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NPEP Success Story: Aetna Wire
Aetna Insulated Wire, Inc. Reduces the Lead in Raw Materials by Over 85,000 Pounds
Aetna Insulated Wire, Inc. is an organization that has been in operation for over 70 years. The company’s manufacturing and distribution are located in Virginia Beach, VA. Aetna Insulated Wire, Inc. manufactures specialty power cable and building wire. Their main customers are electrical distributors. Aetna Insulated Wire, Inc.’s product is manufactured from its own stock of copper rod. The manufacturing process includes wire drawing, stranding, insulating, cabling, armoring and jacketing.
Aetna Insulated Wire, Inc.’s Goal
Aetna Insulated Wire, Inc. enrolled in the National Partnership for Environmental Priorities Program in Fiscal Year 2006 on September 18, 2007. Aetna Insulated Wire, Inc.’s goal was to implement a lead reduction plan for its wire and cable production. Polyvinyl chloride (PVC) was mainly used as a protective coating in some of their products. The PVC contained lead as a heat stabilizer. Aetna Insulated Wire, Inc.’s plan was to offer lead-free PVC alternatives to customers through the use of flexible vinyl formulations that contained heat stabilizers other than lead. Aetna Insulated Wire, Inc. wanted to offer a less toxic alternative product line while remaining competitive in the market place.
Source Reduction, Recycling and Recovery Alternatives Considered
Aetna Insulated Wire, Inc. investigated and implemented a lead reduction alternative which offered equivalent or better lead-free product choices to their customers. Starting in 2006 Aetna Insulated Wire, Inc. began qualifying non-lead PVC jacket compound material with the cable listing organizations Underwriters Laboratories, Inc. (UL) and the Canadian Standards Association (CSA). Aetna Insulated Wire, Inc. manufactured and their customers purchased the lead-free alternative products, which led to an overall reduction of lead consumption.
Hurdles Faced
Aetna Insulated Wire, Inc. faced some challenges in implementing their plan. First, Aetna Insulated Wire, Inc. had to convince their customers that they were purchasing an equivalent or superior alternative to the lead product. Second, Aetna Insulated Wire, Inc. needed to have their new alternative products tested and qualified by two major certification bodies, Underwriters Laboratories, Inc. (UL) and the Canadian Standards Association (CSA). This second step would help to surmount the first issue of selling customers on the alternative product. Finally, engineering and production personnel needed to prove out the new material’s compatibility with the existing production equipment and make set-up changes as necessary.
Results
Aetna Insulated Wire, Inc.’s overall lead reduction in their products from 2006 to 2008 was 85,144 lb. In 2006 the total lead contained in Aetna Insulated Wire, Inc.’s products was estimated to be 135,859 lb. In 2008 the total lead used in Aetna Insulated Wire, Inc.’s products was reduced to 50,715 lb. Customers are satisfied with the products. Aetna is poised to move forward with their new innovative lead-free products, which should open new opportunities for the company.
Lessons Learned
Superior and less toxic products can be manufactured and installed with the combined team efforts in a company and in partnership with customers. Aetna Insulated Wire, Inc. and their customers are striving to protect human health and the environment by reducing the amount of lead products that are put into service. Projects such as Aetna Insulated Wire, Inc.’s lead reduction initiative encourage innovation, improve efficiencies, save money and increase profit potential for customers and industry.