Coffin Manufacturer

Background

Our client is a large coffin manufacturer with a finishing operation that runs across stains, clear lacquers and coloured coatings. Sustainability was already a core part of the company’s identity and commercial positioning. What brought the issue forward was growth. As the business expanded, its solvent usage expanded with it, and a visit from the local authority confirmed what the company already suspected: carrying on down that path would take its VOC emissions past the limits it was permitted to operate under.

That put a ceiling on expansion, which made the decision straightforward. Reducing emissions was not simply a matter of staying within the permit; it was what would allow the company to keep taking on more work. The environmental case aligned with where the business already wanted to go, so the commercial and the strategic arguments pointed the same way.

The Challenge

The existing process used acid-catalysed solvent-based products throughout, including a sealer and separate topcoat for clear finishes, plus a primer and colour coat for coloured finishes. Acid-catalysed products typically contain around 60% VOCs and emit formaldehyde during application, creating both environmental and health and safety concerns.

The main technical challenge in moving to water-based alternatives was drying time. Water-based products generally take longer to dry than solvent-based ones and in a high-volume production environment any increase in drying time can directly affect throughput. The company needed a way to make the transition without slowing down the line.

The Solution

After reviewing the requirements of the client and assessing their manufacturing processes, Redwood recommended a full conversion from acid-catalysed products to water-based products from Hesse across the entire finishing range. The new products fell within the ultra-low VOC category, with an average VOC content of approximately 3%, representing one of the lowest available while still delivering a consistent, quality finish.

The existing two-product clear coat system, a sealer followed by a separate topcoat, was replaced with a water-based multi-coat system. Using the same product for both clear coats simplified the process, reduced the number of products required and lowered waste.

Converting a high-volume line properly meant investing in the process as well as the products. To address the drying time challenge, the company put in heated drying rooms, ovens and dedicated drying equipment. This was a significant capital commitment, but the projected return demonstrated clear commercial value: maintaining throughput while improving finish quality and cutting VOC emissions substantially.

New air-assisted airless pumps were also introduced. The existing pumps required significant ongoing maintenance, so the changeover provided a logical opportunity to replace them at the same time.

Redwood supported the implementation through on-site trials and training, ensuring the team was fully comfortable with the new system before the full changeover took place.

The Outcome

The results of the conversion were significant across emissions, safety, process efficiency and finish quality.

VOC content reduced from approximately 60% to 3%
Keeping the company comfortably within its permitted limits, with headroom to keep growing

Formaldehyde from the coating eliminated
As the water-based system does not produce the formaldehyde associated with acid-catalysed products

Hazardous waste reduced
With fewer products required overall and a simpler one-part system removing the need to mix before use

Production times maintained
With the investment in drying equipment offsetting the longer natural drying time of water-based products

Finish quality improved
The new system delivers a better result than the acid-catalysed process it replaced

The project demonstrated that moving from solvent-based to water-based finishing does not have to mean a trade-off between environmental performance and production efficiency. With the right products, the right equipment and the right support, the company improved its finish, reduced its emissions and gave itself space to grow into.

Interested in reviewing your finishing process?