Coatings World - July 2011

“As a world-leading coating company, Valspar champions the concept of openness and innovation, and an important element of this concept is external partnership and sharing of resources. Dow is the largest and most respected chemical company in the world, and it shares a similar concept to ours,” said Robert G. Duan, technical director of Valspar Asia. “I’m extremely delighted to see these two companies working together towards a common goal, and developing break-through technologies for the coating industry. Innovation Day has been a great success, marking a good beginning to our closer collaboration in the long run.”

Dunn-Edwards starts paint manufacturing
facility in Arizona

Dunn-Edwards has opened what it says is the world’s first LEED-certified paint manufacturing facility. Located in Phoenix, AZ the 336,000-sq.-ft. facility was custom designed to be the greenest and most efficient in the coatings industry, according to the company. The building encompasses manufacturing, product development, quality control laboratories, a distribution center, retail outlet and office space.

“We have incorporated innovative, energy-efficient equipment and protocols, such as unique high-efficiency process equipment with integrated dust suppression technology, so that no particulates are emitted to ambient air, and advanced wastewater recycling techniques to conserve water. Our systems are classified as ultra-low discharge, meaning that waste generation is greatly minimized,” said Karl Altergott, president.

According to Dunn-Edwards, it is considered one of the most environmentally-friendly paint manufacturers and an industry leader in eco-efficient principles - all part of its Greener by Design philosophy. Throughout its operations the company focuses on initiatives such as energy efficiency, waste minimization, recycling, emissions reduction, and health and safety protection. “So, not only are we manufacturing paint that is more eco-friendly, we have taken great steps to conserve energy and material resources, and to reduce waste in our physical environment,” said Altergott.

The company eliminated cardboard boxes for packaging one-gallon containers and now use heat shrink wrap. Dunn-Edwards is the only paint plant in the U.S. using heat shrink wrap. This amounts to a reduction of cardboard consumption by one million boxes, which equates to approximately 250 tons of cardboard per year.

Altergott reports that energy calculations on the new plant show a 50% reduction over its two existing operations; one was first built in the mid-1950s and the other in the mid-1970s. “Our innovative automation at the new plant is one of the most comprehensive systems in the industry and light years beyond what we had at the older facilities,” he explained. “We are so much more efficient -- saving time, money and resources. Increased automation has reduced the physical demands of workers, and thus potential injuries.” With more than 50% more space than our two former plants combined, this new plant meets Dunn-Edwards’ needs for long-term growth and has room to expand another 40,000 sq. ft.