Kalas Manufacturing Inc. is a family-owned company founded in 1958 in
Kalas' NPEP Goals
Kalas established National Partnership for Environmental Priorities (NPEP) goals to reduce the amount of lead processed at two of its facilities. A commitment was made to reduce the amount of lead processed at the Plant No. 2 facility by 20 percent or 20,000 pounds through substituting reduced lead or lead-free compounds and color concentrates. A reduction goal of 25 percent or 10,500 pounds was set at the Plant No. 3 facility through solderless product offerings to customers.
NPEP Project Implementation
Plant No. 2
Lead is typically used as a heat stabilizer in PVC compounds and color concentrates purchased for extrusion of copper wire at Plant No. 2. Kalas partnered with its compound and color concentrate suppliers, including Sylvin Technologies and PolyOne, to develop and purchase lead-free versions.
Plant No. 3
In order to reduce the amount of lead processed at its Engineered Cable Division, Kalas considered either switching to pre-tinned terminals (solderless) or using lead-free solder. Solder (60 percent lead, 40 percent tin) is used to prevent corrosion of battery cable terminals. The choice was clear because solderless terminals offered significant advantages over lead-free and leaded solder. These advantages included more flexible termination points, improved contact surface, higher corrosion resistance, cost savings, and less environmental impact. Several customers, including International Truck and Engine Corporation, have converted to the solderless battery cable.
Hurdles Faced
Since these product modifications resulted in engineering changes, they created both internal and external (customer) issues. New product engineering specifications had to be created and approved, customers had to be notified, and changes to raw material and final product costing had to be made. Sample runs were also conducted and sent to third party certification laboratories and customers to ensure continued product quality.
Waste Minimization Results
Plant No. 2
In 2004, Kalas processed 100,000 pounds of lead in compounds and color concentrates at its Plant No. 2 facility. Through the substitution of lead-free versions, Kalas has exceeded its original goal (20 percent or 20,000 pound reduction) by achieving an 80 percent or 80,000 pound reduction.
Plant No. 3
In 2004, Kalas processed 42,000 pounds of lead in solder at its Plant No. 3 facility. The initial reduction goal of 25 percent or 10,500 pounds was exceeded despite increased customer demand for engineered cable products. The lead solder processed at Plant No. 3 has been reduced to 21,000 pounds annually for a 50 percent reduction. In addition, two lead solder pots have been removed from assembly lines to increase productivity.
During the waste minimization process, the European Directive 2002/95/EC, commonly known as the Restriction of Hazardous Substances (RoHS) went into effect, creating demand for lead-free electrical wire and cable products. Kalas is now able to offer lead-free versions for most of its product line to allow customers to comply with this directive.
Lessons Learned
Communication was the key factor in meeting and exceeding Kalas' goals for reducing lead at its facilities. Several of the companies involved in the supply chain had similar goals and were key partners in the waste minimization process.
