Wisconsin Administrative Code
Department of Natural Resources
NR 400-499 - Environmental Protection - Air Pollution Control
Chapter NR 440 - Standards of performance for new stationary sources
Subchapter II - Standards of Performance
Section NR 440.72 - Industrial surface coating: surface coating of plastic parts for business machines

Universal Citation: WI Admin Code § NR 440.72

Current through August 26, 2024

(1) APPLICABILITY AND DESIGNATION OF AFFECTED FACILITY.

(a) The provisions of this section apply to each spray booth in which plastic parts for use in the manufacture of business machines receive prime coats, color coats, texture coats, or touch-up coats.

(b) This section applies to any affected facility for which construction, modification, or reconstruction begins after January 8, 1986.

(2) DEFINITIONS AND SYMBOLS.

(a) As used in this section, all terms not defined in this subsection have the meanings given them in s. NR 440.02.

1. "Business machine" means a device that uses electronic or mechanical methods of process information, perform calculations, print or copy information, or convert sound into electrical impulses for transmission, such as:

a. Products classified as typewriters under SIC code 3572 in the Standard Industrial Classification Manual, incorporated by reference in s. NR 440.17;

b. Products classified as electronic computing devices under SIC Code 3573;

c. Products classified as calculating and accounting machines under SIC Code 3574;

d. Products classified as telephone and telegraph equipment under SIC Code 3661;

e. Products classified as office machines, not elsewhere classified, under SIC Code 3579; and

f. Photocopy machines, a subcategory of products classified as photographic equipment under SIC Code 3861.

2. "Coating operation" means the use of a spray booth for the application of a single type of coating (e.g., prime coat); the use of the same spray booth for the application of another type of coating (e.g., texture coat) constitutes a separate coating operation for which compliance determinations are performed separately.

3. "Coating solids applied" means the coating solids that adhere to the surface of the plastic business machine part being coated.

4. "Color coat" means the coat applied to a part that affects the color and gloss of the part, not including the prime coat or texture coat. This definition includes fog coating, but does not include conductive sensitizers or electromagnetic interference/radio frequency interference (EMI/RFI) shielding coatings.

5. "Conductive sensitizer" means a coating applied to a plastic substrate to render it conductive for purposes of electrostatic application of subsequent prime, color, texture, or touch-up coats.

6. "Electromagnetic interference/radio frequency interference (EMI/RFI) shielding coating" means a conductive coating that is applied to a plastic substrate to attenuate EMI/RFI signals.

7. "Fog coating" (also known as mist coating and uniforming) means a thin coating applied to plastic parts that have molded-in color or texture or both to improve color uniformity.

8. "Nominal 1-month period" means either a calendar month, 30-day month, accounting month, or similar monthly time period that is established prior to the performance test.

9. "Plastic parts" means panels, housings, bases, covers, and other business machine components formed of synthetic polymers.

10. "Prime coat" means the initial coat applied to a part when more than one coating is applied, not including conductive sensitizers or electromagnetic interference/radio frequency interference shielding coatings.

11. "Spray booth" means the structure housing automatic or manual spray application equipment where a coating is applied to plastic parts for business machines.

12. "Texture coat" means the rough coat that is characterized by discrete, raised spots on the exterior surface of the part. This definition does not include conductive sensitizers or EMI/RFI shielded coatings.

13. "Touch-up coat" means the coat applied to correct any imperfections in the finish after color or texture coats have been applied. This definition does not include conductive sensitizers or EMI/RFI shielded coatings.

14. "Transfer efficiency" means the ratio of the amount of coating solids deposited onto the surface of a plastic business machine part to the total amount of coating solids used.

15. "VOC emissions" means the mass of VOCs emitted from the surface coating of plastic parts for business machines expressed as kilograms of VOCs per liter of coating solids applied (i.e., deposited on the surface).

(b) As used in this section, all symbols not defined in this subsection have the meanings given them in s. NR 440.03.

Dc = density of each coating as received (kilograms per liter)

Dd = density of each diluent VOC (kilograms per liter)

Lc = the volume to each coating consumed, as received (liters)

Ld = the volume of each diluent VOC added to coatings (liters)

Ls = the volume of coating solids consumed (liters)

Md = the mass of diluent VOCs consumed (kilograms)

Mo = the mass of VOCs in coatings consumed, as received (kilograms)

N = the volume-weighted average mass of VOC emissions to the atmosphere per unit volume of coating solids applied (kilograms per liter)

T = the transfer efficiency for each type of application equipment used at a coating operation (fraction)

Tavg = the volume weighted average transfer efficiency for a coating operation (fraction)

Vs = the proportion of solids in each coating, as received (fraction by volume)

Wo = the proportion of VOCs in each coating, as received (fraction by weight)

(3) STANDARDS FOR VOLATILE ORGANIC COMPOUNDS.

(a) Each owner or operator of any affected facility which is subject to the requirements of this section shall comply with the emission limitations set forth in this subsection on and after the date on which the initial performance test, required by s. NR 440.08 and sub. (4) is completed, but not later than 60 days after achieving the maximum production rate at which the affected facility will be operated, or 180 days after the initial startup, which ever date comes first. No affected facility may cause the discharge into the atmosphere in excess of:

1. 1.5 kilograms of VOCs per liter of coating solids applied from prime coating of plastic parts for business machines.

2. 1.5 kilograms of VOCs per liter of coating solids applied from color coating of plastic parts for business machines.

3. 2.3 kilograms of VOCs per liter of coating solids applied from texture coating of plastic parts for business machines.

4. 2.3 kilograms of VOCs per liter of coatings solids applied from touch-up coating of plastic parts for business machines.

(b) All VOC emissions that are caused by coating applied in each affected facility, regardless of the actual point of discharge of emissions into the atmosphere, shall be included in determining compliance with the emission limits in par. (a).

(4) PERFORMANCE TESTS AND COMPLIANCE PROVISIONS.

(a) Section NR 440.08(4) and (5) does not apply to the performance test procedures required by this subsection.

(b) The owner or operator of an affected facility shall conduct an initial performance test as required under s. NR 440.08(1) and thereafter a performance test each nominal 1-month period for each affected facility according to the procedures in this subsection.

1. The owner or operator shall determine the composition of coatings by analysis of each coating, as received, using Method 24 of Appendix A, 40 CFR part 60, incorporated by reference in s. NR 440.17(1), from data that have been determined by the coating manufacturer using Method 24, or by other methods approved by the administrator.

2. The owner or operator shall determine the volume of coating and the mass of VOC used for dilution of coatings from company records during each nominal 1-month period. If a common coating distribution system serves more than one affected facility or serves both affected and nonaffected spray booths, the owner or operator shall estimate the volume of coatings used at each facility by using procedures approved by the department.

a. The owner or operator shall calculate the volume-weighted average mass of VOCs in coatings emitted per unit volume of coating solids applied (N) at each coating operation (i.e., for each type of coating used, prime, color, texture, or touch-up) during each nominal 1-month period for each affected facility. Each 1-month calculation is considered a performance test. Except as provided in subd. 2. c., N will be determined by the following procedures:

1) Calculate the mass of VOCs used (Mo+ Md) for each coating operation during each nominal 1-month period for each affected facility by the following equation: See PDF for diagram

where n is the number of coatings of each type used during each nominal 1-month period and m is the number of different diluent VOCs used during each nominal 1-month period. (SLdj Ddj will be 0 if no VOCs are added to the coatings, as received.)

2) Calculate the total volume of coating solids consumed (Ls) in each nominal 1-month period for each coating operation for each affected facility by the following equation: See PDF for diagram

where n is the number of coatings of each type used during each nominal 1-month period.

3) Select the appropriate transfer efficiency (T) from Table 1 for each type of coating applications equipment used at each coating operation. If the owner or operator can demonstrate to the satisfaction of the administrator that transfer efficiencies other than those shown are appropriate, the administrator may approve their use on a case-by-case basis. Transfer efficiency values for application methods not listed below may be approved by the administrator on a case-by-case basis. An owner or operator shall submit sufficient data for the administrator to judge the validity of the transfer efficiency claims.

4) Where more than one application method is used within a single coating operation, the owner or operator shall determine the volume of each coating applied by each method through a means acceptable to the department and compute the volume-weighted average transfer efficiency by the following equation: See PDF for diagram

where n is the number of coatings of each type used and p is the number of application methods used

Table 1. - Transfer Efficiencies

Application Methods	Transfer Efficiency	Type of Coating
a)	Air atomized spray	0.25	Prime, color, texture, touch-up, and fog coats.
b)	Air assisted airless spray	0.40	Prime and color coats.
c)	Electrostatic air spray	0.40	Prime and color coats.

5) Calculate the volume-weighted average mass of VOCs emitted per unit volume of coating solids applied (N) during each nominal 1-month period for each coating operation for each affected facility by the following equation: See PDF for diagram

(Tavg = T when only one type of coating operation occurs).

b. Where the volume-weighted average mass of VOCs emitted to the atmosphere per unit volume of coating solids applied (N) is less than or equal to 1.5 kilograms per liter for prime coats, is less than or equal to 1.5 kilograms per liter for color coats, is less than or equal to 2.3 kilograms per liter for texture coats, and is less than or equal to 2.3 kilograms per liter for touch-up coats, the affected facility is in compliance.

c. If each individual coating used by an affected facility has a VOC content (kg VOC/l of solids), as received, which when divided by the lowest transfer efficiency at which the coating is applied for each coating operation results in a value equal to or less than 1.5 kilograms per liter for prime and color coats and equal to or less than 2.3 kilograms per liter for texture and touch-up coats, the affected facility is in compliance provided that no VOCs are added to the coatings during distribution or application.

d. If an affected facility uses add-on controls to control VOC emissions and if the owner or operator can demonstrate to the administrator that the volume-weighted average mass of VOCs emitted to the atmosphere during each nominal 1-month period per unit volume of coating solids applied (N) is within each of the applicable limits expressed in subd. 2. b. because of this equipment, the affected facility is in compliance. In such cases, compliance will be determined by the administrator on a case-by-case basis.

(5) REPORTING AND RECORDKEEPING REQUIREMENTS.

(a) The reporting requirements of s. NR 440.08(1) apply only to the initial performance test. Each owner or operator subject to the provisions of this section shall include the following data in the report of the initial performance test required under s. NR 440.08(1).

1. Except as provided for in subd. 2., the volume-weighted average mass of VOCs emitted to the atmosphere per volume of applied coating solids (N) for the initial nominal 1-month period for each coating operation from each affected facility.

2. For each affected facility where compliance is determined under the provisions of sub. (4) (b) 2. c., a list of the coatings used during the initial nominal 1-month period, the VOC content of each coating calculated from data determined using Method 24, of Appendix A, 40 CFR part 60, incorporated by reference in s. NR 440.17(1), and the lowest transfer efficiency at which each coating is applied during the initial nominal 1-month period.

(b) Following the initial report, each owner or operator shall:

1. Report the volume-weighted average mass of VOCs per unit volume of coating solids applied for each coating operation for each affected facility during each nominal 1-month period in which the facility is not in compliance with the applicable emission limits specified in sub. (3). Reports of noncompliance shall be submitted on a quarterly basis, occurring every 3 months following the initial report; and

2. Submit statements that each affected facility has been in compliance with the applicable emission limits specified in sub. (3) during each nominal 1-month period. Statements of compliance shall be submitted on a semiannual basis.

(d) Each owner or operator subject to the provisions of this section shall maintain at the source, for a period of at least 2 years, records of all data and calculations used to determine monthly VOC emissions from each coating operation for each affected facility as specified in s. NR 440.07(5).

(e) Reporting and recordkeeping requirements for facilities using add-on controls will be determined by the administrator on a case-by-case basis.

(6) TEST METHODS AND PROCEDURES.

(a) The reference methods in Appendix A, of 40 CFR part 60, incorporated by reference in s. NR 440.17, except as provided under s. NR 440.08(2), shall be used to determine compliance with sub. (3) as follows:

1. Method 24 for determination of VOC content of each coating as received.

2. For Method 24, the sample shall be at least a 1-liter sample in a 1-liter container.

(b) Other methods may be used to determine the VOC content of each coating if approved by the administrator before testing.

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