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P2 for Printing Processes
MI DEQ & RETAP Pollution Prevention (P2) Training
Cam Metcalf, Executive DirectorRichard Meisenhelder, P2 SpecialistLori Hoetker, Technical Coordinator
Kentucky Pollution Prevention Center (KPPC)
❒ DO NOT LOOK @ Upcoming SLIDES!
❒ Turn to page 54 in the GUIDE & use these Process Maps (Levels 1 & 2 only) to determine printing process:
ActivitiesProductsServices
Planning Exercise: Activities, Products & Services
Activities Products Services(Subactivities)
Prepress
Press
Postpress
Art/Copy AssemblyGraphic Arts ProcessingPlatemaking
Press Make-ReadyPrinting
Cutting/FoldingBinding/Finishing
Printed MaterialsBrochuresCatalogsArt PrintsEtc.
ReceivingShippingMaintenanceAdmin.PurchasingEHSManagersLaboratory
Input/Output Map forPrepress Processes
Art/Copy Assembly& Design Production
Plano-graphic Plate making
Graphic Arts Photography/Image Processing
Paper
FilmWashWater
DeveloperFixer
Cleaning Solution,Chemical Storage
Containers
Plates Water
Developer,Gum ArabicGlue
Spray
WastePaper
VOCsUsed Film,
RinseWater
SpentDeveloper and Fixer,
Silver, VOCs
Dirty Rags,Empty
ContainersUsedPlates
RinseWater
SpentDeveloper
Activity Aspect Impact
Prepress
Air EmissionsVOCs
Solid Waste Generated:Paper, film, rags, plates
Containers, etc.
SpentDeveloper & Fixer
Rinse Water
Recycling ofPaper, film,
plates
Reuse of Rags (Commercial
Laundry)
Air Pollution
Use of Landfill(Hazardous or non-hazardous)
Reduced useof landfillReduced use
of landfillWater
Pollution & SpillsContamination ofwater, air & soil
Water Pollution
Improve Overall Controls
❒ Environmentally Preferable Purchasing (EPP)
Raw materials review & purchasing program (SW)
❒ Inventory control: First In, First Out❒ Practice Waste Separation❒ Employee Training ❒ Inspect waste storage containers for leaks
Pre-Press Processes❒ Photo-processing
DevelopingCover developer and fixative containersMinimize dragout – rollers, squeegeesRecycle spent developer and fixer
Water rinsesOptimize bath temperature to 80 FWater conservation by intermittent water control Silver recovery from waste water
Reduce Solid Waste – improperly exposed film, packaging, containers, customer rework
Segregate and recycle
❒ Latest Trend --Increased digital work now –
Pre-Press Processes Cont.❒ Plate Production
Chemical etching of plate (high quality, $$$)Nitric acid etching chemical Proper handling, minimizationHazardous waste handling
Optical etching of plates (typical)Developer – see previous controlsWater – see previous controls
Solid WasteRecycle aluminum plates
Intermittent/Ancillary ProcessesGraphic Arts Photography
Mixing Solutions(fixer & developer)
1-1-a1
Camera/ProcessorMaintenance
1-1-d1
Gloves
Filling SolutionBarrels1-1-a2
Aprons
Water
Aprons
DirtyAprons
Wastewater
SpilledSolution
Solution
Aprons
SpilledSolution
WasteCleaner
Dirty Rags
GlassCleaner
Lubricant?Rags
DirtyAprons
Intermittent/Ancillary ProcessesGraphic Arts Photography
WashwaterRecycling Unit
1-1-b1
Wastewater
Filling SolutionBarrels1-1-a2
Silver SpentFixer
Sludge
DirtyWashwater
CleanWashwater
Spent FixerContaining
Silver/MercurySilver,
Mercury
Pre-Press Processes
❒ Press PreparationInspect rolls, machinery for defectsTest Proof
Reduce solid waste by proofing before running production.
Optimize press production planningMinimize solvent use for changes and clean-up.
Printing Processes
❒ Press Make-ready❒ Printing
Solid WasteSet up press carefully w/ test runs
InksSelection of inks w/ low metals, VOC content.Keep containers closedAnti-skin additive
Press Clean-up
❒ SolventSwitch to an automatic wash-up if possible (Reduce solvent by 1/3)Switch to least toxic solvent as possible (may require new ink)Minimize use by applying on towel and not machine. Recover solvent by distillation, microwave treatment, etc.
❒ TowelsLaunder and reuse after recovery process.
❒ Excess InkReadjust runs to reduce amount of excess ink. Filter and save for next color runSend to ink recycler for off-site treatment
Post-Press Processes
❒ Post-PressAdhesives
Select low VOC glues
Solid wastePlan layout before printing to minimize wasteMinimize overrunsRecycle trimmingsRecycle rejects
Resource Conservation❒ Latest technologies:
May require less energy, water, labor & chemicalsMay reduce set-up & make-ready times
❒ Monitor electric & water to determine:What activities consume them? Assign costs to those areas and activities.What measures might reduce usage?
❒ Monitor solid and hazardous wasteAssign & track costs in areas that generate it.
Employee “Involvement”
❒ P2 roles & responsibilities for all employees
❒ Training & awareness programs
❒ Reward program for P2 suggestions & accomplishments
MI DEQ & RETAP Pollution Prevention (P2) Training
Cam Metcalf, Executive DirectorRichard Meisenhelder, P2 SpecialistLori Hoetker, Technical Coordinator
Kentucky Pollution Prevention Center (KPPC)
www.kppc.orgThe Next Steps:
Assess P2 Opportunities