# MEMORANDUM

DATE: October 19, 2010

SUBJECT: Impacts of Implementing a Limit on Formaldehyde Usage in the Wood

Furniture Manufacturing Oper ations Source Category

FROM: Kaye Whitfield, EPA/OAQPS/SPPD/NRCG

TO: Docket No.: EPA-HQ-OAR-2010-0786

The purpose of this memo is to document the impacts of implementing a limit on the amount of

formaldehyde used by wood furniture faciliti es in the Wood Furniture National Emission

Standards for Hazardous Air Pollutants (NESHAP).

For the Wood Furniture Manufacturing Operations source category, to provide an ample margin

of safety to protect public health and prevent adverse environmental effects for the purpose of

meeting the requirements of CAA section 112(f)(2), one of the changes being proposed is to

limit formaldehyde emissions by restricting fo rmaldehyde use to 400 pounds per rolling 12-

month period. If a control device is used, formaldehyde emissions would be limited to an

amount adjusted from 400 pounds per rolling 12-month period based on the overall control

efficiency of the control system.

1

# The proposed limit would apply to wood furniture coatings and contact adhesives. This

emissions level is currently in cluded in Table 5 of the Wood Furniture Manufacturing NESHAP

(promulgated in 1995) as part of the work practice requirement to have a Formulation

Assessment Plan for finishing operations and was promulgated in 1995 as a part of the MACT

standards. The usage level pr ovided in Table 5 is 0.2 tons per year (400 pounds per year).

Under the current NESHAP requirements, if a f acility’s annual usage of formaldehyde exceeds

its baseline level, the owner or operator of the facility provides a written notification to the

permitting authority describing the amount of the increase and explains the reasons for

exceedance of the baseline level. If the ex ceedance is no more than 15 percent above the

baseline, then, no further explanation is requ ired. The proposed option would change the

formaldehyde usage level in the existing Wood Fu rniture NESHAP to a limit not to be exceeded

at any time. (See 40 CFR 63.803(l).) Accord ing to the 2005 NEI data set, there are 141

facilities that emit formaldehyde, as shown in Ta ble 1 below. The total formaldehyde emissions

from the 141 facilities are 20.1 tons. Of these 141 facilities, 39 facilities reported emissions of

0.2 TPY or greater of formaldehyde. By setti ng a usage limit of 400 pounds per rolling 12

month period, the formaldehyde emissions from these 39 facilities will, at a minimum, be

reduced from 15.6 TPY to 9.5 TPY, a 6.1 TPY or 39 percent reduction. These reductions are

shown on a facility by facility ba sis in Table 1 of this memo.

There are many coatings and contact adhesives av ailable from several s uppliers that contain no

or low quantities of formaldehyde and that are appr oximately equivalent in cost to those coatings

and contact adhesives that contai n formaldehyde. No coatings or contact adhesives with higher

than 1 percent formaldehyde were identified in our search - examples are shown in Table 2.

2

# 3 Many facilities currently use these no- or low-fo rmaldehyde coatings and contact adhesives. In

some cases where we identified facilities with formaldehyde emissions above 400 pounds per

year (based on the 2005 NEI), some of those facilities have eliminated all formaldehyde

emissions over the last 5 years by switching to new coating formulations (see Chromcraft

Furniture located in Senatobia, MS in Table 1.) Based on the information in our RTR data set,

the wood furniture manufacturing operations at the facilities using more than 400 pounds per

rolling 12-month period of formaldehyde are simila r to operations at fac ilities currently using

less than 400 pounds per rolling 12 -month period of formaldehyde. Therefore, we believe it is

feasible for the remaining facilities to switch to coatings and adhesi ves containing no or low

amounts of formaldehyde, at little or no extra cost, and reduce their ove rall usage to no more

than 400 pounds per rolling 12-month period. Howeve r, facilities would also have the option to

control formaldehyde emissions using an add-on control device. In c onclusion, the impacts of

implementing a usage limit on formaldehyde will have little or no cost impact s, and will result in

at least a 30 percent reduc tion in formaldehyde usage.Table 1. Facilities that Reported Formaldehyde EmissionsFacility_NameCityStateFormaldehyde emissions(tpy)Estimated formaldehydereductions (tpy)Akin IndustriesMonticelloAR1.98e-020Alabama Inter-Forest CorporationEufaulaAL1.3501.150American Furniture Co Inc.MartinsvilleVA8.25e-020American Woodmark Corporation -HardyCo.MoorefieldWV0.2120.012Americas Finest Woodworking Team IncLexingtonKY1.11e-020Arete' Mdf LLC Dba Cox CabinetCampbellsvilleKY1.17e-020Armstrong Cabinet Prod/ThompsontownThompsontownPA0.3720.172Ashley Furniture IndustriesArcadiaWI0.6120.412Bernhardt Furn Plts 2 And 5LenoirNC2.17e-020Bernhardt Furn Plts 3 & 7LenoirNC4.51e-020Bertch Cabinet Manufacturing Inc LegacyDivJesupIA0.7500.550Bertch Cabinet Mfg., Inc. - OelweinOelweinIA0.1900Bertch Cabinet Mfg., Inc. - Waterloo/OasisFacilitWaterlooIA0.5500.3504Formaldehyde emissionsEstimated formaldehydeFacility_NameCityState(tpy)reductions (tpy)Brayton International IncHigh PointNC5.67e-030Brochsteins, Inc.HoustonTX0.1550C.O. Mfg. Group Of AmericaLancasterTX3.41e-020Cabinet Manufacturing FacilityWestJordanUT9.25e-020Cabinet Manufacturing FacilitySalt Lake CityUT6.53e-020Cathedral Church InteriorsAutryvilleNC4.40e-030Cedar Hill PlantCedar HillTX0.2220.022Century Furniture IndustriesPlant #1HickoryNC6.50e-050Chromcraft Furniture****SenatobiaMS0.7490Classic Mill & CabinetSantaRosaCA0.4150.215Cleator CorporationSan DiegoCA4.14e-030Cliff's Cabinet CompanyNashvilleTN1.00e-020Cochrane Eastern Div of CochraneFurniture CompanyWarrentonNC6.55e-040Cochrane Furniture Divisions 10 20 35 And55LincolntonNC4.07e-020Colby Furniture CoHamiltonAL8.00e-020Collegedale Casework LLCCollegedaleTN4.00e-020Comm-Kab IncSeagroveNC5.00e-040Conestoga Wood Specialties/EastEarlEast EarlPA4.99e-020Councill Company LLC - Plant #1DentonNC2.00e-0405Formaldehyde emissionsEstimated formaldehydeFacility_NameCityState(tpy)reductions (tpy)Country Expressions IncDouble SpringsAL4.00e-020Crown City Furniture MfgIndustryCA5.78e-020Crystal Cabinet Works IncPrincetonMN0.2170.017Dar/Ran Furniture IndustriesHighPointNC5.07e-030Design Des CarolinesMorgantonNC1.25e-040Devaughn WoodworksMariettaMS5.00e-030Dinaire LLCCheektowagaNY0.1030Dorfile CompanyCommerceCA8.20e-020Ellingers Agatized Wood IncSheboyganWI0.4140.214Ethan Allen Inc MayvilleDivisionChautauquaNY5.75e-030Ethan Allen - Pine ValleyDivOld FortNC2.36e-020Ethan Allen Operations, Inc. –Spruce Pine DivisionSpruce PineNC1.95e-020Ethan Allen Operations, Inc. MaidenDivisionMaidenNC1.37e-020Eudys Cabinet Mfg CoStanfieldNC6.80e-030Fairfield Chair Plant No. 2LenoirNC1.17e-020Fleetwood Homes Of Mississippi IncLexingtonMS0.5950.395Flexcel N.O.F. (National Office Furniture)DanvilleDanvilleKY7.78e-030Flexcel N.O.F. (National Office Furniture)FordsvilleFordsvilleKY6.12e-0206Formaldehyde emissionsEstimated formaldehydeFacility_NameCityState(tpy)reductions (tpy)Funder America IncMocksvilleNC0.1650Furniture ContractorsFort WorthTX1.70e-030Furniture Manufacturing PlantTremontonUT4.45e-030Geiger International IncLake MillsWI6.34e-030Guardian Fabrication, IncReedleyCA9.83e-030Halcon CorpStewartvilleMN0.3640.164Harden Furniture IncAnnsvilleNY6.69e-020Hickory Chair Company, Plant 7HickoryNC1.80e-040Hickory Leather CompanyValeNC4.30e-030Houston Wood ProductsArleyAL0.1800Huntwood IndustriesLiberty LakeWA0.1560Hws Company Inc. Dba Hickory WhiteHickoryNC5.50e-060Jim Bishop CabinetMontgomeryAL0.2200.020Johnston Tombigbee Furniture Company, CoColumbusMS1.85e-020Kanowsky Furniture IncSacramentoCA2.30e-040Kincaid Furn Plt 6HudsonNC3.09e-030Kincaid Furn Plt 8LenoirNC1.65e-050Kitchen Kompact IncJeffersonvilleIN1.0080.808Kohler Co., Dba Baker FurnitureConnellysSpringsNC1.30e-040L & J G Stickley IncManliusNY2.85e-030La Z Boy, Scanlan StreetNewtonMS2.40e-020La-Z-Boy Chair Company-La-Z-BoyMidwestNeoshoMO8.43e-0207Formaldehyde emissionsEstimated formaldehydeFacility_NameCityState(tpy)reductions (tpy)Lb Furniture Industries LLCHudsonNY4.29e-020Legacy CabinetsEastabogaAL1.1000.900Leick Furniture, IncorporatedSheboyganWI6.55e-040Leland Manufacturing LLCLelandMS3.05e-020Mapleton Wood Products IncThorpWI1.45e-020Marge Carson IncRosemeadCA1.08e-020Marsh Furniture CompanyHigh PointNC0.2850.085Marshalls FinishingHigh PointNC6.00e-050Masterbrand Cabinets, Inc. Plant 4/22FerdinandIN5.20e-070Masterbrand Plant #3JasperIN0.2000Mbci - Masterbrand CabinetsKinstonNC2.64e-020Mccammish ManufacturingColumbiaKY1.93e-020Medallion Cabinetry IncWaconiaMN0.3230.123Medallion Cabinetry Inc.IndependenceOR8.25e-020Merillat CorporationAtkinsVA8.33e-020Mid Continent CabinetryNewtonKS0.9400.740Mid Continent CabinetryCottonwoodMN0.3030.103Mouser Custom CabinetryLLCElizabethtownKY0.4940.294Null Industries IncMaidenNC2.93e-050O'sullivan Industries IncLamarMO0.3850.1858Formaldehyde emissionsEstimated formaldehydeFacility_NameCityState(tpy)reductions (tpy)Panam Expr Fab & CtngSan AntonioTX0.2600.060Panels Services & Components IncMocksvilleNC1.50e-040Paoli, Inc.OrleansIN0.1900Period FurnitureMadisonvilleKY1.54e-020Plato Woodwork IncPlatoMN0.1600Pleasant Garden Enterprises,LLCPleasantGardenNC1.21e-020Plywood Cabinet PlantMarshallTX1.3771.177Progressive Furniture IncClaremontNC1.31e-030Quality Cabinet & FixturesSan DiegoCA1.06e-020Qualserv Corp Fort Smith DivFort SmithAR1.00e-040Ready FixturesShell LakeWI9.03e-030Republic Industries IncMarshallTX0.6770.477Richardson Brothers CompanySheboygan FallsWI0.1070Salman IncFullertonCA5.00e-030Sandberg Furniture Mfg CoLos AngelesCA0.3080.108Sheldon Laboratory SystemsCrystal SpringsMS2.85e-020Southwest Wood ProcessingOklahoma CityOK4.00e-030Spectrum ManufacturingChippewa FallsWI4.50e-030Stanley Furniture CompanyRobbinsvilleNC0.6330.4339Formaldehyde emissionsEstimated formaldehydeFacility_NameCityState(tpy)reductions (tpy)Store Kraft Man Co Greenwood FixtureGreenwoodAR2.10e-030Superior Wood Products IncThomasvilleNC7.65e-040T.J. Hale CompanyMenomoneeFallsWI2.93e-020Taylor Dykema Mfg Co.San DiegoCA8.87e-020Terra Furniture IncIndustryCA2.54e-030Texwood Industries, L.P.DuncanvilleTX1.20e-020Thomasville Furniture Industries, Inc. -Lenoir PlantLenoirNC0.4800.280Thomasville Furniture Plant C/M/W/SbThomasvilleNC4.90e-060Thomasville Furniture Plant DThomasvilleNC3.70e-030Thomson Crown Wood Products Company** Inactive **MocksvilleNC2.91e-040Thonet Industries A Division Of FalconCantonMS0.1260Townesquare FurnitureHillsboroTX1.28e-020Treeforms IncGreensboroNC6.20e-030Tri C Wood Products Inc, UnionUnionMS5.00e-040Triangle Pacific Corp.LodiCA1.45e-020Tru-Wood Cabinets IncAshlandAL0.1400Tuohy Furniture Corp - ChatfieldChatfieldMN0.164010Formaldehyde emissionsEstimated formaldehydeFacility_NameCityState(tpy)reductions (tpy)Tupelo Manufacturing CompanyTupeloMS8.00e-040Valley Cabinet, IncDe PereWI6.34e-020Valley Casework IncEl CajonCA5.21e-020Walker Wood Products IncSan MarcosCA1.38e-020Watauga Wood Products IncBooneNC0.1590Watson Laminates IncSan DiegoCA6.99e-040Webb-Massey Co IncOrangeCA6.25e-020Wellborn Cabinet Inc.AshlandAL0.2000Wellborn Forest ProductsAlexander CityAL0.1000Wilco Cabinet Makers, Inc.Green BayWI1.05e-020Woodharbor Molding And Millworks, Inc.Mason CityIA1.00e-020Woodmark ManufacturingSacramentoCA2.00e-030Woodpro Cabinetry Inc-CaboolCaboolMO4.35e-02020.139.46****Chromcraft eliminated all formaldehyde useafter the formaldehyde data were gathered.1112Table 2. Coatings InformationNoCoating NameCoating DescriptionSize(gal)Formaldehyde(%)Cost($)Cost($/gal)Source1Poly-Soy Clear SatinFinish Topcoat10$48.95$48.95www.ecosafetyproducts.com2Magna Max ClearTopcoat10$38.35$38.35www.baersupply.com3Zenith Basecoat-Neutral10$40.44$40.44www.baersupply.com4Zenith ConversionVarnishconversionvarnishwater-based10$44.10$44.10www.baersupply.com5Campbell Clear TopcoatMLC C1191solvent borne post catalyzed high solidsconversion varnish.10$49.28$49.28www.baersupply.com6Valspar PROD WWPrecat 60 3706Pre-catalyzedready to spray lacquer50-0.099$109.61$21.92www.baersupply.com7Valtec Ulta Precat GL3809Pre-catalyzed ready to spray lacquer10-0.1$40.79$40.79www.baersupply.com8Valtec Ult white 3419Pre-catalyzed ready to spray lacquer white10-0.1$56.18$56.18www.baersupply.com9Valspar DuraspeedConversion Varnishconversion varnish5<0.1$174.96$34.99www.baersupply.com10Campbell Clear TopcoatMLC C145solvent borne post catalyzed high solidsconversion varnish. "ultra-lowformaldehyde"1<0.1$41.69$41.69www.baersupply.com11Campbell Clear TopcoatMLC C1166Post catalyzed conversion varnish; describedas "ultra low formaldehyde", apparently mustadd catalyst C1491 (no MSDS only pds)10% per gal by volume5<0.1$196.55$39.31www.baersupply.com12Global Ultra SSCV 550LH-40conversion varnish -cabinets exceptionaldurability10.1-1$44.10$44.10www.baersupply.com13Valtec Precat 680-903009Pre-catalyzed ready to spray lacquer10.1-1$31.34$31.34www.baersupply.comAverage price 1-13 w/formaldehyde$41.20Average price 1-13 wo/formaldehyde$44.22