figure 8 shows a typical Jet-O-Drier system. G. Silo storage 

### Two silos will beused; onewill 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, manufacturedbyPeabody TecTank [17] (Appendix C). With a ten foot head clearance, each silo has a capacity of7000 

### cubic feet (28,000 

### pounds @ 

### four pounds per cubic foot). One full silo will support about eight hours ofproduction on the form, fill, and seal line whenproducingthe largest panel size (l"x28"x30") 

### at 85% 

### efficiency. Changeover from silo to silo will be simple and quick through the use ofelectronically controlled, rotary actuated valves. Silos will bepiped so they canbe filled from anyof the flash driers and can feed any ofthe densifiers. Table 6 shows that starting with onefull silo and using the schedulingplan shown in Table 7, two silos are adequate to accommodate a continuous flow ofsilica froin the silica plant. The maximum silica inventoryreaches 39,040 pounds at the end ofthe panel 8, 9 and 10

- run and drops to a low of 14,816 pounds at the end ofthepanel 1 and 5 run. Two silos will hold 56,000 

### pounds ofsilica at the planned density offour pounds per cubic foot. H. Densifying 

### Silica will flow from the silo into a densifier by means ofa pneumatic transfer system. The densifier will increase the silica density to 8-10 pounds per cubic foot.**-25~** 

### Immediately after beingprocessed through the flash drier the silica would have 

## a density" "" ofaboutone pound per cubic foot. It

### would redensify to about four poundsper cubic foot as it 

### settled in the silo. Air 

### wouldbe removed from thetop ofthe silo to speed up densification. Figure 8 shows a typical Jet-O-Drier system. G. Silo storage 

### Two silos will beused; onewill 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, manufacturedbyPeabody TecTank [17] (Appendix C). With a ten foot head clearance, each silo has a capacity of7000 

### cubic feet (28,000 

### pounds @ 

### four pounds per cubic foot). One full silo will support about eight hours ofproduction on the form, fill, and seal line whenproducingthe largest panel size (l"x28"x30") 

### at 85% 

### efficiency. Changeover from silo to silo will be simple and quick through the use ofelectronically controlled, rotary actuated valves. Silos will bepiped so they canbe filled from anyof the flash driers and can feed any ofthe densifiers. Table 6 shows that starting with onefull silo and using the schedulingplan shown in Table 7, two silos are adequate to accommodate a continuous flow ofsilica froin the silica plant. The maximum silica inventoryreaches 39,040 pounds at the end ofthe panel 8, 9 and 10

- run and drops to a low of 14,816 pounds at the end ofthepanel 1 and 5 run. Two silos will hold 56,000 

### pounds ofsilica at the planned density offour pounds per cubic foot. H. Densifying 

### Silica will flow from the silo into a densifier by means ofa 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 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% MoistlreTable 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 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 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 OFDIMENSIONS GlANGEDWHEN CHANGING TOPANEL 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 OFDIMENSIONS GlANGEDWHEN CHANGING TOPANEL 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 fillingDry 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 

### 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 ofthe V ACUPRESS operating principle is: liThe densifying effect is achieved by a combination.ofvacuum andmechanical 

### pressure. The V ACUPRESS process is achieved bymeans oftwo drums turning in opposite directions, designated filter drum 

### and pressure drum. [Figure 9] 

### ''Theproductto be 

### densified encloses the filter drum and thereby allows the filter or de-aeration action to takeplace. As 

### the drumrevolves, the particles rearrange to form byvacuum effect a continuous layer on the surface ofthe filter drum and pre-densifybythe exhausting air passed through. The layer of**de-aerat~d** 

### powderpasses through the gap between the filter and pressure drums whereit is subjected to a preselected rolling pressure. The rolling pressure action brings the de-aerated powder particles closer together as dense powderor soft agglomerates. Mterwards, the densified productis continuously stripped offthe filter drumup to the filter layer and leaves the machine." A typical V ACUPRESS installation is shown inFigure 10. I. Bag filling 

### Dry and dense silica ateight to ten pounds per cubic foot and less than onepercent moistureis 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 ofthe V ACUPRESS operating principle is: liThe densifying effect is achieved by a combination.ofvacuum andmechanical 

### pressure. The V ACUPRESS process is achieved bymeans oftwo drums turning in opposite directions, designated filter drum 

### and pressure drum. [Figure 9] 

### ''Theproductto be 

### densified encloses the filter drum and thereby allows the filter or de-aeration action to takeplace. As 

### the drumrevolves, the particles rearrange to form byvacuum effect a continuous layer on the surface ofthe filter drum and pre-densifybythe exhausting air passed through. The layer of**de-aerat~d** 

### powderpasses through the gap between the filter and pressure drums whereit is subjected to a preselected rolling pressure. The rolling pressure action brings the de-aerated powder particles closer together as dense powderor soft agglomerates. Mterwards, the densified productis continuously stripped offthe filter drumup to the filter layer and leaves the machine." A typical V ACUPRESS installation is shown inFigure 10. I. Bag filling 

### Dry and dense silica ateight to ten pounds per cubic foot and less than onepercent moistureis 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

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 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 Iieo 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 Iieo to Auger Feederchanged 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 LineThe 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. 

### changed with thepush of a button. Fills for each panel are controlled to plus orminus a .few grams. Five different fills are required for thepanels used in this study. Change over wouldbe instantaneous. A Mateer-BurtNeotron 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 ofplus orminus two to three

### grams. J. Panel 

### Manufacturing line 

### The auger filler feeds a vertical form, fill, and seal machine whichbags the silica in a p0- 

### rous bag [1). The machine then places theporous bag into a multi-layer plasticbag which is inserted into a vacuum chamber where it is evacuated and sealed. Process specifications for the form, fill, and seal line are shown inFigure 11. Horizontal equipment could beused and should bereviewed further before discounting it [2]. Also, some other types of equipment can vacuumform thebarrierbag into a tray. This could be an advantage,butwas not considered because it

### was felt that the multi-layer barrierbag could notbe vacuumformed without destroying its integrity. This capability shouldbe investigated further before ruling it out. Vertical equipment was assumed to be .'. best suited for manufacturing VIPs.

-32- 

### changed with thepush of a button. Fills for each panel are controlled to plus orminus a .few grams. Five different fills are required for thepanels used in this study. Change over wouldbe instantaneous. A Mateer-BurtNeotron 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 ofplus orminus two to three

### grams. J. Panel 

### Manufacturing line 

### The auger filler feeds a vertical form, fill, and seal machine whichbags the silica in a p0- 

### rous bag [1). The machine then places theporous bag into a multi-layer plasticbag which is inserted into a vacuum chamber where it is evacuated and sealed. Process specifications for the form, fill, and seal line are shown inFigure 11. Horizontal equipment could beused and should bereviewed further before discounting it [2]. Also, some other types of equipment can vacuumform thebarrierbag into a tray. This could be an advantage,butwas not considered because it

### was felt that the multi-layer barrierbag could notbe vacuumformed without destroying its integrity. This capability shouldbe 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 

# 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 onforth • 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 ofmercury (1 

### Torr) 5. Maximum panel size-l"x21 "x 30" 6. Semiautomatic changeover for thickness and length 7. Capability for two thicknesses (OS' & 

### 1.0"), and twolengths (21" & 

### 28") 8. Five pounds maximum fill 9. 85% efficient**10~** 

### Reject rate < 

### 1% 

### at steady state 11. Materials: porous bag-Snow Filtration TYVEK barrierbag-Fres-CoVECAT 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 onforth • 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 ofmercury (1 

### Torr) 5. Maximum panel size-l"x21 "x 30" 6. Semiautomatic changeover for thickness and length 7. Capability for two thicknesses (OS' & 

### 1.0"), and twolengths (21" & 

### 28") 8. Five pounds maximum fill 9. 85% efficient**10~** 

### Reject rate < 

### 1% 

### at steady state 11. Materials: porous bag-Snow Filtration TYVEK barrierbag-Fres-CoVECAT 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 

### Form, fill, and**se~** 

### machines havelongbeen used in the food industryfor vacuumpacked products such as coffee, and are a proventechnology (AppendixE). Although VIPs are somewhatlarger than the typical food package, itis felt that these machines canbe designed to producethem. Form, fill, 

### and seal machines typicallyrun from 80 to 100 pieces perminute. The VIP process will run only 15 panels perminute. FIgure 12 shows the layout of a form, fill, and seal machinefor food packaging. Theprocess sequence in 

### theform, fill, 

### and seal machine for VIPs wouldbe: Station 1 - Form porousbag, seal bottom, fill with silica, seal top (which is 

### bottom ofnext bag), cutoffand drop onbelt conveyor. Thebagis formed as a continuous tube which is 

### fIlled bythe volumetric auger filler. The tube is sealed at selected dimensions by a resistance heatedhotbar and cut offby a shear. Station 2 - Locate bag, vibrate to level silica and press to compact. Station 3 - Formbarrierbag around porous ba(>" sealon three sides and tack /.); fourth side. Station 4 - Load and unload evacuation chambers. Fourpanelsper chamber. Station 5 Evacuation. Inside each chamberthe 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 are26 vacuum chambers and 20 vacuum lids on the line. With four panels perchamber,five and one-third minutes ofevacuation will
occurfor each panel atthe four second line cycle. Station 6 - Secondary seal all four sides ofbarrierbag-threehotbar. hits per side. Station7 - Transfer tobeltconveyor. Changeovers from one size panel to another will necessitate changingporousbag and barrierbag 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 havelongbeen used in the food industryfor vacuumpacked products such as coffee, and are a proventechnology (AppendixE). Although VIPs are somewhatlarger than the typical food package, itis felt that these machines canbe designed to producethem. Form, fill, 

### and seal machines typicallyrun from 80 to 100 pieces perminute. The VIP process will run only 15 panels perminute. FIgure 12 shows the layout of a form, fill, and seal machinefor food packaging. Theprocess sequence in 

### theform, fill, 

### and seal machine for VIPs wouldbe: Station 1 - Form porousbag, seal bottom, fill with silica, seal top (which is 

### bottom ofnext bag), cutoffand drop onbelt conveyor. Thebagis formed as a continuous tube which is 

### fIlled bythe volumetric auger filler. The tube is sealed at selected dimensions by a resistance heatedhotbar and cut offby a shear. Station 2 - Locate bag, vibrate to level silica and press to compact. Station 3 - Formbarrierbag around porous ba(>" sealon three sides and tack /.); fourth side. Station 4 - Load and unload evacuation chambers. Fourpanelsper chamber. Station 5 Evacuation. Inside each chamberthe 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 are26 vacuum chambers and 20 vacuum lids on the line. With four panels perchamber,five and one-third minutes ofevacuation will
occurfor each panel atthe four second line cycle. Station 6 - Secondary seal all four sides ofbarrierbag-threehotbar. hits per side. Station7 - Transfer tobeltconveyor. Changeovers from one size panel to another will necessitate changingporousbag and barrierbag 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 PUMPEpf' 

### t i

ELECTRICAL CABINET

317ES ARE APPROXIMATE 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 '--

_______ -'

S1ZE5 ARE APPAOXIMATE 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 '--

_______ -'

S1ZE5 ARE APPAOXIMATE 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. 

### thickness change is made, and adjustinghot

## 1>ar sealers. It

### is estimated that changeovers 

### will takefrom onehour for a onedimension change to threehours for a three dimension change. Theline canbe scheduled sothat there arenothree dimension changeovers. Thebestrun sequencewhichrequires two onedimension changes and onlythree two dimension chartges is shown inTable 7. Planningrun and changeover sequence will reduce overall setup time which is the major component ofefficiency loss. The line normally will run each panel for eighthours and then change to another. This 

### planwill produce a maximum of 7209 panels on eachrun, i.e., one week's requirement for onepanel for therefrigerator plant (6980 

### units/week). With a five day, 24 hour work week, this schedule allows 80 hours per weekfor production (10 panels x 8 hoursper pane!), 20 hours for changeovers (10 changeovers x 2 hours average time per changeover), and 20 hours for maintenance, downtime, and otherlosses.

-36- 

### thickness change is made, and adjustinghot

## 1>ar sealers. It

### is estimated that changeovers 

### will takefrom onehour for a onedimension change to threehours for a three dimension change. Theline canbe scheduled sothat there arenothree dimension changeovers. Thebestrun sequencewhichrequires two onedimension changes and onlythree two dimension chartges is shown inTable 7. Planningrun and changeover sequence will reduce overall setup time which is the major component ofefficiency loss. The line normally will run each panel for eighthours and then change to another. This 

### planwill produce a maximum of 7209 panels on eachrun, i.e., one week's requirement for onepanel for therefrigerator plant (6980 

### units/week). With a five day, 24 hour work week, this schedule allows 80 hours per weekfor production (10 panels x 8 hoursper pane!), 20 hours for changeovers (10 changeovers x 2 hours average time per changeover), and 20 hours for maintenance, downtime, and otherlosses.

-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 PANELNUMBER 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 CHANGEDWHEN DIMENSIONS CHANGING TOPANELNUMBER 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~:~:':::::::::::::::::::::::** PANELNUMBER 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 CHANGEDWHEN DIMENSIONS CHANGING TOPANELNUMBER 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 entirepanel 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].



### K. Quality Control 

### -Panels coming offthepanel line wouldbe 100% tested to determine whether ornotthe pressure wasbelow an established limit. This test would be doneinthefour second cycle and panels without the proper vacuum wouldbe diverted into a reject bin and an alarm wouldbe sounded. Controls wouldbeintegrated so that the line could be shut down and a control person summoned if

### a panel failed the test limit. This test wouldbedone using a singlehead transducer which generates an electromagnetic impulse which then creates an audible tone. The frequency orpitch ofthe tone indicates the relative vacuum orpressurein thepanel. A high pitch denotes high vacuum and a low pitch represents lowvacuum [14]. This technology is 

### proven, and equipmentwhich is nowbeing used to test vacuum bagged products is commercially available (AppendixF). Further development wouldberequired 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 plantto an outside dumpster daily. A quality control laboratory would perform more accurate vacuum measurements on.an auditbasis. Laboratory equipment wouldbe a different type, which would-allow anentire panel to be

### placed into a vaCl,lum chamber which wouldbepulled down until an equilibrium with theinternal vacuumin thepanel was reached. Optic sensors would detect a slightmovement ofthe outerpanel membrane atthis point. This equipment, which would be accurate withinoneor two Torr, has been producedfor laboratory use [16] (Appendix G). Equipmentwhich would use only a small vacuumhead placed against thepanel but using the sameprinciple is being developed at ORNL [15].

-38- 

### K. Quality Control 

### -Panels coming offthepanel line wouldbe 100% tested to determine whether ornotthe pressure wasbelow an established limit. This test would be doneinthefour second cycle and panels without the proper vacuum wouldbe diverted into a reject bin and an alarm wouldbe sounded. Controls wouldbeintegrated so that the line could be shut down and a control person summoned if

### a panel failed the test limit. This test wouldbedone using a singlehead transducer which generates an electromagnetic impulse which then creates an audible tone. The frequency orpitch ofthe tone indicates the relative vacuum orpressurein thepanel. A high pitch denotes high vacuum and a low pitch represents lowvacuum [14]. This technology is 

### proven, and equipmentwhich is nowbeing used to test vacuum bagged products is commercially available (AppendixF). Further development wouldberequired 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 plantto an outside dumpster daily. A quality control laboratory would perform more accurate vacuum measurements on.an auditbasis. Laboratory equipment wouldbe a different type, which would-allow anentire panel to be

### placed into a vaCl,lum chamber which wouldbepulled down until an equilibrium with theinternal vacuumin thepanel was reached. Optic sensors would detect a slightmovement ofthe outerpanel membrane atthis point. This equipment, which would be accurate withinoneor two Torr, has been producedfor laboratory use [16] (Appendix G). Equipmentwhich would use only a small vacuumhead placed against thepanel but using the sameprinciple 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 plantand 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 andstacked manually. The Adjustoveyor will be mounted on tracks to allow it to travel between shipping docks [10].

39 

### This approach could reducethe cost oflaboratory equipment. Its capability to meet a four second manufacturing cycle and be feasible on a manufacturing line is yet to beestalr lished. Hit shouldprovefeasible, accuracy would probablybe significantly improved over the magneticpulse approach. L. 

### Packaging Panels coming offthe form, fill, and seal lineeveryfour seconds will be automatically stacked into bundles and strapped. Bundles are sized sothey canbehandled manuallyto avoid theneed for skids and fork lift handling. Weights for each sizebundle are shown in Table 8. A cardboard top and bottom cap will beplaced oneachbundle as it

### is stackedby
an automatic stacking machine. Each stack will betransferred automatically into a Cyklop ASM-lA (Appendix H) 

### automatic strapping station whereeach bundlewill be secured with two plastic straps [13]. 

### This equipment, suppliedby Ze]erbach, heat seals the strap anc1

. 

### makes high strength sealjoints

- which are easily removable without tools. The ASM lA is fully automatic and incorporates
a powered belt conveyor and photo-electric controls. Alternativepackaging considered included shrinkbundling and shrink wrap. These alternates were discardedbecause more dunnage wouldbegenerated at the refrigerator plant and the extraprotection was not warranted since thebundles will be 

### handled automatically or manuallywithout fork lifts. Bundles ofpanels will be 

### transported automaticallybybelt conveyors to an Adjustoveyor (Appendix I) 

### which will carry them into a vantrailer where they will be**~oaded** 

### and· stacked manually. TheAdjustoveyor will bemounted on tracks to allow it

### to tra:vel between shipping docks [10].

-39- 

### This approach could reducethe cost oflaboratory equipment. Its capability to meet a four second manufacturing cycle and be feasible on a manufacturing line is yet to beestalr lished. Hit shouldprovefeasible, accuracy would probablybe significantly improved over the magneticpulse approach. L. 

### Packaging Panels coming offthe form, fill, and seal lineeveryfour seconds will be automatically stacked into bundles and strapped. Bundles are sized sothey canbehandled manuallyto avoid theneed for skids and fork lift handling. Weights for each sizebundle are shown in Table 8. A cardboard top and bottom cap will beplaced oneachbundle as it

### is stackedby
an automatic stacking machine. Each stack will betransferred automatically into a Cyklop ASM-lA (Appendix H) 

### automatic strapping station whereeach bundlewill be secured with two plastic straps [13]. 

### This equipment, suppliedby Ze]erbach, heat seals the strap anc1

. 

### makes high strength sealjoints

- which are easily removable without tools. The ASM lA is fully automatic and incorporates
a powered belt conveyor and photo-electric controls. Alternativepackaging considered included shrinkbundling and shrink wrap. These alternates were discardedbecause more dunnage wouldbegenerated at the refrigerator plant and the extraprotection was not warranted since thebundles will be 

### handled automatically or manuallywithout fork lifts. Bundles ofpanels will be 

### transported automaticallybybelt conveyors to an Adjustoveyor (Appendix I) 

### which will carry them into a vantrailer where they will be**~oaded** 

### and· stacked manually. TheAdjustoveyor will bemounted 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 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 thecardboard 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 14,000panels 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- 

### M. Bar coding 

### Eachbundle ofpanels will receive a labelbar code to identify the panel size and dateof manufacture. Label bar coding was selected because ofits superior clarity overink

### jetbar 

### coding when applied to cardboard. Labels will be printed atthe line and placed on the cardboard cap ofeachbundleofpanels automatically. Equipment selected for this applicati,on is 

### the LP 

### A/BOTthermal label printer/ applicator manufacturedbyLord Label Systems,

. Inc. [13] (Appendix

# n.

N. Shipping and Transportation 

### Panels will be shipped to the refrigerator plant onajust-in-timebasis by a captive trailer fleet. Trailers will beDorsey vans (48'L X 8.5'W X 13.5'H) which willbe**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 productionfrom thepanel**plan~** 

### will beloaded directlyinto trailers. A sufficient mim-
. beroftrailers is provided to store the equivalent oftwo shifts ofproduction for therefrigerator plantin addition to having onebeing loaded and an empty standingby. The average dailyrequirement for production at the refrigerator plantwill be about 14,000 panels or 1000 bundles (Table 8). An 

### average ofone 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 dustrespirator is recommended. A Material Safety Data Sheet is shown in Appendix K.

-41- 

### M. Bar coding 

### Eachbundle ofpanels will receive a labelbar code to identify the panel size and dateof manufacture. Label bar coding was selected because ofits superior clarity overink

### jetbar 

### coding when applied to cardboard. Labels will be printed atthe line and placed on the cardboard cap ofeachbundleofpanels automatically. Equipment selected for this applicati,on is 

### the LP 

### A/BOTthermal label printer/ applicator manufacturedbyLord Label Systems,

. Inc. [13] (Appendix

# n.

N. Shipping and Transportation 

### Panels will be shipped to the refrigerator plant onajust-in-timebasis by a captive trailer fleet. Trailers will beDorsey vans (48'L X 8.5'W X 13.5'H) which willbe**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 productionfrom thepanel**plan~** 

### will beloaded directlyinto trailers. A sufficient mim-
. beroftrailers is provided to store the equivalent oftwo shifts ofproduction for therefrigerator plantin addition to having onebeing loaded and an empty standingby. The average dailyrequirement for production at the refrigerator plantwill be about 14,000 panels or 1000 bundles (Table 8). An 

### average ofone 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 dustrespirator 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. I**~** N I 

# Table 9 48 Foot Trailer Loading

BUNDlE WAD / BUNDLES/DAY 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/DAY 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 andwould 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 assemblylines would average running VIP models only six shifts per week, this is a very conservative inventory plan. 

### PANEL INSTALLATION INTO REFRIGERATORS This 

### section describes the facility modifications and equipmentneeded at the refrigerator planttoreceive, handle, and install 3,000,000 VIPs peryear into three hundred thousand.21 or 24 0lbicfoot refrigerators. Modifications arebased on generic plantassumptions and wouldbe 

### different for an actual plant and varyfrom oneplant 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 plantequipment and incremental operating costs A. In plant receiving, material handling, and storage 

### Panels would bereceived at two new docks in a new 9,774 square foot building addition. (Figure 13) Panels wouldbe 

### unloaded using an extendable adjustoveyor inreverse ofthe 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 ofthe 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 thebundle to that tier. A second reader would divert the bundleinto the properflow-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 enoughpanels to allow therefrigerator assembly line to run two continuous shifts ofmodels 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 inventoryplan. -43- 

### PANEL INSTALLATION INTO REFRIGERATORS This 

### section describes the facility modifications and equipmentneeded at the refrigerator planttoreceive, handle, and install 3,000,000 VIPs peryear into three hundred thousand.21 or 24 0lbicfoot refrigerators. Modifications arebased on generic plantassumptions and wouldbe 

### different for an actual plant and varyfrom oneplant 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 plantequipment and incremental operating costs A. In plant receiving, material handling, and storage 

### Panels would bereceived at two new docks in a new 9,774 square foot building addition. (Figure 13) Panels wouldbe 

### unloaded using an extendable adjustoveyor inreverse ofthe 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 ofthe 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 thebundle to that tier. A second reader would divert the bundleinto the properflow-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 enoughpanels to allow therefrigerator assembly line to run two continuous shifts ofmodels 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 inventoryplan. -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 

## 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 rai 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 rai 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 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 1Both 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]. BOth the sortation conveyor and theflow-through racks would be center drive belt conveyors controlledby

# a common controller and integrated with laserbar codereaders [11]. Three hourlypaid material handlers, oneach oftwo shifts, would unload the panels from thevan trailers onto the adjustoveyor and from the flow-through racks onto a continuous conveyorfor delivery to thepre-foam areas. 

### B. Delivery to assembly areas Fouroptions were considered to move thepanels 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 dunnageremoval problems. They would also add to product cost. Belt conveyorwould offer the possibility offeeding individual panels to specific stations on eachlir:e by the use ofbar coding. 

### Pant:'; could be automati(:.illy fed into magazines for robotic pick up, eliminating the need for manual material transfer. Iiowever,it wouldbe 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 probablybe installed in most plants even though considerable rearrangement ofexisting facilities may be required. Fifteen hundred feet ofenclosed track conveyor with 250 four tray hangers on six foot centers wouldbe installed. The conveyor would run about 18 feet per minute, whichwould provide as many as 120 panels perminute to anyone station. The case line would require only 18 panels perminute. This system, withrequired drives and other auxiliary equipment, was estimated by Unibuilt, a division ofJervis B. Webb Company (Appendix L) to cost approximately $110 per foot, installed [12]. -46- BOth the sortation conveyor and theflow-through racks would be center drive belt conveyors controlledby

# a common controller and integrated with laserbar codereaders [11]. Three hourlypaid material handlers, oneach oftwo shifts, would unload the panels from thevan trailers onto the adjustoveyor and from the flow-through racks onto a continuous conveyorfor delivery to thepre-foam areas. 

### B. Delivery to assembly areas Fouroptions were considered to move thepanels 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 dunnageremoval problems. They would also add to product cost. Belt conveyorwould offer the possibility offeeding individual panels to specific stations on eachlir:e by the use ofbar coding. 

### Pant:'; could be automati(:.illy fed into magazines for robotic pick up, eliminating the need for manual material transfer. Iiowever,it wouldbe 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 probablybe installed in most plants even though considerable rearrangement ofexisting facilities may be required. Fifteen hundred feet ofenclosed track conveyor with 250 four tray hangers on six foot centers wouldbe installed. The conveyor would run about 18 feet per minute, whichwould provide as many as 120 panels perminute to anyone station. The case line would require only 18 panels perminute. This system, withrequired drives and other auxiliary equipment, was estimated by Unibuilt, a division ofJervis 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 toinstall 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-aertionOn 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. It

### was assumed that 2000 squarefeet offloor space would have tobe 

### added, either as a mezzanine or a building appendage, to offset the space consumed byrearrangement to install this system. Actual rearrangement requirements and costs would have tobe

### adjusted for a givenplant and would depend onthatplant's construction, layout, and available floor space. 

### This conveyor would deliver panels to casepre-foam, door·pre-foam, and liner pre-foam,· and have storage capacity for abouteighthours ofproduction. Panels will be

### unloaded manually from the monorail conveyor, the strap will be 

### removed, and individualpanels will be placed on the appropriate queuing conveyor ateach case line, liner line, or door line station. Two material handlers per shift will service the case and liner lines, and one material handlerper 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 bepositioned via shotpins or some otherpositioning 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 spraypatterns needed tohold the six VIPs to be

### placed at the succeeding stations. Both robots will be supplied from a common Nordson hot melt unit (AppendixN) [5]. The hot melt material cost is included @$O.08 / square foot. Threemore GMF 5-500 robots will beused to place six panels into the case as showninFigure 14. Each robot will place two panels.

. 

### Hotmelt and panel placement stations wouldbe 

### added between the existing case seal stations and the foam release stations, requiring someline rearrangement. The existing foam release stations wouldbe converted to panel adhesive application and two new foam release stations would be added aIter panel insertion.

-47- It

### was assumed that 2000 squarefeet offloor space would have tobe 

### added, either as a mezzanine or a building appendage, to offset the space consumed byrearrangement to install this system. Actual rearrangement requirements and costs would have tobe

### adjusted for a givenplant and would depend onthatplant's construction, layout, and available floor space. 

### This conveyor would deliver panels to casepre-foam, door·pre-foam, and liner pre-foam,· and have storage capacity for abouteighthours ofproduction. Panels will be

### unloaded manually from the monorail conveyor, the strap will be 

### removed, and individualpanels will be placed on the appropriate queuing conveyor ateach case line, liner line, or door line station. Two material handlers per shift will service the case and liner lines, and one material handlerper 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 bepositioned via shotpins or some otherpositioning 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 spraypatterns needed tohold the six VIPs to be

### placed at the succeeding stations. Both robots will be supplied from a common Nordson hot melt unit (AppendixN) [5]. The hot melt material cost is included @$O.08 / square foot. Threemore GMF 5-500 robots will beused to place six panels into the case as showninFigure 14. Each robot will place two panels.

. 

### Hotmelt and panel placement stations wouldbe 

### added between the existing case seal stations and the foam release stations, requiring someline rearrangement. The existing foam release stations wouldbe 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 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 Dperntors 

# ® Added Material HQnd!l'!"s 

### :/Shift 3

### ~ 

## I 6 

# t®_J-- C4ses Frol'l 

### F

QbrlcQtion



## .. 

# 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 Dperntors 

# ® Added Material HQnd!l'!"s 

### :/Shift

### ~ 

## I 6 

# t®_J C4ses Frol'l 

### F

QbrlcQtion



## .. 

# r----,

# :~~I

__I

# ~I~I L
___ --..1

7On 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 

### On the liner pre-foam line, one GMF 5-500 will apply adhesive to thefresh food back panel and plaCe thepanel onthe liner back (Figure 14). A third Nordson hotmeltunitwould**~** 

### used for this robot. Two GMF 5-500 robots 

### willberequired onthe door pre-foam line. Each ofthese robots 

### will apply adhesiveinside the doors andplace oneor two panels into the doors. The robots will place oneor twopanels on alternate cycles to meetthe station cycle time. Figure 15 shows· the modified layout ofthe door pre-foam area. Some rearrangement also will be required on this line. A commonNordsonhot melt unitwouldfeed both ofthese robots. It

### was assumed that4000 squarefeet ofmezzanine orbuilding appendage would have to be added to accommodate rearrangementrequired 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 thatplant's layout and available floor space. A budgetestimate ofthe cost for these stations, including eightrobots, end effectors, panel and case/liner/ door positioning stations and hotmelt units was developed by Remtec, Inc. and is showninAppendix 

### 0 [7]. Remtecs cost estimates for the hot melt andpre-foam
. stations were deemed to beconsiderably 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 vacuumbefore it

### is placed into the case, door, or onto the liner. This will be 

### done using a TapTone magnetic impulse unit as partofthe robot end effector or as an independentunitat the end ofthe panel queues [14].

-49- 

### On the liner pre-foam line, one GMF 5-500 will apply adhesive to thefresh food back panel and plaCe thepanel onthe liner back (Figure 14). A third Nordson hotmeltunitwould**~** 

### used for this robot. Two GMF 5-500 robots 

### willberequired onthe door pre-foam line. Each ofthese robots 

### will apply adhesiveinside the doors andplace oneor two panels into the doors. The robots will place oneor twopanels on alternate cycles to meetthe station cycle time. Figure 15 shows· the modified layout ofthe door pre-foam area. Some rearrangement also will be required on this line. A commonNordsonhot melt unitwouldfeed both ofthese robots. It

### was assumed that4000 squarefeet ofmezzanine orbuilding appendage would have to be added to accommodate rearrangementrequired 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 thatplant's layout and available floor space. A budgetestimate ofthe cost for these stations, including eightrobots, end effectors, panel and case/liner/ door positioning stations and hotmelt units was developed by Remtec, Inc. and is showninAppendix 

### 0 [7]. Remtecs cost estimates for the hot melt andpre-foam
. stations were deemed to beconsiderably 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 vacuumbefore it

### is placed into the case, door, or onto the liner. This will be 

### done using a TapTone magnetic impulse unit as partofthe robot end effector or as an independentunitat the end ofthe 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 

## Door Delivery 

### fron Point



# CD

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# Figure 15 \\ 

# Door Pre-Foam Area with VIPs

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### Asseri>ly**L-~~~~~r** 

# - - - - - --' ) 1 

# Door Foan



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### . I I I I I I 

## JJ**~~=rr~~=,~~~nm~** 

## - - - - - --/



# ® 5

-50- 

### 1. Freezer Door 2. Fresh Food Ibr 

### 3. lood Foon. 

### (mveyor 4. tillood Foon 

### Conveyor 5. PoneI Del 

### ivery 

### Conveyor 6. 

### Attesive 

## Awl icotion & 

### PoneI Plocenent 

### Robots 

# CD fblUl I

### ~Qtors 

# ® Adred fbteriol ItlOOler 

## Door Delivery 

### fron Point



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# 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 

## JJ**~~il_+_------/ ~~r**  

## - - - -._-

5 1. Freezer Door 2. Fresh Food Ibr 

### 3. lood Foon. 

### (mveyor 4. tillood Foon 

### Conveyor 5. PoneI Del 

### ivery 

### Conveyor 6. 

### Attesive 

## Awl icotion & 

### PoneI 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. 

### E. Foaming ar.ound VIPs 

### After VIPs arepositioned inthe cases and doors and on the liner back, units will enter the respective fOaIl) systems where the VIPs will befoamed inplace. Both the dimensions and location oftheVIPs will affect 

### the foam flow path and, therefore the quality ofthe fill. 

### Panel sizes usedinthis studywere developed with this consideration. Considerable developmentofVIP sizes and foam chemical compositions and distribution will berequired prior to implementation ofa production system. Compatibility between foam chemicals and barrier envelopes could also be an issue which mayrequire further development. F. Refrigerator plant equipment and Incremental operating cost 

### Equipmentrequired for the refrigerator plantis summarized inTable 11, along with the associated costs. A 25% contingency is included. Additional personnel and incrementciI operating costs are summarized inTable 12.

-51- 

### E. Foaming ar.ound VIPs 

### After VIPs arepositioned inthe cases and doors and on the liner back, units will enter the respective fOaIl) systems where the VIPs will befoamed inplace. Both the dimensions and location oftheVIPs will affect 

### the foam flow path and, therefore the quality ofthe fill. 

### Panel sizes usedinthis studywere developed with this consideration. Considerable developmentofVIP sizes and foam chemical compositions and distribution will berequired prior to implementation ofa production system. Compatibility between foam chemicals and barrier envelopes could also be an issue which mayrequire further development. F. Refrigerator plant equipment and Incremental operating cost 

### Equipmentrequired for the refrigerator plantis summarized inTable 11, along with the associated costs. A 25% contingency is included. Additional personnel and incrementciI operating costs are summarized inTable 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 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 NSTALLATIOI\

$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 GLAPA1 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 

## 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% ofthe 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 CostsProduct 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 

### TOTAL PROGRAM AND PRODUCT COST FOR 

### VAC,UUM INSULATION PANEL PRODUCTION AND INSTALLATION Program Cost Program,costs are non-recurring costs to plan and implementthe project. These costs indudeinvestment to purchase and install facilities and equipment, expensefor tooling, and anyrearrangement expenserequired in'theexisting refrigerator plant. Historic ratios ofinvestment and expense for similar projects were used. Program costs also include manpower to plan and implementtheproject, and start-up cost incurred inboththepanel plant and therefrigerator plant. Seventy-five thousand dollars petmanyear was used for manpower cost. Start-up costs for the panel plantincludes 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% 

### ofthe silica can be reclaimed from panels produced during development. An 

### estimate ofstart-up cost at therefrigerator plant also is included. A summaryofthe program cost is shownin Table 13. 

### Product Costs Product costincludes all direct material and direct labor includedin or added to the product or its packaging and shipping and associated overhead cost. Overhead includes items such as overtimepremium, night shiftbonus, rework, scrap, and hourlyemployeebenefits (medical insurance, vacation and holiday pay, etc.). Other operating costs include utilities, trashremoval, taxes, insurance, office expenses, security, safety, etc. No added warranty costs areincluded although there is 

### likely to be additional warranty cost as a result ofthe incorporation ofVIPs. Some amount ofwarranty reservE;?S should be

### planned for service calls whlch mayresult 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 implementthe project. These costs indudeinvestment to purchase and install facilities and equipment, expensefor tooling, and anyrearrangement expenserequired in'theexisting refrigerator plant. Historic ratios ofinvestment and expense for similar projects were used. Program costs also include manpower to plan and implementtheproject, and start-up cost incurred inboththepanel plant and therefrigerator plant. Seventy-five thousand dollars petmanyear was used for manpower cost. Start-up costs for the panel plantincludes 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% 

### ofthe silica can be reclaimed from panels produced during development. An 

### estimate ofstart-up cost at therefrigerator plant also is included. A summaryofthe program cost is shownin Table 13. 

### Product Costs Product costincludes all direct material and direct labor includedin or added to the product or its packaging and shipping and associated overhead cost. Overhead includes items such as overtimepremium, night shiftbonus, rework, scrap, and hourlyemployeebenefits (medical insurance, vacation and holiday pay, etc.). Other operating costs include utilities, trashremoval, taxes, insurance, office expenses, security, safety, etc. No added warranty costs areincluded although there is 

### likely to be additional warranty cost as a result ofthe incorporation ofVIPs. Some amount ofwarranty reservE;?S should be

### planned for service calls whlch mayresult 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 ITEM

I 

### 81 Panel Plant I RefrigeratorPlant 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 RefrigeratorPlant 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 $23.6Table 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 resultantcost 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 

### Table 14 summarizes the added product cost to add 29 board feet ofVIPs to 21 or24 cubic 'foot refrigerators being produced at a volume of300,000 per year. Some appliancemanufacturers mayhave designs with condenser loops to heat the mullion
or crossbraces in the doors. These partsmayneed to beretooled to removeinterference with VIPs. Cost to retool these parts and the added productcost, if

### theyrequire additional material, is not included in these summaries. Sensitivity Analysis 

### To test.the sensitivity ofcosts perboard foot ofVIPs, a sensitivity analysis was madeby varying certain elements ofproduct cost and program cost and recalculating theresultant cost perboard foot. In

### order toincludeprogram cost in this analysis, these cost were amortized

### over a five year period or43.5 millionboard feet ofVIPs (300,000 refrigerators/year x 29 board feet ofVIPs/refrigerator x five years). This analysis is shown in Table 15. Project Schedule and Start-Up 

### After feasibility is established and funds are appropriated, itwould take a.bout two andone halfyears tobeinproduction as depicted in Figure 16. Since productredesign is 

### limited to the addition ofVIPs to existing refrigerators, the longest tasks are equipmentprocurement, installation, and development. Some minor modifications to existing refrigerator**par~** 

### tooling maybe necessary and considerableproductevaluation wouldberequired. The panel plant wouldbe staffed with partial crews six months prior to start-up. These would includethe plantmanager, quality control manager, material control manager, financial manager, oneforeman, one skilled maintenanceperson, onecontrol person, and
one material handler. The full plantcrewwould be added two months priorto 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 ofVIPs to 21 or24 cubic 'foot refrigerators being produced at a volume of300,000 per year. Some appliancemanufacturers mayhave designs with condenser loops to heat the mullion
or crossbraces in the doors. These partsmayneed to beretooled to removeinterference with VIPs. Cost to retool these parts and the added productcost, if

### theyrequire additional material, is not included in these summaries. Sensitivity Analysis 

### To test.the sensitivity ofcosts perboard foot ofVIPs, a sensitivity analysis was madeby varying certain elements ofproduct cost and program cost and recalculating theresultant cost perboard foot. In

### order toincludeprogram cost in this analysis, these cost were amortized

### over a five year period or43.5 millionboard feet ofVIPs (300,000 refrigerators/year x 29 board feet ofVIPs/refrigerator x five years). This analysis is shown in Table 15. Project Schedule and Start-Up 

### After feasibility is established and funds are appropriated, itwould take a.bout two andone halfyears tobeinproduction as depicted in Figure 16. Since productredesign is 

### limited to the addition ofVIPs to existing refrigerators, the longest tasks are equipmentprocurement, installation, and development. Some minor modifications to existing refrigerator**par~** 

### tooling maybe necessary and considerableproductevaluation wouldberequired. The panel plant wouldbe staffed with partial crews six months prior to start-up. These would includethe plantmanager, quality control manager, material control manager, financial manager, oneforeman, one skilled maintenanceperson, onecontrol person, and
one material handler. The full plantcrewwould be added two months priorto 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) 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 PorousBag (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 PorousBag (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 ':::::::::.::

....:;:;::::;. 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 existingbuilding at $25/squre foot $0.48 Building at0$ costfrom 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 yearsor43.5MM 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 existingbuilding at $25/squre foot $0.48 Building at0$ costfrom 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 yearsor43.5MM 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

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 II1IIform, fill, and seal equipment felt this was a conservative estimate, considering the development period planned [181.

60 

### form, fill, and seal equipmentfelt this was a conservativeestimate, considering thedevelQpmentperiodplanned [18].

-60- 

### form, fill, and seal equipmentfelt this was a conservativeestimate, considering thedevelQpmentperiodplanned [18].

-60-

## Figure 17 Startup Curve - VIP Plant

100%
% OF SCHEDULE 

# ---------- -------------------------------------------.----------------------------------------------------------x---------------------------- x x x x

x 50% x

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## Figure 17 Startup Curve - VIP PI-ant·

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# 16 18

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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 onsmaller 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. 

### ScenariosFour 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. 

### THICK WALL ALTERNATIVE Another approach to increasing the thermal ;resistance ofthe refrigerator cabinetis to increase thickness by adding additional non-CFC foam insulation. This section estimates the manufacturing cost impact ofincreasing insulation. Since this scenario is morelikely on smaller refrigerators «21') an 18' refrigerator, whichrepresents a major share ofthe market, was used for this analysis. Facility Assumptions 

### A facility producing five hundred thousand 18 cubic foot refrigerators per year was assumed. Multiple models inmultiple sizes would further complicate this analysis and would definitely affect the cost estimates. Scenarios 

### Four increases in insulation thickiless from the currentrepresentative 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 ofthe unit to increase. 

### ThiS case maintained the exact internaldimensions as well as the width ofthefront flange.

• :Case "H" allowed only the height ofthe unit to change to accommodate the change in thickness, and reconfigured the inside to maintain 18 cubic feet ofstorage space. For example, when 1" 

### ofinsulation is added to the top, bottom, back, doors, and both sides, the new height mustbecome 74.5" 

### since the width is held at 29.5" 

### and the depth at 31.5" 

### (Table 16). Theliner wouldbelong and narrow.

-62- 

### THICK WALL ALTERNATIVE Another approach to increasing the thermal ;resistance ofthe refrigerator cabinetis to increase thickness by adding additional non-CFC foam insulation. This section estimates the manufacturing cost impact ofincreasing insulation. Since this scenario is morelikely on smaller refrigerators «21') an 18' refrigerator, whichrepresents a major share ofthe market, was used for this analysis. Facility Assumptions 

### A facility producing five hundred thousand 18 cubic foot refrigerators per year was assumed. Multiple models inmultiple sizes would further complicate this analysis and would definitely affect the cost estimates. Scenarios 

### Four increases in insulation thickiless from the currentrepresentative 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 ofthe unit to increase. 

### ThiS case maintained the exact internaldimensions as well as the width ofthefront flange.

• :Case "H" allowed only the height ofthe unit to change to accommodate the change in thickness, and reconfigured the inside to maintain 18 cubic feet ofstorage space. For example, when 1" 

### ofinsulation is added to the top, bottom, back, doors, and both sides, the new height mustbecome 74.5" 

### since the width is held at 29.5" 

### and the depth at 31.5" 

### (Table 16). Theliner wouldbelong 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. 

### • Case 'W" 

### allowed only the width ofthe unit to change and maintained the internal volume.

• Case ''D''allowedonly the depth ofthe unit to change andmaintained the internal volume. All cases except Case "All" change theinternal dimensions ofthe refrigerator. Typically, a given size box is used for numerous models which then have different internal parts or features to upgradethe 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 depthbeyond the current 27.75" 

### (w/ 0 

### door) prohibits entrythrough 28" 

### doors and, reduces the market served; shallowness is an important consumer feature and any increase in depth makes thebox 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 byhaving 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 ofa top mountfreezer is an important consumer consideration, whichputs 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 maypresentprocess 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 ofthe unit to change and maintained the internal volume.

• Case ''D''allowedonly the depth ofthe unit to change andmaintained the internal volume. All cases except Case "All" change theinternal dimensions ofthe refrigerator. Typically, a given size box is used for numerous models which then have different internal parts or features to upgradethe 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 depthbeyond the current 27.75" 

### (w/ 0 

### door) prohibits entrythrough 28" 

### doors and, reduces the market served; shallowness is an important consumer feature and any increase in depth makes thebox 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 byhaving 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 ofa top mountfreezer is an important consumer consideration, whichputs 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 maypresentprocess 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 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 withrefrigerator doors removed
.

.... Exceeds FHA specificationdimensions
.

...... Exceeds FHA dimensions with 12" cabinetunder 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 notfit through 28" door withrefrigerator doors removed
.

.... Exceeds FHA specificationdimensions
.

...... Exceeds FHA dimensions with 12" cabinetunder 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 cuberail 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 levelswere reduced in lieu of adding warehouse space, service to dealers would be adversely affected, resulting in lost sales. 

### Table 16 is a matrix ofdimensions for each'scenario. Some combination ofthe above cases maybe 

### thebest solution when all factors are considered. Cost 

### Analysis'. 

### A cost impact analysis was completed for all four levels ofthickness increase, using Case 

### "All". A retooling matrix was done for theother three cases but cost analyses werenot

. completed. All foam insulation costs were based on CFC 11. Alternativeblowing agents

would very likely make these changes more expensive, at least initially.

• Variable manufacturing cost increase-An analysis ofthe required changes was completed for each case and the percentincrease 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 ofthe additional foam insulation, which accounted for well over halfofthe 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 ofrefrigerators per load was calculated for each
. thickness increase in case "All" and compared tothe existing load size. Using an estimated average mileage to a distribution center, an average cost per truck and rail
car and an estimated percentage oftruck versus rail, a transportation cost increaseper 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 wouldbe 

### $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 ofdimensions for each'scenario. Some combination ofthe above cases maybe 

### thebest solution when all factors are considered. Cost 

### Analysis'. 

### A cost impact analysis was completed for all four levels ofthickness increase, using Case 

### "All". A retooling matrix was done for theother three cases but cost analyses werenot

. completed. All foam insulation costs were based on CFC 11. Alternativeblowing agents

would very likely make these changes more expensive, at least initially.

• Variable manufacturing cost increase-An analysis ofthe required changes was completed for each case and the percentincrease 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 ofthe additional foam insulation, which accounted for well over halfofthe 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 ofrefrigerators per load was calculated for each
. thickness increase in case "All" and compared tothe existing load size. Using an estimated average mileage to a distribution center, an average cost per truck and rail
car and an estimated percentage oftruck versus rail, a transportation cost increaseper 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 wouldbe 

### $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 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.



### • 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 ofthe four levels ofthickness change in case 1/ 

### All". Increases in foam demold time, causedby 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 anestimate ofthis quality. A matrix ofrequired changes is showninTable 18. Investment costs are for capital expenditures and can be depreciated over several years. Tooling and other expenses mustbe written offas they areincurred. The same is true for manpower and start up cost.

• Manpower cost-Designengineering, manufacturing engineering, quality assurance, and other man years were estimated to implement each level ofchange in case "All". Seventy-five thousand dollars perman year was used to calculate manpower cost.

• Startup costs-Costs to build development models and run trial runs in the plant, plus the cost oflost units while each change is implemented, were estimated. Product cost, including transportation, for thicker foam insulation ranges from $12.28 

### for one-halfinch to $37.65 for twoinches. 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% ofthenumbers above. A summaryof all 

### cost impactelements is shownin Table 19. A sensitivity analysis for product cost increase/unit when the cost offoam material is increased is shownin Table 20. 

### The cost impactofincreasing 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 ofthe four levels ofthickness change in case 1/ 

### All". Increases in foam demold time, causedby 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 anestimate ofthis quality. A matrix ofrequired changes is showninTable 18. Investment costs are for capital expenditures and can be depreciated over several years. Tooling and other expenses mustbe written offas they areincurred. The same is true for manpower and start up cost.

• Manpower cost-Designengineering, manufacturing engineering, quality assurance, and other man years were estimated to implement each level ofchange in case "All". Seventy-five thousand dollars perman year was used to calculate manpower cost.

• Startup costs-Costs to build development models and run trial runs in the plant, plus the cost oflost units while each change is implemented, were estimated. Product cost, including transportation, for thicker foam insulation ranges from $12.28 

### for one-halfinch to $37.65 for twoinches. 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% ofthenumbers above. A summaryof all 

### cost impactelements is shownin Table 19. A sensitivity analysis for product cost increase/unit when the cost offoam material is increased is shownin Table 20. 

### The cost impactofincreasing 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 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 shelftracks 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 shelftracks 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 I

# ncrease 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. 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 orreplacement (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 orreplacement (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 

## 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



# C

# ost 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. 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. Equipmentmodification or replacement (ifdeemed necessary) to accomodate larger tools notincluded. 2. Margin loss due to lost sales/reduced market notincluded
.



## .

# . 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. Equipmentmodification or replacement (ifdeemed necessary) to accomodate larger tools notincluded. 2. Margin loss due to lost sales/reduced market notincluded
.



## .

# . 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 andimplement, 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. Implementation Timetable 

### Changes ofthis magnitude woud take atleast one and one-halfto two years to design and implement, depending on the manufacturer's model mix andproduction equipmentflexibility. The major time elements wouldbeproductredesign, tool and equipmentredesign and procurement, and prototypeevaluation.

-72- Implementation Timetable 

### Changes ofthis magnitude woud take atleast one and one-halfto two years to design and implement, depending on the manufacturer's model mix andproduction equipmentflexibility. The major time elements wouldbeproductredesign, tool and equipmentredesign and procurement, and prototypeevaluation.

-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 ofone inch of foam produces the same energy reduction as the inclusion of the vacuum panels. Similar results would be expected for the larger units. 

### ENERGY ANALYSIS The total energy consumption of 18 cubic**~oot** 

### refrigerators with thicker foam insulation·or vacuuminsulation was modeled using the EPA Refrigerator Analysis program [21]. A
.. IItypkal" 1991 refrigerator was used as thebaseline for the analyses. Someofthe dimensions and characteristics ofthebaseline unit, i.e. the unit without thicker walls orvacuum insulation, are shown in Table 22. Additional details can be

### found inthe description of Model D given-in reference 22. Thicker foam calculations weremade onthe 18 cubic foot unit with 0.5, 1, 1.5 or 2 inches offoam added on all ofthe exterior surfaces, including doors. Refrigerators which had 18,21 or 24 cubic feet total volumes and contained vacuumpanels having a resistivity of25 h ft2 

### OF / (Btu inch) and the dimensions shown inTable 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 ofthe 18 to make a 21 cubic foot unit and 2 inches added to the 18 to make it into a 24. Calculated energy consumption perday decreasedby as much as 24 percentfor adding two inches offoam to the exterior ofthe 18 cubic foot unit, see Table 23. Similar energy. reductions would occur for adding insulation to the exterior ofthe 21 and 24 cubic foot units.

" 

### Incorporating the vacuum panels into the refrigerator produced an average 16 percent energyreduction, with the 18 cubic foot unit having a slightlybetter improvement and the 24 slightly worse. Since panels sized for the 18 were modeled in all three units, the pariels cover less ofthe area in the larger units and the energy reduction decreases accordingly. Finally, comparison ofthe calculations for the 18 cubic foot unit indicates that addition of
one inch offoam produces the same energy red.uction as the inclusion ofthe vacuumpanels. Similar results wouldbeexpected for the larger units.

-73- 

### ENERGY ANALYSIS The total energy consumption of 18 cubic**~oot** 

### refrigerators with thicker foam insulation·or vacuuminsulation was modeled using the EPA Refrigerator Analysis program [21]. A
.. IItypkal" 1991 refrigerator was used as thebaseline for the analyses. Someofthe dimensions and characteristics ofthebaseline unit, i.e. the unit without thicker walls orvacuum insulation, are shown in Table 22. Additional details can be

### found inthe description of Model D given-in reference 22. Thicker foam calculations weremade onthe 18 cubic foot unit with 0.5, 1, 1.5 or 2 inches offoam added on all ofthe exterior surfaces, including doors. Refrigerators which had 18,21 or 24 cubic feet total volumes and contained vacuumpanels having a resistivity of25 h ft2 

### OF / (Btu inch) and the dimensions shown inTable 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 ofthe 18 to make a 21 cubic foot unit and 2 inches added to the 18 to make it into a 24. Calculated energy consumption perday decreasedby as much as 24 percentfor adding two inches offoam to the exterior ofthe 18 cubic foot unit, see Table 23. Similar energy. reductions would occur for adding insulation to the exterior ofthe 21 and 24 cubic foot units.

" 

### Incorporating the vacuum panels into the refrigerator produced an average 16 percent energyreduction, with the 18 cubic foot unit having a slightlybetter improvement and the 24 slightly worse. Since panels sized for the 18 were modeled in all three units, the pariels cover less ofthe area in the larger units and the energy reduction decreases accordingly. Finally, comparison ofthe calculations for the 18 cubic foot unit indicates that addition of
one inch offoam produces the same energy red.uction as the inclusion ofthe vacuumpanels. Similar results wouldbeexpected 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 

## Table 22 Baseline 1991 Refrigerator

Internal Volume lS.0ft3 Recip. Compressor 5.3EER Refrigerant CFC12 .INSULATION r-value 7.9 h ft2 °F/(Btu in) Freezer walls 2.375 inches Freezer top 2.375 inches Freezerdoor 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.0ft3 Recip. Compressor 5.3EER Refrigerant CFC12 .INSULATION r-value 7.9 h ft2 °F/(Btu in) Freezer walls 2.375 inches Freezer top 2.375 inches Freezerdoor 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) 

## 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 vacuumpackaging) 3. Mateer-Burt Co. Inc., Wayne, Pa., Diehl Mateer (auger fillers) 4. North America Silica, Ridgefield Park, N. J. (as of3/1/92,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/StewartGlapat, 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., ChuckAndres, Gary Wei! (strapping and bar coding equipment and strap and cardboard cap material) 14. TapTone, NorthFalmouth, 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 vacuumpackaging) 3. Mateer-Burt Co. Inc., Wayne, Pa., Diehl Mateer (auger fillers) 4. North America Silica, Ridgefield Park, N. J. (as of3/1/92,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/StewartGlapat, 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., ChuckAndres, Gary Wei! (strapping and bar coding equipment and strap and cardboard cap material) 14. TapTone, NorthFalmouth, 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) 

### 16. Babcock/Wllcox, Lynchburg, Va., Kenneth Camplin (vacuum test equipment) 17. PeabodyTeeTank, Parsons Kansas, Sharon Long (silos) 18. JFG Coffee Co., Knoxville, Tn., Brian Morse (user ofform, fill, and seal equipment and
vacuumpackaging) 19. WorldWide Equip./Kenworth, Lexington, Ky., 

### GregMills (Kenworth truckS and Dorsey trailers) 20. PortmanMaterial Handling/Clark, Lexington, Ky., Thomas DeLuca (Clark fork trucks) 21. Merriam, R. L. 

### 1992. ERA, TheEPA Refrigerator Analysis Model and ComputerProgram. in press, U.S. Environmental Protection Agency, Washington, D.C. 22. Environmental Protection Agency. 1992. Multiple Pathways to Super Efficient Refrigerators, inpress, U.S. Environmental Protection Agency, Washington, D.C. 23. SnowFiltration,Cincinnati, Ohio, DanWenke (pourous bagmaterial)

-76- 

### 16. Babcock/Wllcox, Lynchburg, Va., Kenneth Camplin (vacuum test equipment) 17. PeabodyTeeTank, Parsons Kansas, Sharon Long (silos) 18. JFG Coffee Co., Knoxville, Tn., Brian Morse (user ofform, fill, and seal equipment and
vacuumpackaging) 19. WorldWide Equip./Kenworth, Lexington, Ky., 

### GregMills (Kenworth truckS and Dorsey trailers) 20. PortmanMaterial Handling/Clark, Lexington, Ky., Thomas DeLuca (Clark fork trucks) 21. Merriam, R. L. 

### 1992. ERA, TheEPA Refrigerator Analysis Model and ComputerProgram. in press, U.S. Environmental Protection Agency, Washington, D.C. 22. Environmental Protection Agency. 1992. Multiple Pathways to Super Efficient Refrigerators, inpress, U.S. Environmental Protection Agency, Washington, D.C. 23. SnowFiltration,Cincinnati, Ohio, DanWenke (pourous bagmaterial)

-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 

### 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 

### Strappingmachine I 

### Adjustoveyor 

## J Bar coding unit K 

### Material safety data sheet -FK500LS L**U~built** 

### enclosed track conveyor M GMF 5-500 robot N Nordsonhotmelt equipment 0 

### Remtec estimate ofadhesive 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 

### Strappingmachine I 

### Adjustoveyor 

## J Bar coding unit K 

### Material safety data sheet -FK500LS L**U~built** 

### enclosed track conveyor M GMF 5-500 robot N Nordsonhotmelt equipment 0 

### Remtec estimate ofadhesive 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 for2 hours @ 105 deg-C 1 (2) based on material ignitedfor 2 hours Ca) 1000 deg-C ("') currentlynot 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 

### 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 SURFACEAREA (MlCROMERmCS) arm/g MOISTURE (1) (DIN53198) pH-VALUE**(5~,** DIN53200) TAPPED DENSITY (DIN53194) AVERAGEAGGLOMERATESIZE (COULTER) DBPABSORPTION(1) gl100g SIUCONDIOXIDE (2) S04 (2) Al203(2) Fe20J (2) (1) basedon material driedfor2 hours @ 105**~** I (2) basedon materialignitedfor2 hours @ 1000 deg-C (""") currentlynota standardmethod 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 results. 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 SURFACEAREA (MlCROMERmCS) arm/g MOISTURE (1) (DIN53198) pH-VALUE**(5~,** DIN53200) TAPPED DENSITY (DIN53194) AVERAGEAGGLOMERATESIZE (COULTER) DBPABSORPTION(1) gl100g SIUCONDIOXIDE (2) S04 (2) Al203(2) Fe20J (2) (1) basedon material driedfor2 hours @ 105**~** I (2) basedon materialignitedfor2 hours @ 1000 deg-C (""") currentlynota standardmethod 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 results. 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. 

## 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 

## 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-AAPPENDIX C 1 of 3 AFFENDIX C 1 of 3APPENDIX 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 forboth 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. 

# • • 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 yourtank requiremenla ca': for a large multiple tank installation or onlyone 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 ofweather 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 yourguarantee. 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 yourtank requiremenla ca': for a large multiple tank installation or onlyone 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 ofweather 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 yourguarantee. 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. 

### 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 TeeTank'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 TeeTank'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 3APPENDIX 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. 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-2

# 6

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 

# fre

# s-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. 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-plyLaminates -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-plyLaminates -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 ^ tvAPPENDIX 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. MODEL DESCRIPTION 

# IPV2000-CM 

### i TRACKEAlConveyor Mount 1 PV2000-SA TRACKEAlStand Alone 

# I

SQ-l PLASTIC BOTTLE INSPECTOR 4014-PF 

# IPUFFER 

# I 4024-1 

# ILOW SPEED TAPTONE
4044-1 

### ! HIGH SPEED TAPTONE , 

# I

4044-CB AUTOMATIC LINE TAPTONE FOR VACUUM TESTING FOIL PACKAGES 40S4-2-CB I AUTOMATIC CASE 

# ITAPTONE FOR VACUUM

TESTING FOIL PACKAGES 40S4-4 AUTOMATIC CASE TAPTONE i

4104-4 AUTOMATIC SWELLED CAN DETECTOR 4049-4A 

### I CASE SCANNER 1 I 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 orjar lines where headspace is available and speeds do not exceed 3S0 cpm. Can orjar 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 

# IPV2000-CM 

### i TRACKEAlConveyor Mount 1 PV2000-SA 

# ITRACKEAlStand Alone 

# I

SQ-l PLASTIC BOTTLE INSPECTOR 4014-PF 

# IPUFFER 

# I 4024-1 

# ILOW SPEED TAPTONE
4044-1 

### ! HIGH SPEED TAPTONE , 

# I

4044-CB AUTOMATIC LINE TAPTONE FOR VACUUM TESTING FOIL PACKAGES 40S4-2-CB I AUTOMATIC CASE 

# ITAPTONE FOR VACUUM

TESTING FOIL PACKAGES 40S4-4 AUTOMATIC CASE TAPTONE i

4104-4 AUTOMATIC SWELLED CAN DETECTOR 4049-4A 

### I CASE SCANNER 1 I 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 orjar lines where headspace is available and speeds do not exceed 3S0 cpm. Can orjar 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 NlAAPPENDIX 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 i s 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 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 deflaction (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 deflaction (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 onAPPENDIX 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. 

### 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.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 120lbs. 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. APPENDIX H



## Automatic, All-Electric Plastic StrappingMachines for a Variety ofBundling, Carton Closing and Unitizing Applications

IT'S PORTABLE! The ASM Series feature swivel casters for machine portability and ajacking 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 Afeatures 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 StrappingMachines for a Variety ofBundling, Carton Closing and Unitizing Applications

IT'S PORTABLE! The ASM Series feature swivel casters for machine portability and ajacking 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 Afeatures 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. APPENDIX I 1 of 2



# Adjustoveyor extendable conveyors offer many MONEY-SAVING 

# ben"efits When you usethejob-provenAdjustoveyor you can expect these benefits to your dock andwharehouse operations:

- Laborproductiviy improvement of500% in 

### most applications

- Reduced turnaround time for trucks, improving their on-the-road

productivity

- Reducedproduct damage, resultinginfewer claims and improved

product quality -Improved dock space utilizationthrough the avoidance ofstaging areas

- Smoothuninterupted flow 

### to or from the truck These operatingbenefits 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 resultin 

### a payback ofless than one year! If

### the productivity improvement ofyour overall system is one ofyour objectives, the Adjustoveyoris yourbest investment. APPENDIX I 1 of 2



# Adjustoveyor extendable conveyors offer many MONEY-SAVING 

# ben"efits When you usethejob-provenAdjustoveyor you can expect these benefits to your dock andwharehouse operations:

- Laborproductiviy improvement of500% in 

### most applications

- Reduced turnaround time for trucks, improving their on-the-road

productivity

- Reducedproduct damage, resultinginfewer claims and improved

product quality -Improved dock space utilizationthrough the avoidance ofstaging areas

- Smoothuninterupted flow 

### to or from the truck These operatingbenefits 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 resultin 

### a payback ofless than one year! If

### the productivity improvement ofyour overall system is one ofyour objectives, the Adjustoveyoris yourbest 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 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 cAPPZNDD14 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 waterresistant. 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 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) 647-2504APPENDIX J 2 of 2 

# lPf^/80T & lPf^/86T SPE^IfICf^TIONS

El A

73" 22% (57) (185) 

# 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 fromany 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 waterresistant. Paper is available for infrared scannable barcodes (900 nanometers). Label Formatting: Available barcodes are interleaved 2 of 5, Code 39, UPCand 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 APPENDIX J 2 of 2 

# lPA/80T & 

# lPA/86T 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/86T 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



### 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 

## 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 

## 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 SiO

### z 20mppcf (5mg/m3 ) SiO

### z Respirable dust. 8 hour time weighted average.**TL~:** 10mg/m 3 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 SiO

### z 20mppcf (5mg/m3 ) SiO

### z Respirable dust. 8 hour time weighted average.**TL~:** 10mg/m 3 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 216·668·3846APPENDIX 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 incorporatereliability, 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:

1Completely enclosed chain helps prevent accidental contact with moving parts.

2 An enclosed track helps prevent contminationfrom 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. 4The enclosed track design helps provide protection from the elements for the chain and other moving parts. 5 Shorter radius curves and closer spacing ofcurve tangents are possible due to the universal link chain. 6Easier 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 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. 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 600 0/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 downtime. • Analog control output signal 

# 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 600 0/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 downtime. • Analog control output signal 

# 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 ab o Ebor--cr pnast
^ d

r--

_ Moon tend A)ft .+elt Spwd P :. ^• " ^. 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 

## ran= 

# GW, 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 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 axis4 1IlCis5

'+'

...... tt -t

.....**~;.**
-"**~=**

150'

,..;**FIcor-1l'~** also**~l:IhWIiniIed** n.iQBv1d8PIIII1 .",<.**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 axis4 1IlCis5

"'tt I"**~**

.....**~;.**
-"**~= ~** **FIcor-1l'~** also**~l:IhWIiniIed** n.iQBv1d8PIIII1 .",<.**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" -20060AYYXNL)1X N 1 of 3

Automatic Density Control The Nordson 170 SeriesProcessors 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 ±2.5percentage 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 therequirements of almost any application. In addition to standard singlemodule and mufti module guns, 170units 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 supplyand return passages combined in the same bundle, biaxial hoses are very cost eff ective, and theirsuperior 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 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 capabilityAPPENDIX N 2 of 3 

# Vlorsom Foam Melf 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. fn 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 APPENDIX N 2 of 3 

# Nordson® 

# FoamMelt® 170Series Processors

Specifications Type of System Holding Capacity Melt Rate l 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. 11,000watts

. 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® 170Series Processors

Specifications Type of System Holding Capacity Melt Rate l 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. 11,000watts

. 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 6190APPENDIX 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 theperformance 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 ProcessorsThe 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. Theseries includes two types of processors, a unit with a tank (the 170T), and a unit with a heated hopperand 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 largergears, forces inert gas into solution with the adhesive. Highly Automated Control System WA 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 indicatorsare 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. 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 varietyof 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 varietyof 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 

### 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) 860-4587APPENDIX 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 5,0006-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 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 15,000APPENDIX 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 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'vision 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'vision 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 $ 1,039,000APPENDIX 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 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