p.1 

OAR Box 1384 

Prepped by Charmelle Mathews 

Document Number: 

p/£03)ll-E-163 

Docket Number: 

A-94-52 

Printed 7/2/2008 8:42:10 AM Sheet 203 of 264 
P.2 

I 06/29/98 MON 13:44 FAX 2195227042 

ne 2e 9t» 1T:4£ &191S941023-1 

MILLENNIUM PRODUCTS 

PES RTP NC 

IgjUUZ 

@UU2/004 

"?E:-|6 3 

From; 

Date: 

Contact: 

Company: 

Contact Report 

Robert Jemison, Pacific Envkonmental Services, Inc. (PES) 

June 26,1998 

Mr. Earl H. Miller 

Millennium Products, Inc. 

Telephone Number: (219)293-3340 

Far Number: (219) 522-7042 

Contact Summary: 

Mr. Earl H. Miller was contacted to update information provided in the 1993 EPA Reinforced 

Plastic/Composites Screening Survey submined by Millennium Products, Inc. for their facility 

located in Elkhart, Indiana. In response to my questions Mr. Miller indicated the following; 

The facility produces various parts for the automotive industry including van tops, running 

boards, and lids for pick-up tracks. 

The facility has discontinued use of the fabrication processes known as reactive injection 

molding (RIM) and resin transfer molding (RTM). 

The facility still uses the hand lay-up fabrication process but only on an occasional basis for 

die repair of molds. The volume of resin used by this fabrication technique is inconsequential 

compared to die volume used hi die non-atomized mechanical spray-up fabrication process. 

The facility uses non-atomized mechanical resin application (Le. a flow-coater) in the 

fabrication of certain products for the automotive industry. The unfilled polyester resin applied by 

this device contains approximately 34% HAP by weight (34% styrene) and does not contain a vapor 

suppressant. The unfilled polyester resin used for the manufacture of certain automotive products 

accounts for approximately 88% of the resin used by the facility to manufacture automotive products 

and approximately 79.2% of the facility's total resin usage. 

The facility uses atomized mechanical resin application (i-c. spray lay-up) in the fabrication 

of certain products for the automotive industry. The filled polyester resin applied using spray lay-up 

contains approximately 34% HAP by weight (34% styrene as supplied without filler) and does not 

contain a vapor suppressant- The calcium carbonate filler present in this resin system is added by 

the facility. The filled polyester resin used to manufacture certain products for the automotive 

industry accounts for approximately 12% of the resin used by the facility to manufacture automotive 

products and approximately 10.8% of the facility's total resin usage. 

INFORMATION IS ACCURATE 
P.3 

06/29/98 MON 13:45 FAX 2195227042 

Utf/26,-'98 17:45 ©19199410234 

MILLENNIUM PRODUCTS 

PES RTP NC 

l£|UUJ 

0)003/004 

ill*- 

Contact Report 

Mr. Earl H. Miller - Millennium Products, Inc. 

June 24,1998 

Page Two 

The facility uses atomized mechanical resin application (i.e. spray lay-up) to apply an 

unfilled polyester resin in the manufacture of molds. This unfilled polyester resin couiains 

approximately 52% HAP by weight (52% styrene) and does not contain a vapor suppressant. The 

unfilled polyester resin used for mold mantu^cturing accounts for approximately 10% of die 

facility's total resin usage. 

No additional HAP is added to any of the polyester resins during or prior to the fabrication 

process with the exception of small amounts of HAP that may (or may not) be present in initiators, 

promoters and/or catalysts added to the resins. 

The facility uses atomized spray lay-up to apply several pigmented production gel coats in 

the fabrication of certain products. The facility also uses two pigmented tooling gel coats in the 

manufacture of molds. The styrene and methyl methacrylate (MMA) contents of each of these gel 

coats axe listed in the table below. For the pigmented production gel coats, the grey sandable gel 

coat accounts for approximately 90% of the total pigmented production gel coat used by die facility. 

The remaining pigmented production gel coats are used when requested by customers. 

Type of 

Gel Coat 

Production 

Production 

Production 

Production 

Production 

Production 

Production 

Production 

Production 

Production 

Tooling 

Tooling 

Color of 

Gel Coat 

Grey Sandable 

Airstar Grey 

Medium Grev 

Green 

Tub Green 

Dark Blue 

Airstar Red 

Brandy wine 

Frost White 

Black 

Tangerine 

Black 

HAP 

Content 

fYftbvm) 

32.24% 

41.01% 

42.49% 

41.68% 

41.00% 

40.18% 

39.47% 

41.27% 

35.10% 

39-02% 

39.94% 

39.97% 

Styrene 

Content 

<%Kvwt:> 

3224% 

36.01% 

37.49% 

36.68% 

36.00% 

35.18% 

34.47% 

36.27% 

31.10% 

35.02% 

36.94% 

36.97% 

MMA 

Content 

f% bv wt.) 

0.00% 

5.00% 

5.00% 

5.00% 

5.00% 

5.00% 

5.00% 

5.00% 

4.00% 

4.00% 

3.00% 

3.00% 

No additional HAP is added to any of die pigmented or tooling gel coats during or prior to 

the fabrication process with the exception of small amounts of HAP that may (or may not) be present 

in initiators, promoters and/or catalysts added to tiie gel coats. 

INFORMATION IS ACCURATE (gjjU (?£6K 

2, 
P.4 

' 06/29/98 MON 13:45 FAX 2195227042 MILLENNIUM PRODUCTS WW* 

08,26 98 I7:4t$ ©1919941U234 PES RTP NC @JU04/U04 

Contact Report 

Mr. Earl H. Miller - Milleuuium Products, Inc, 

June 24,1998 

Page Three 

The facility mixes polyester resin with calcium carbonate in a shear mixer. The resin is 

pumped directly into the mixer. The calcium carbonate is added through an opening in the cover of 

the mixer. This opening lias a hinged cover that is closed except when adding the calcium carbonate. 

The mixing shaft (with sealed ball bearings) extends through the top of the non-hinged portion of 

the mixer cover. The mixer cover is kept in place due to gravity (no gasket or seal is present). The 

mixer is closed at all times during mixing operations (except when adding calcium carbonate). The 

facility does not apply a vacuum to the mixer nor does it actively vent emissions from the mixer to 

the atmosphcre. 

ESTFORMATTON IS ACCURATE 

3 
08/29/98 MON 13:44 FAX 2195227042 MILLENNIUM PRODUCTS IfflOOl 

MB! 

MILLENNIUM 

PRODUCTS INC 

Molding Tomorrow's Technology Today 

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ATTN: fdt>*Jf" "TH ^»o-c^fl^-^^ 

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NUMBER OF PAGES TO BE FAXED INCLUDING COVER: S' 

4 

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57755 Holiday Place • P.O. Box 1186 • Elkhart. IN 46515-1186 • (219)293-3840 • FAX (219) 522-7042