TURI Case Study: Replacing Toxic Adhesive and Cleaner

This case study is based on TURI’s (Toxics Use Reduction Institute) August Case Study, which highlights Conklin Office Furniture’s efforts to reduce hazardous chemicals in its manufacturing and remanufacturing processes.

Conklin Office Furniture set out to find a safer adhesive and cleaner that would reduce employee exposure to hazardous chemicals used in production. Located in an environmental justice community, the company also recognized that reducing these chemicals could benefit the surrounding community by minimizing potential environmental impacts.

To accomplish this, the company partnered with the Toxics Use Reduction Institute (TURI) to identify alternatives to a methylene chloride-based adhesive and a toluene-containing cleaner. Because both chemicals pose serious health risks, including cancer, neurotoxicity, and reproductive harm, technical assistance was used to evaluate safer alternatives that could still meet production requirements.

With TURI’s support, the company tested alternatives over two years. The project ultimately resulted in a successful transition to a water-based adhesive along with process improvements that reduced the amount of cleaner required.

At the urging of environmental consultant Lynn Rose, Conklin applied for and received a TURI small business grant. The company then worked closely with TURI and the Massachusetts Office of Technical Assistance and Technology (OTA) to find alternative products that met the specific demands of its production processes.

TURI evaluated potential alternatives for toxicity and other hazards using its Pollution Prevention Options Analysis System (P2OASys), which allows users to compare the relative hazards associated with chemical or process changes. TURI evaluated each viable alternative to ensure replacing one chemical would not simply introduce another significant hazard.

The team contacted several vendors and tested more than 20 adhesive products. Finding a replacement cleaner was an additional challenge because technicians had used a single cleaner to remove two different types of adhesives. The TURI lab tested numerous recommended products, and TURI researchers also experimented with solvent blends developed specifically for the application.

Among the many products remanufactured at the Holyoke facility are open-plan workstations. As part of this process, workers refinish privacy screens using a spray adhesive to attach fabric to a board.

The adhesive previously used contained methylene chloride, a chemical associated with cancer and serious neurological effects. Reducing worker exposure and removing methylene chloride from the process became an important objective.

The team evaluated potential alternatives for their environmental, health, and safety profiles before performance testing began. We eliminated products containing halogenated solvents such as methylene chloride or trans-dichloroethylene before performance testing.

The alternative adhesive then had to pass two performance-based tests:

1. A “pull test” to ensure the fabric remained laminated to the substrate.
2. A humidity test to verify that the fabric would not sag under humid conditions.

Initially, there were concerns that water-based adhesives could damage the screens or cause fabric dyes to run. After further evaluation, the team agreed to test water-based alternatives.

Simalfa visited the facility with the appropriate equipment to demonstrate how two of its water-based products would perform under actual production conditions. The manufacturer also provided on-site training for employees using the alternative adhesives and new spray guns.

Based on the testing and guidance, the team selected Simalfa 321 as the new water-based adhesive.

The benefits extended beyond workstation screens. The same adhesive could also be used when reupholstering chairs, eliminating methylene chloride from the facility. Because the replacement is water-based, only water is needed to clean the spray guns. Testing also showed that less adhesive could be used overall, providing an additional cost benefit.

A separate production process presented another challenge. Desktop manufacturing uses two different types of adhesives: water-based and hot melt.

TURI received samples of both adhesives and tabletop laminate for testing, and the team also conducted additional in-house performance testing.

Previously, a toluene-based cleaner removed both types of adhesive. Toluene is associated with serious health effects, including reproductive hazards and neurological effects.

The process uses a Wilsonart water-based adhesive for laminate top adhesion and a Jowat hot melt adhesive for edge banding. Any replacement cleaner needed to remove excess material from both adhesives without damaging the laminate.

Finding one product that could effectively clean both proved difficult. Several alternatives worked on only one adhesive type. The team also tested mechanical cleaning devices to improve the performance of promising cleaners, but this increased labor requirements and processing time.

The TURI lab then used the Hansen Solubility Parameters in Practice (HSPiP) test method and software to develop two specialized solvent blends for the process. TURI staff also visited the facility to observe cleaning procedures and test the mixtures on product samples.

Although the original goal was to find a single replacement cleaner, testing ultimately identified different solutions for the two adhesives.

Windex emerged as the best-performing and safest tested option for removing the water-based adhesive. It was less hazardous than the other tested alternatives, less expensive, and readily available. For the hot melt adhesive, the TURI-developed Mixture 1 performed best.

The testing process also led employees to identify ways to reduce the need for cleaning altogether. Using less adhesive limited excess material, while wiping boards with water between production steps prevented adhesive from setting and spreading.

Together, these process improvements reduced cleaner use by 25%.

After two years of testing and process development, the switch to Simalfa 321 eliminated methylene chloride use at the facility.

Because the new adhesive is water-based, paint thinner is no longer required to clean adhesive applicator guns. The change also reduced costs and provided a single adhesive for both workstation screens and chair reupholstery.

Changes to the desktop manufacturing process also successfully reduced the amount of toluene-based cleaner required. Using less adhesive and cleaning between production steps generates less excess adhesive waste and makes final cleaning easier.

These improvements also helped the company stay ahead of the EPA’s prohibition on methylene chloride in adhesives, while reduced toluene-based cleaner use lowered VOC emissions.

The result is a production process that uses fewer hazardous chemicals while still meeting the performance requirements for remanufactured office furniture.

“By eliminating this hazardous substance, we are taking a crucial step towards ensuring a safe workplace for our employees and a healthier environment for our community. This transition is not only about regulatory compliance; it’s about leading the industry toward a more sustainable future. Our commitment to ‘Greener, better, safer’ reflects our dedication to quality, safety, and environmental stewardship. We are proud to set an example in the industry and to offer products that are both effective and environmentally responsible.”