POLLUTION PREVENTION FOR THE PRINTING INDUSTRY · preferred:1 • Identify less polluting materials that can be substituted in the process • Use the existing materials in ways that

POLLUTION PREVENTION FOR THE PRINTING INDUSTRY

Disclaimer

This manual contains information about technology, equipment, andoperating practices that are available to the printing industry, and whichhave environmental advantages. However, not every technology isappropriate to every facility. In addition, mention of brand names is notan endorsement of that brand, but is used to provide examples of types oftechnologies or approaches.

Produced by: Research Triangle InstitutePost Office Box 12194

Research Triangle Park, North Carolina 27709-2194http://www.rti.org

Authors:Melissa Malkin Weber

Mark Bahner

http://www.rti.org/

Table of ContentsINDUSTRY PROFILE 3

OVERVIEW OF CURRENT PRACTICES AND TECHNOLOGIES ............................................. 3Imaging..........................................................................................................3Pre-Press Operations.....................................................................................3Press Operations............................................................................................3Lithography....................................................................................................3Gravure..........................................................................................................4Flexography...................................................................................................4Letterpress......................................................................................................5Screen printing ..............................................................................................5

POLLUTION PREVENTION (P2) 6

OVERVIEW ............................................................................................................... 6POLLUTION PREVENTION ASSESSMENTS ........................................................................ 6BARRIERS TO, AND MOTIVES FOR, POLLUTION PREVENTION ........................................... 7COMPARISON OF POLLUTION PREVENTION TO CONVENTIONAL “END-OF-PIPE”ENVIRONMENTAL SOLUTIONS...................................................................................... 8

STEPS FOR POLLUTION PREVENTION IN THIS INDUSTRY 10

IMAGING ............................................................................................................... 10PLATE MAKING....................................................................................................... 10PRESS OPERATIONS ................................................................................................. 11POST-PRESS OPERATIONS ........................................................................................ 14

STRATEGIES FOR TREATMENT AND DISPOSAL 15

IMAGING AND PRE-PRESS OPERATIONS..................................................................... 15PRESS OPERATIONS ................................................................................................. 15POST-PRESS OPERATIONS ........................................................................................ 15

ENVIRONMENTAL MANAGEMENT SYSTEMS (EMS) 16

EMS FOR IMPROVED DATA COLLECTION, EVALUATION, PROCESS OPERATIONS .......... 16EMS ELEMENTS NOT REQUIRED BY ISO 14001.......................................................... 18

Environmental Accounting Concepts ......................................................22Systematic Process Optimization Methods ..............................................22Measure Pollution Prevention ....................................................................22Life-Cycle Concepts...................................................................................22

APPENDIX A: RESOURCES, INCLUDING USEFUL INTERNET SITES 24

EPA DOCUMENTS .............................................................................................. 24JOURNAL ARTICLES ........................................................................................... 24IDENTIFICATION AND CONTACTS FOR U.S. TRADE ORGANIZATIONS......... 25USEFUL INTERNET LINKS...................................................................................... 25

3©Research Triangle Institute 1999

INDUSTRY PROFILE

Overview of CurrentPractices and Technologies

The technologies and products ofthe printing industry are diverse.This makes it difficult to describethe processes and environmentalissues faced by the industry as awhole. However, approximately97 percent of all printing facilitiesuse one or more of the followingprocesses: lithography, gravure,flexography, letterpress, andscreen printing.

There are four fundamental stepsused in most printing operations.These stages are: imaging, pre-press, printing, and post-pressoperations.

Brief descriptions of these fourstages, and the environmentalissues associated with them, aredescribed below.

Imaging

In this step, an image of thematerial to be printed isproduced. Traditionally, thisimage has been producedphotographically. However,electronic imaging is being usedwith increasing frequency.Wastes can include used andout-of-date film (when electronicimaging is not used), developer,

fixer, wash water, cleaningsolutions, and empty chemicalstorage containers.

Pre-Press Operations

In these operations, an imagecarrier (such as a plate) isproduced to transfer ink in theimage area, and repel ink in thenonimage area. The imagecarrier may become a solidwaste.

Press Operations

During printing, the image istransferred to a substrate ofpaper or some other material.Typical waste streams include:inks, substrate, and cleaningsolutions. Air pollution (from theevaporation of solvents in theinks) may also be produced.

Post-Press Operations

These operations can includecutting, folding, collating,binding, and many others. Themost environmentally significantpost-press environmental issuesarise from the glues used forbinding. Noise may generatedduring cutting, folding, andcollating may also be a concern.

The techniques used to produceprinted images are brieflydescribed below.

Lithography


Lithography relies on the propertythat oil and water do not mix. Aprinting plate coated with a lightsensitive material becomesreceptive to petroleum-basedinks, when exposed to light. Thenon-image areas remain water-receptive. Water-based“fountain solutions” are thenapplied to increase the ink-repelling ability of the non-imageareas. These fountain solutionstypically contain 5 to 10 percentisopropyl alcohol. Ink is thenapplied to the plate with rollers.The ink adheres only to the imagearea. The image is transferred toa rubber roller (“blanket”) andthen transferred to the printedarea.

Lithographic inks contain solvents,to speed the drying process. Inksthat are cured by ultraviolet (UV)light or electron beams are nowbecoming available; these inksdo not contain solvents.

Gravure

Gravure printing uses an electro-mechanically engraved coppercylinder to transfer ink to thesubstrate. The cylinder isengraved with tiny indentations,using a diamond stylus. Today,digital image files are used todirect the diamond stylus inalmost all gravure applications.

Ink is applied to the gravurecylinder, then wiped from thesurface using a “doctor blade”.This leaves ink only in the image

area. The substrate is pressedagainst the cylinder with enoughpressure to pick up ink left in thedepressions on the cylinder. Inksused in gravure printing must below in viscosity, in order to fill thetiny depressions. Therefore, manygravure inks contain solvents. Thesubstrate receives ink from thecylinder, then passes throughdrying ovens to dry the ink anddrive off solvents. Solvent-ladenair is frequently passed throughcarbon beds for adsorption. Thesolvents are then desorbed forreuse or destroyed byincineration. If low volatileorganic compound (VOC) inksare used, then the carbon bedsare not needed.

Flexography

Flexographic printing employsplates with raised images. Ink isapplied to the plate, thentransferred to the substrate. Thetypical flexograpic printing systemhas four rollers. Two rollers areinvolved in ink delivery. The thirdroller is the plate cylinder, and thefourth roller (the impressioncylinder) applies pressure to theplate cylinder, therebytransferring the image from theplate to the substrate.Flexographic presses have severalstations, with each station printinga single color. There are dryersafter each color station, and anoverhead tunnel dryer tocompletely remove all residualsolvents after the substrate exitsthe final color station.


Web widths range from approxi-mately 0.1 to 2.9 meters. Manywide-web installations now useenclosed doctor blade systems toreduce emissions from ink pans.Many narrow-web applicationshave converted to UV-curableinks.

Letterpress

Letterpress, like flexography,employs a plate with a raisedimage. There are three types ofletterpresses: platen, flat-bed,and rotary presses. Both platenand flat-bed letterpresses aremuch slower than flexographic,lithographic, or gravure presses.The most common letterpress isthe web-fed rotary letterpress,which is used for printingnewspapers. However, letterpressusage has declined significantlyin the United States. For example,most newspapers in the U.S. arenow printed with flexographic orlithographic presses.Letterpresses are used primarilyfor printing books and advertisingbrochures.

Screen printing

Screen printing, as its nameimplies, uses a very fine mesh.The mesh is stretched over aframe. A stencil is used to definethe image that will be produced.A squeegee applies pressure tothe ink, forcing it through themesh.

There are five types of inks used inscreen printing: solvent-based,water-based, or UV curable forgraphic applications, andplastisols or water-based fortextile applications. Screenprinting can be used with a widevariety of substrates.


POLLUTION PREVENTION (P2)

Overview

Pollution Prevention (P2) refers tothe systematic use of productsand industrial processes designedfrom their inception to preventthe pollution of air, water, andland. P2 also involves reducingwastes, making efficient use ofraw materials, such as energyand water. Finally, P2 means thecontinuous application of anintegrated preventiveenvironmental strategy toprocesses and products, toreduce risks to humans and theenvironment.

P2 looks at the following options,with the first being the mostpreferred:1

• Identify less polluting materialsthat can be substituted in theprocess

• Use the existing materials inways that create lesswaste/emissions

• Recycle or reuse thewaste/emissions on-site

1These priorities follow the “wastereduction hierarchy” established by theU.S. Environmental Protection Agency.(For more details see the US EPA’s 1997Pollution Prevention Report atwww.epa.gov/opptintr/p2_97/.)

• Recycle or reuse thewaste/emissions offsite

• Safely dispose of unavoidablewastes.

Methods for P2 include processmodification, raw materialsubstitution, equipment changes,procedural changes, andproduct development. Theobjectives are to minimizeresource use, quantity of wastesgenerated, and content ofenvironmentally harmfulsubstances.

Pollution PreventionAssessments

Facilities that are investigating P2often conduct systematic P2assessments. These assessmentshave the principal objective ofimproving the environmentalperformance of a facility byidentifying points where emissionsare being generated, includingsolid waste, hazardous waste,liquid waste, water, air emissions,and hazardous air emissions, andfinding ways to reduce thoseemissions. Each of these wastestreams represents points ofinefficiency in the process.

In addition, the P2 assessmentconsiders improvements in energy


efficiency. Energy efficiency canbe a strong cost driver for afacility. Where fossil fuels are used,energy is associated with airpollution. Where hydroelectricpower is used, energy demandcan be associated with disruptionof rivers and ecosystems.

Worker protection is also ofconcern in a P2 assessment, sinceworker safety is often affected byplant emissions. Worker safety is afinancial concern to companies(as well as a social concern),since an injured or disabledworker is less productive. Thisproductivity decline may betemporary or long-term. If theproductivity decline is long-term,a replacement worker may needto be trained. In addition, theremay be medical bills incurred.Firms can also expect to seelower employee turnover infacilities that are safer.

The issues of accident preventionand mitigation are alsoconsidered in a P2 assessment,since accidents like explosionsand fires are a serious, althoughinfrequent, environmentalperformance problem in industrialfacilities.

Barriers to, and Motives for,Pollution Prevention

P2 barriers that are internal to afacility include:

• A lack of information andexpertise

• A low awareness ofenvironmental issues

• Financial obstacles.• Lack of communication in

firms• Management inertia• Labor force obstacles• Difficulty in implementing

cleaner technology.

Barriers external to a facilityinclude:

• Difficulty in accessing externalfinance for pollutionprevention projects

• Improper economic incentives• An absence of markets for

recycled goods• Economic cycles.

Internal drivers (motives) forpollution prevention include:

• Environmental managementsystems and continuousimprovement

• Voluntary initiatives• Environmental leadership• Corporate environmental

reports• Environmental accounting• Improvements in productivity.

External drivers for pollutionprevention include:

• Innovative regulation andpollution prevention

• Negotiated self-regulation• Economic incentives


• Industry codes of practice (likethe Chemical Manufacturers’Association Responsible Careprogram)

• Education and training• Industry networking• Buyer supplier relations• Financial institutions• Community perceptions and

involvement• Environmental auditors• Green consumers• Increased access to

international markets

Comparison of PollutionPrevention to Conventional“End-of-Pipe” EnvironmentalSolutions

End-of-pipe treatment andcontrol solutions are curative.They apply changes in theindustrial process just before apollutant would have entered theenvironment. Examples includewastewater treatment plants andsolid waste storage and disposalfacilities.

Pollutants and wastes may simplybe collected, stored, or disposedof elsewhere. End-of-pipetreatment and control involvestechnological response toenvironmental pollution; littlechange is required inmanagement, direction, or theactual manufacturing process.

To date, “end-of-pipe” has beenthe predominant industry

response to environmentalimprovement.

P2 is a preventative approach. Itis a management process thatseeks out and eliminates thecauses of pollution, wastegeneration, and resourceconsumption at their source. P2uses materials input reduction orsubstitution, pollution prevention,internal recycling and moreefficient production technologyand processes. P2 requires a shiftin corporate philosophy, awayfrom reactive solutions, towardsan integrated approach whereenvironmental considerationsform a central component of thedecision making process. Itemphasizes a systems-basedapproach to environmentalmanagement in addition to thepurchase of new technologies.

Environmental benefits of P2include:

• Avoidance or reduction of theamount of waste produced

• A reduction in the use andproduction of toxic materials

• More efficient use of energyand resources

• The prevention of pollution atits source

• The production ofenvironmentally soundproducts and services.


Competitiveness benefits thatmay accrue to industry include:

• Improvements in productivity

• Savings on energy and rawmaterials

• Decreased storagerequirements for waste andtoxic materials;

• Decreased liability andaccident potential

• Savings on pollution controlexpenditure

• A focus on continuousimprovement

• An improved public profile.


STEPS FOR POLLUTION PREVENTION INTHIS INDUSTRY

Imaging

One significant opportunity forpollution prevention in theimaging process is the use ofelectronic devices to produceimages. Digital cameras, whichgenerate pictures through anarray of charge-coupled devices(CCDs), or with arrays ofcomplementary metallic oxidesemiconductors (CMOS), cancompletely eliminate film wastefrom imaging operations. At thepresent time, the picture qualityof digital cameras is not equal tothat of film, except in veryexpensive digital cameras.However, the cost of digitalcameras, like computers, isdropping extremely rapidly.Therefore, every printer shouldconsider the possibility of digitalimage production, at least inlong-term planning.

Another opportunity, short ofdigital photography, is in the useof non-silver photographic films,which are currently underdevelopment.

Operational and work practicechanges can extend the life ofdeveloping baths and reduce the

amount of chemicals used andwastewater produced.

The US EPA obtained data from70 plants conductingphotoprocessing operations. Theaverage total water use for the 70plants was 3.85 gallons per squarefoot ( 156.85 L/m2) of paperand/or film processed andranged from a low of 0.220 gal/ft2

(8.96 L/ m2)) to a high of 14 gal/ft2

(570.36 L/ m2)). More than 95percent of the process water usein each facility was for film andpaper washing. The US EPA alsoobtained data on typicalvolumes of silver-rich (high silverconcentration) and silver-poor(low silver concentration)wastewaters at printing/graphicart facilities with photoprocessingoperations. (See “PreliminaryData Summary for thePhotoprocessing Industry”, EPA-821-R-97-003, March 1997.)

Inventory control measures canbe used to reduce spoilage ofphotodeveloping chemicals andsupplies such as paper and film.

Plate Making

Liquid waste streams from the useof developer and fixer represent


significant pollution preventionopportunities in plate making.Liquid waste can be reduced byrecovering and recyclingdeveloper and fixer. Techniquessuch as counter-current washingcan be used to reduce theamount of wastewatergenerated duringcleaning/rinsing. Finally, carefulmeasurement and adjustment ofthe amount of water used toclean each plate cansignificantly lower wastewatergeneration.

One long-range method forreducing wastewater is through“washless” plate-processingsystems. These systems areexpensive to install, but they canreduce wastewater by as muchas 97 percent.

Plates and plate materials canfrequently be recycled to themanufacturer. Alternatively, thematerials can be sent to a metalrecoverer.

Long-range potential changes toplate-making operations includethe use of laser plate making,using non-silver films. Laser plate-making operations are currentlyunder commercial developmentin the United States. This systemcould replace chemicaldevelopment of plates.

Press Operations

A significant source of pollutionfrom most printing operations isthe volatile organic compounds(VOCs) that are driven off wheninks containing these compoundsare dried. Another source ofVOCs is in the cleaning productsused to clean the presses.Therefore, a primary pollutionprevention measure is usingalternative ink and cleaningproducts with reduced VOCemissions. Lowering the VOCemissions from printing and presscleanup may be accomplishedusing vegetable oil-based inks orwater-based inks (rather thansolvent-based inks) wherepossible, and using low-VOC orVOC-free cleaning solutions.

A more recent development inthe U.S. printing industry is the useof ultraviolet (UV) light or electronbeam curing, using newlyformulated inks. In many cases,UV and electron beam systemscan provide substantial gains inproductivity, in addition to virtualelimination of VOC emissions.These gains in productivity comebecause line speeds can bemuch higher with UV andelectron beam curing. Use of UVand electron beam curing isspreading beyond commercialprinting to include coatings forpackaging and vinyl flooring.http://www.epri.com/EPRI_Journal/dec_1994/Electech_cure.html

A significant problem with UVsystems is heat buildup, causedby the high line speeds and

http://www.epri.com/EPRI_Journal/dec_1994/Electech_cure.html

http://www.epri.com/EPRI_Journal/dec_1994/Electech_cure.html


dissipation of energy from thelamps. One company providesCold UV Excimer lamps toaddress this problem.http://www.colduv.com/

In the flexographic and gravureprocesses, open pans in the inkdelivery systems allow solvents toevaporate into the press room.This can create both employeesolvent exposure problems andan increase in fugitive emissionsto the atmosphere. Theseproblems can be addressed byusing enclosed doctor bladesystems. Enclosed doctor bladesystems also reduce solventusage for ink feed systemcleaning and result in less leftoverink at the end of the print run.Enclosed doctor blade systemscan also improve print quality,resulting in less solid waste fromoff-spec product. “FugitiveEmission Reductions Due to theUse of Enclosed Doctor BladeSystems in the Flexographic andRotogravure Printing Industries”,EPA-600/R-98-050, April 1998.

Small, on-site solvent distillationsystems can recover reusablesolvents from “spent” solvents orfrom cleaning wipes. Thesesystems use heat to evaporatepure solvents and then recoverthe solvents by condensation.One manufacturer of suchsystems is SRS Environment, withoffices in the United States andCanada. http://srsenv.com

A case study for a small on-sitesolvent recovery system wasperformed at Fildes Pty Ltd. Theyinstalled a special washingcabinet and distillation unit thatenabled the collection andreclamation of dirty solvent fromequipment cleaning operationsand ink residues. Prior installingthe system, Fildes had shippedapproximately 9,600 liters ofsolvent off-site for disposal,annually. Now clean solvent isrecovered, and the inert solidresidue (ink pigments) is sent to alandfill. The installation cost atFildes was approximately $26,600and the annual savings areapproximately $10,000. Thisrepresents a payback period ofapproximately 2.6 years.http://kaos.erin.gov.au/portfolio/epg/environet/ncpd/auscase_studies/fildes.htm

Automatic cleaning equipmentcan frequently be retrofitted toexisting presses and operations.These systems typically allowlower volumes of cleaningformulations to be applied. Aircontact, and thus volatilization, isreduced, and most automaticcleaning systems are designed toinclude recycling and reuse ofcleaning solutions.

Using diaphragm pumps, ratherthan mechanical vane pumps,can reduce ink vaporization.Diaphragm pumps do not heatink as much as mechanical vanepumps.

http://www.colduv.com/

http://srsenv.com/

http://kaos.erin.gov.au/portfolio/epg/environet/ncpd/auscase_studies/fildes.htm




Automatic ink levelers andautomatic viscosity measurementand control can maintain optimalink conditions and thus reducerejects.

Finished product rejects can bereduced by installing automated(noncontact) monitoringtechnologies to detect tears inthe web and to evaluate pressperformance.

Procedural changes can also beused to prevent pollution fromprinting operations. Theseprocedural changes can include:

• posting and requestingemployee input on indexes ofproduction efficiency (such asthe fraction of non-conformingproduct, scrap as a totalpercentage of materialproduced, air emissions as afunction of production),

• training employees on wastereduction and hazardousmaterials management,

• scheduling jobs according toincreasing darkness of inkcolor,

• covering reservoirs andcontainers (to reduce solventevaporation),

• using wipes as long aspossible, and controllinginventory,

• labeling all containers withcontents and use information,

• recycling waste solvents on-site or off-site,

• keeping the shop clean andorderly to help identify andeliminate spills and leaks,

• segregating solvents, to allowa second use (e.g., forequipment cleaning or inkthinning),

• recycling waste inks wherepossible, and

• recycling product rejectswhere possible.

The amount of waste papergenerated by printing operationsis highly variable. Paper wastegeneration rates at US printingoperations are dependent on thetype of process used (e.g.flexography, gravure, lithography,etc.). Paper waste also dependson the number of colors printed,the size of printing runs, and thetypes of post-printing operationsthat are used.

The Graphic Arts TechnicalFoundation (Pittsburgh,Pennsylvania) publishes TheLithographers Manual, whichcontains a table with scrapestimates for lithography. Thetable shows one-color, one-sidescrap rates varying from 8% for1,000 print runs, down to 3% for25,000+ print runs. Four colorscrap rates for 25,000+ runs areshown at 5-7%. Bindery wastesare shown to vary from 2-4% forfolding, stitching, and trimming,


up to 3-7% for varnishing andgumming. Details can be foundat the Graphic Arts TechnicalFoundation (GATF) website,http://gatf.lm.com/


One significant pollutionprevention opportunity in post-press operations is replacingVOC-based adhesives withwater-soluble adhesives.Replacement with water-solubleadhesives also allows recycling ofthe product, since adhesives thatare not water-soluble mayinterfere with the recyclingprocess.

Hot-melt adhesives andmechanical binding are otheralternatives to VOC-basedadhesives.

http://gatf.lm.com/


STRATEGIES FOR TREATMENT AND DISPOSAL

Imaging and Pre-PressOperations

The wastewater from pre-pressphotoprocessing operations hasbeen a focus of US regulationsdue to a number of parameters,including toxic metals (e.g.,silver), toxic chemicals, oxygendemand, ammonia, andbionutrients.

Virtually all pre-pressphotoprocessing operations inthe US use some form of silverrecovery. The most commontype is electrolytic recovery, withmore than 80% using this process.Other recovery methods includesteel-wool canisters, ionexchange membranes, andevaporation/distillation.

Press Operations

High-production publicationrotogravure operations in theUnited States have typically usedtoluene-based inks. High-production flexographic printingprocesses have

typically used alcohol/acetate-based inks. Carbon adsorption isfrequently used to remove theseVOCs from the dryer exhauststreams. The solvents are thendesorbed for reuse or destroyedby incineration.

It is possible to reduce the cost ofair pollution control equipment byreducing the air flow requirementfor capture of the solvent fumes.“Microprocessor Control ofRotogravure Airflows”,EPA/600/S2-86/068, November1986.


The amounts of volatilecompounds emitted from post-press operations usually do notjustify VOC controls. In order toprotect workers from exposure tovolatile compounds in post-pressadhesives (if the volatilecompounds can’t be eliminated)local close-capture local exhausthooding is recommended, ratherthan general room ventilation.


ENVIRONMENTAL MANAGEMENT SYSTEMS(EMS)

An EMS involves a structured,systematic way of identifying,addressing, and correctingenvironmental problems. The EMSwould normally involve elementslike assessing environmentalconcerns, establishing targets forenvironmental improvement,training managers and workers inenvironmental issues, andreviewing the facility’s progress.Typically, all of these activities willbe guided by an environmentalpolicy statement from thecompany’s management, whichprovides “top down” direction forenvironmental protection at thefacility.

ISO 14001 provides widelyrecognized specifications for anEMS. Many companies areadopting ISO 14001 EMSs as away of demonstrating to theircustomers or stakeholders thatthey have an acceptable level ofdealing with environmental issues.A company that hasimplemented an ISO 14001 EMScan hire an outside auditor tocome in and certify complianceto the ISO standard, or they cando their own internal audits andself-certify. Self-certification canbe a good interim option forcompanies that want the benefits

of an EMS, but do not yet havecustomer requirements for a full,externally certified EMS.

EMS For Improved DataCollection, Evaluation,Process Operations

Implementing a systematicstructured EMS can providebenefits to the company that gobeyond market drivers. A goodEMS, like a good quality system,can be a structure to ensureefficiency and can ensureconsistency of outcomes/products. Table 1 shows howcomponents of an ISO 14001 EMSoverlap with better processoperations.

Additional information about howdeveloping an EMS is availablefrom the following sources:

http://www.iso14000.com/DN_Article.htm—Provides overview ofbenefits of ISO 14001 in businessterms, including avoided liability,improved materials usage andbetter supply management.

http://www.epa.gov/OWM/wm046200.htm—EnvironmentalManagement Systems: An


Implementation Guide for Smalland Medium-Sized Organizations


Table 1. How ISO 14001 Components Relate to Process Operations

ISO 14001 Component Connection to Better Process Operations

Identify EnvironmentalAspects

Emissions points that are identified often arepoints of inefficient usage or potentialaccidents. Facilities should use their list ofenvironmental aspects to assess opportunitiesfor improved operations and better materialsuse (e.g., find ways to recirculate water,recycle scrap materials, reduce solventcleaning tank losses). They should also look atenvironmental aspects to see if there is aneed for better hazardous-accidentprevention.

Identify EnvironmentalTargets

When a facility chooses the targets that theywant to achieve, often they go back andre-analyze their production processes tofigure out how to achieve the targets.Periodic process analysis is beneficial toensure that all systems are optimized.

Evaluate Progresstowards EnvironmentalGoals

When evaluating whether goals have beenmet, facilities often keep closer track of theiremissions than they normally would. Forinstance, they may carefully monitor solventusage to identify the quantities of solventbeing used. This information can also be usedto identify optimal process conditions. Thepractices that lead to most efficient solventusage can then be implemented on a regularbasis.

http://www.epa.gov/opptintr/dfe/pwb/case_studies/case7/ --shows example of how onecompany (a printed wiring boardmanufacturer) developed itsaspects, objectives, and targets.

Table 2 provides a sample ofsoftware available to assist withISO 14001 implementation.

EMS Elements Not Requiredby ISO 14001


In addition to the requiredidentification of ISO aspects,impacts, and targets, there areelements of a good EMS topromote environmental


Table 2: ISO 14001 and EMS Software

Software Title Software Function Cost (if available) Available From

GreenScore Deals with environmentalself- assessment, ISO 14000readiness and evaluatesenvironmental policies andpractices

Program, $300.additional services:customized profile,$50; expert analysis,$150.

National Center forManufacturing Sciences,3025 Boardwalk Drive, AnnArbor, MI 48108-3266.Phone: (800) [email protected]://www.ncms.org

EHS/Life Cycle Facility Management;Environmental Health andSafety; RegulatoryCompliance for US Laws;Environmental planningand management;Incorporatesenvironmental costinformation withenvironmental data

Cost dependentupon system andoptions selected

Essential Technologiesformerly EIS InternationalCorporation, 1401Rockville Pike, Suite 500,Rockville, MD 20852.Phone: (3 01) 738-6900,(800) 999-5009; Fax: (301)738-1026.http://www.eisintl.com ;Email: [email protected]

EnvironmentalManagementSystems

Components includeMaterials (including surplusmanagement), MaterialSafety Data Sheets, Facility,Human Resources, AirManagement, WasteManagement (includingwastewater), Reporting,Bar Coding, and Navigate(Searching).

Cost will depend onoptions—modular/integrated andsingle user/network.e.g., site license (1-4workstations) for anintegrated system is$18,000 (+15%annual systemsupport); single useroption for a WasteMeasurement andReporting Package is$3,800.

Chemical SafetyCorporation; SybilKelly([email protected]), 5901 ChristieAvenue, Suite 208,Emeryville, CA94608-1932. Phone: (510)594-1000, (888) 594-1100;Fax: (510) 594-1100.http://www.chemicalsafety.com,[email protected]

EMS-Plus EMS-Plus helps usersevaluate an EMS based onwhether it incorporatescomponents known topromote environmentalimprovement. The toolleads the users through aseries of questions abouthis or her EMS, and thenprovides a report based onthe key EMS components

Free tool, accessedvia world wide web(used on—line, notdownloaded to userscomputer).

Research Triangle Institute;Melissa Malkin([email protected]), P.O.B.12194, Research TrianglePark, NC 27709. Phone(919) 541 6154. Fax: (919)541 7155.http://ems.rti.org/

(continued)


Table 2: ISO 14001 and EMS Software (continued)

Software Title Software Function Cost (if available) Available From

ICF 14000Workstation

Information managementtool to enable companiesto meet the ISO 14001specification. Lotus-basedapplication. Main modulesinclude assessment,conformance andsupporting documents

1 copy $1,295; 5copies $4,500,Additionalinstallation and usersupport $800,training $1,000.

ICF Kaiser International,Inc., 9300 Lee Highway,Fairfax, VA 22031 [email protected]

ISO 14000 EMSConformanceSeries

Software is designed tohelp the user develop andEMS, prepare for 14000implementation and learnto do internal audits for14000.

Each CD costs $1000for a total of 5 CD’s.Each can bepurchasedseparately or can bepurchased togetherwith a 10% discount.

Reality Interactive, 7500Flying Cloud Drive, fourthfloor, Eden Prairie, MN USA55344, (800) 675-7789

ISOsoft 14001 Contains four sections.Reference containsinformation on ISO 14001and developing an EMS;Assessment analyzes gapsbetween existing and ISO14001 requirement;Management organizesand tracks EMS tasks anddocument control.Manages informationabout EMS activities andprocedures(documentation, training,and inspections). Recordswhether ISO14001nonconformanceoccurred, which staffmanaged thenonconformance, whatsolutions were employed.

$1,495 for singlesite/single user; morefor multiple andnetwork licenses.

Intelex Technologies, Inc.,93 Skyway Ave., Suite 101,Etobicoke, Ontario M9W6C7 Canada, (800)387-4019,http://www.intelex.com/14000.html

ISO 14001ImplementationSoftware

Implementing ISO 14001,tracking documents andcompliance with ISO 14001administrativerequirements. Theimplementation toolprovides worksheets andguidance from ISO 14004.Assessment and auditingsoftware are alsoavailable.

$1,199 Single user,$2,099 for up to 5users.

Greenware EnvironmentalSystems, Inc. 145 KingStreet East, Suite 200,Toronto, Ontario, M5C 2Y8Canada, (416) 363 5577,[email protected]


improvement that are notspecifically required for ISO 14001.We refer to these as non-ISO EMSelements. Several of theseconcepts are described below.

Environmental AccountingConcepts

Environmental accountingconcepts suggest that a facilityshould integrate the cost ofwastes into decision-making. Forinstance, if a specific product linegenerates a hazardous wastethat causes fire insurance costs toincrease, then the facility shouldinclude that added cost into theprice they charge for the productline.

For an overview of environmentalaccounting as a businessmanagement tool see:http://www.epa.gov/opptintr/acctg/earesources.htm/ For casestudies and further informationsee: http://www.epa.gov/opptintr/acctg/ The TellusInstitute describes the relatedconcept of total cost accounting:http://www.tellus. org/r-tca.html

Systematic Process OptimizationMethods

Systematic process control helpsa facility optimize use of rawmaterials and energy, andreduce emissions and waste.Process optimization can beachieved with a variety ofmethods from simple

spreadsheets to computerizedsensing devices and statisticalprocess control methods.

Measure Pollution Prevention

Measurement is important toachieve good environmentalmanagement. In order to trackprogress towards environmentalgoals and objectives facilitiesshould track changes in wasteand raw materials over time.When this data is combined withinformation about production thefacility will have a betterunderstanding of how well theirenvironmental improvements areworking. See http://www.rti.org/units/ese/p2/documents.html formore information.

Life-Cycle Concepts

Life-cycle assessments (LCA) canbe used to provide a verydetailed comparison of theenvironmental impacts of aproduct, including all impactsassociated with its raw materials,usage, and disposal.

Traditional LCA can be quiteexpensive and data-intensive.However, the concepts of LCAcan be used in a less rigorous wayto help facilities understand thetrue environmental impacts oftheir activities.

For more links and information visitthe following web site:

http://www.epa.gov/opptintr/


http://www.tiac.net/users/tgloria/LCA/lca.html#Environmental andLCA


APPENDIX A: RESOURCES, INCLUDING USEFULINTERNET SITES

EPA DOCUMENTS

EPA Sector Notebook ProjectPrinting and Publishing: Profile ofthe Printing Industry. This sectornotebook provides anenvironmental profile of theprinting industry, industrial processinformation, pollution preventiontechniques, pollutant releasedata, United States (US)regulatory requirements,compliance/enforcement history,government and industrypartnerships, innovativeprograms, contact names, andbibliographic references. Thedocuments are available onlineat http://es.epa.gov/oeca/sector/index.html#print. You canalso order printed bound copiesfrom the Government PrintingOffice (GPO) at a nominal fee ofbetween $5 and $17. September1995.

Preliminary Data Summary for thePhotoprocessing Industry, EPA-821-R-97-003, March 1997.Published by the EPA Office ofWater. Discusses US regulationsfor wastewater, presents aphotoprocessing industry profile,describes photoprocessingoperations, discusses water use,wastewater sources and

characterization, control andtreatment technologies, andassesses environmental impactsof photoprocessing.

Fugitive Emission Reductions Dueto the Use of Enclosed DoctorBlade Systems in the FlexographicAnd Rotogravure PrintingIndustries. The report publicationnumber is EPA-600/R-98-050.Further copies of the report canbe ordered from the NationalTechnical Information Service(NTIS) by phone at 1-800-553-NTIS(6847) or (703) 605-6000 or by faxat (703) 321-8547. NTIS is locatedat 5285 Port Royal Road,Springfield, Virginia 22161.

JOURNAL ARTICLES

Nunez, C.M. and G.W.Deatherage; Evaluation ofInnovative Ink Feed Systems forthe Flexographic and GravurePrinting Industries, Journal of theAir & Waste ManagementAssociation, 46: 267-272, 1996.

Pferdehirt, W.P.; Roll the PressesBut Hold the Wastes: P2 and thePrinting Industry, PollutionPrevention Review, Volume3,Number 4: 437-456, Autumn 1993.

http://es.epa.gov/oeca/sector/index.html#print

http://es.epa.gov/oeca/sector/index.html#print


Wolf, K. ; Handwipe Cleaning:Are Low Vapor Pressure SolventsBetter?, Pollution PreventionReview, Volume 5, Number 3: 25-38, Summer 1995.

Miller, G.D., et al.; Reducing Inkand Cleaner Waste: aFlexographic Printer Moves toWaterbased Inks and Cleaners,Pollution Prevention Review,Volume 4, Number 4: 411-420,Autumn, 1994.

IDENTIFICATION ANDCONTACTS FOR U.S. TRADEORGANIZATIONS

Printing Industries of Americahttp://www.printing.org/PIA has 14,000 membercompanies and is the largestprinting and imaging tradeassociation in the world.

Graphic Arts TechnicalFoundation.200 Deer Run RoadSewickley, PA 15143 USAPhone: 412/741-6860 Fax:412/[email protected]://www.gatf.lm.com/

The Graphic Arts TechnicalFoundation is a member-supported, nonprofit, technical,and education organizationserving the international graphiccommunications industries. Itsmission statement reads “To servethe graphic communicationscommunity as the leading

resource for technical informationand services through researchand education.” GATF iscurrently comprised of nearly2,000 corporate members in 60countries throughout the world.The Foundation employs a staff ofapproximately 70 qualifiedpeople.

Printing Industries of America-Texas http://www.piatexas.org/emails.html PIA-Texas is a not-for-profit trade associationdedicated to providing a varietyof benefits and money-savingprograms to the graphiccommunications industry in allregions of the state except theTexas-Louisiana Gulf Coast.

USEFUL INTERNET LINKS

1. http://www.epa.gov/opptintr/dfe/flexography/flexography.htm The goal of this web site isto provide flexographers withinformation that can helpthem design an operation thatis more environmentally sound,safer for workers, and morecost-effective.

2. http://es.epa.gov/studies/cs614.html Case study ofactivated carbon system thatrecovers lost solvents forprinting plant.

3. http://www.flintink.com/domino/flintink.nsf Very usefulhomepage of Flint Inksfeaturing Product Close-ups(describes how printing inks

http://www.printing.org/

mailto:[email protected]

http://www.gatf.lm.com/

http://www.piatexas.org/emails.html

http://www.piatexas.org/emails.html

http://www.epa.gov/opptintr/dfe/flexography/flexography.html



http://es.epa.gov/studies/cs614.html

http://es.epa.gov/studies/cs614.html

http://www.flintink.com/domino/flintink.nsf

http://www.flintink.com/domino/flintink.nsf


are formulated and details onsome of their products). Alsoincludes companyenvironmental practices, InkPlus (their customer supportstructure), Ask an Expert, aprinters ‘library’, detailedtroubleshooting guidance forvarious types of printingproblems, links to variousprinting associations, andprinting Frequently AskedQuestions (FAQs). The enviro-updates focus mostly on USregulatory issues.

4. http://www.pneac.org/pneac.html This is acommunications-basedcenter. It links trade,governmental, and universityservice providers to efficientlyprovide the most current andcomplete complianceassistance and pollutionprevention information to theprinting industry. The project’sstaff are located within thepartnering organizations. TheGreat Lakes InformationNetwork is providing supportfor the two Internet Listservers.The site contains news, factsheets, case studies, regulatoryinformation.

5. http://es.epa.gov/techinfo/facts/fact2.html WasteReduction for the CommercialPrinting Industry. Thecommercial printing industrygenerates hazardous waste asa result of its variety ofoperations. This fact sheet

introduces the hazardouswaste reduction conceptspecifically for the commercialprinting industry.

6. http://www.epa.gov/earth1r6/6pd/rcra_c/pd-o/tt.htm#P3This site provides links to casestudies including the followingprinting-related studies:

• Distillation recovers solvent forprinting press cleanup

• High pressure spray cleaningequipment for inkmanufacturers

• Manufacturer of printed labels

• Pollution preventionopportunities

• Printer of forms and supplies forthe legal profession

• Printing plant finds distillationan economic way to recoversolvents

• Printing plate preparationsection of a newspaper

• Recycling, material andprocess substitution atphotographic equipmentmanufacture

• Reducing printing waste byrecycling water-based inksand solvent

• EPA Printing sector notebook .

7. http://www.epa.gov/opptintr/dfe/printing/usecluster/This report presents a profile ofthe printing industry and

http://www.pneac.org/pneac.html

http://www.pneac.org/pneac.html

http://es.epa.gov/techinfo/facts/fact2.html

http://es.epa.gov/techinfo/facts/fact2.html

http://www.epa.gov/earth1r6/6pd/rcra_c/pd-o/tt.htm#P3

http://www.epa.gov/earth1r6/6pd/rcra_c/pd-o/tt.htm#P3

http://www.epa.gov/opptintr/dfe/printing/usecluster/

http://www.epa.gov/opptintr/dfe/printing/usecluster/


defines a use cluster. Preparedas background for the U.S.Environmental ProtectionAgency (EPA), Office ofPollution Prevention and Toxicsanalysis of printing use clusterchemicals, this report presentsan overview of the chemicals,technologies, and processesused in the printing industry.Based on publishedinformation, this report’spreparation involved neitheroriginal research nor anindustry survey. A use cluster isdefined as a set of competingchemicals, processes, ortechnologies. Traditionally, EPAassessed the potential hazardsand exposure scenarios ofspecific chemicals, and,generally, left the evaluationof potential substitutes as apost-risk assessmentconsideration. The use clusterapproach considers allsubstitutes within a given use,and leaves consideration ofalternate uses as a potentialfollow up activity.

8. http://www.epa.gov/opptintr/library/ppicdist.htm#orderOrder form for a variety of EPApublications, including casestudies on VOC reductions.

9. http://www.epa.ohio.gov/opp/prntp2x.htmlPrinting Industry PollutionPrevention Resources from theOhio Office of PollutionPrevention.

http://www.epa.gov/opptintr/library/ppicdist.htm#order

http://www.epa.gov/opptintr/library/ppicdist.htm#order

http://www.epa.ohio.gov/opp/prntp2x.html

http://www.epa.ohio.gov/opp/prntp2x.html

Documents

POLLUTION PREVENTION FOR THE PRINTING INDUSTRY · preferred:1 • Identify less polluting materials that can be substituted in the process • Use the existing materials in ways that