Presentation II - Pollution Prevention Techniques …infohouse.p2ric.org/ref/27/26745.pdf · presentation ii: pollution prevention techniques training instructors’ guide slide 11-1

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POLLUTION PREVENTION TRAINING INSTRUCTORS’ GUIDE PRESENTATION II: POLLUTION PREVENTION TECHNIQUES

Slide 11-1

PRESENTATION I1

POLLUTION PREVENTION TECHNIQUES

FOR LITHOGRAPHIC PRINTERS

I1 - 1 MARCH 1996

POLLUTION PREVENTION PRESENTATION 11: POLLUTION PREVENTION TECHNIQUES TRAINING INSTRUCTORS' GUIDE

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Slide 11-2

OVERVIEW

0 PRINTING PROCESS STEPS, MATERIALS USED, WASTES AND EMISSIONS

P2 TECHNIQUES FOR EACH STEP OF THE PRINTING PROCESS

ECONOMIC AND ENVIRONMENTAL BENEFITS OF POLLUTION PREVEN?

0

0

Lithography, the largest sector of the printing industry, accounts for 47% of the U.S. market share. Many of the estimated 35,000 lithographers in the U. S. are small businesses with fewer than 10 employees. Less than 15% of lithographic printers employ more than 20 people.

The U.S. EPA places printing in the top 10 U.S. industries for amounts of toxic waste released to the air, water, and land and disposed of in hazardous waste management facilities. In 1990, printing and allied industries generated 56 million pounds of toxics based on Toxic Release Inventory (TRI) reporting. This figure is likely higher because many small and medium size businesses are not required to report under the TRI program.

IN

the economic and environmental benefits associated with each.

[Instructors' Note: Although we will address the major processes, wastes generated and pollution prevention techniques that apply to this industry, we could not possibly cover everything in this brief training session. Ask the audience to let you know if there are important P2 methods that are missing.]

In this presentation, we will briefly review printing processes, materials used, wastes generated, and other forms of pollution associated with this industry. Then we will discuss P2 techniques, including which pollution-related problems they can solve, and

I1 - 2 MARCH 1996

POLLUTION PREVENTION PRESENTATION II: POLLUTION PREVENTION mCHNIQlJES TRAINING INSTRUCTORS' GUIDE

Slide 11-3

PRINTING STEPS

a PREPRESS - IMAGE PROCESSING AND PLATEMAKING

0 PRESS

a POSTPRESS - BINDING AND FINISHING

In terms of pollution prevention, lithographjc printing can be organized into three steps:

a prepress including image processing and platemaking,

a press, and

a postpress.

The processes to prepare an image and transfer it to a plate are similar because a photographic process is used in both activities.

The press step includes everything that occurs on and around a printing press. Press cleanup is an important activity in printing.

Postpress involves binding and finishing.

Remember that, regardless of the step, pollution prevention techniques are based primarily on reducing the amount and toxicity of materials used and the wastes generated.

[Instructors 'Note: In order to understand the pollution-related problems or concerns that your audience may have, you may want to ask participants about what processes, equipment and materials they use and their issues. This will help you decide which processes, problems and P2 techniques to focus on.]

Wastes are generated from materials and resources used in each step and from cleaning press equipment. The diagram on page II-6 will help you understand the relationship between the materials you use and the wastes that are generated.

Breaking down printing like this should be familiar - many of you develop bids for jobs by looking at the cost of each step. Also, most printing facility employees look at printing this way.

I1 - 3 MARCH 1996


[Instructors 'Note: You should hand out this diagram to your audience. Use the version in Appendix H. To encourage your audience to think about the wastes generated by the various processes, consider covering up the bottom section of the diagram and asking your d e n c e to name the wastes generated. ]

Because image processing and platemaking are similar processes, they use similar materials and generate similar wastes.

The major wastes generated by the three steps include :

Repress

e Film

e Wastewater -- spent fucer and developer

0 Silver

e Toner

0 Toner cartridges

0 Water and energy

Platemaking

e Wastewater -- aqueous developer (usually nonhazardous)

e Used plates -- aluminum, plastic, paper, others

0 Waste ink (waste and reusable)

Waste paper (including film scraps)

VOC emissions from inks, solvents, fountain solutions

0

0

e Empty ink containers

e Waste press lubricating oils

e Energy

Cleaning Equipment

0 Waste solvent

e Cleanup towels

0 Waste ink

e Empty solvent containers

e v o c s

0 Wastewater

Postpress

e Waste paper trimmings

e v o c s

e Waste glue

e Energy

e Water and energy

Press

I1 - 4 MARCH 1996

PRESENTATION II: POLLUTION PREVENTION TECHNIOUES POLLUTION PREVENTION

TRAINING INSTRUCTORS' GUIDE

This presentation will now focus on the source reduction, resource conservation, reuse and recycling techniques that will help you reduce waste and address pollution-related problems associated with prepress, press and postpress processes.

The costs of these techniques, as well as their payback to your business and the environment, will be highlighted.

Before we get into the specific techniques and methods, I want to mention the importance of evaluating the techniques to determine if a technique will work for your facility. Although many of these techniques may be feasible, each facility has different constraints. Presentation I11 will provide some tools to help you determine whether a technique will work for your facility.

I1 - 5 MARCH 1996

PRESENTATION n: POLLUTION PREVENTION TECHNIQUES POLLUTION PREVENTION


INVENTORYCONTROL I. ESTABLISH INVENTORY CONTROL SYSTEM

USE MATERIALS FOR INTENDED PURPOSE

LABEL, DATE, AND INSPECT MATERIALS WHEN PURCHASED

USE A "FIRST IN FIRST OUT" POLICY

CONTROL ACCESS

HANDLE MATERIALS CAREFULLY

Even before you create an image or run a job, you can make decisions that affect waste generation. Prior to looking at prepress, our first printing step, it's important to review proper inventory control, which affects waste generation throughout the facility.

Properly controlling inventory is a relatively easy, cost-effective way to ensure that materials are used efficiently, do not go to waste, or become a problem. Inventory control techniques include:

Establishing an inventory control system that tracks supplies and materials and minimizes the purchase of unneeded materials (e.g., just in time systems). Why purchase new ink if you have the necessary color onsite? There

are simple methods and software packages available to help you accomplish this task. Go to Slide IF5 which shows a printer's ink inventory.

[Instructors' Note: Ink and solvent inventory can be controlled to avoid wastes generated by expiration of materials beyond their shelf life. Any expired inks and solvents must be handled as hazardous waste. The minimum cost for disposal of these expired materials is at least $300 per 55-gallon drum. j

Go to Slide 11-6.

I1 - 7 MARCH 1996

POLLUTION PREVENTION " T A T I O N 11: POLLUTION PREVENTION TECHNIQUES TRAINING INSTRUCTORS GUIDE

0 Using materials only for their intended purpose. For example, don't use a solvent to clean a spill that a shop towel or a wipe could handle.

0 Labeling, dating and inspecting stock as it is received. Use the earliest labeled stock first to prevent material degradation and loss (Le., follow a "first in first out" policy).

0 Control employee access to materials. Designate one or a limited number of employees to maintain and have access to supplies to ensure that employees do not use more materials for a job, or for a cleaning, than are necessary. The pressroom supervisor may be a good candidate for this job.

0 Improving procedures for storing and handling materials carefully to prevent spills. Storing materials to prevent spills (e.g., not overstackmg) and keeping supplies in contained areas to control spills that may occur. Your inventory control coordinator should also have overall responsibility for maintaining storage areas. However, this coordinator could delegate this task to another employee. Go to Slides II-7 and 11-8 which show proper containment of acids and flammable materials.

Go to Slide II-9.

Facility owners and managers should encourage employees to properly control inventory by establishing written procedures and communicating these procedures to employees through training and by posting signs and notices around the facility. Provide incentives to employees to practice pollution prevention, such as considering their efforts in salary reviews and having an awards program (e.g., employee of the month program that encourages job performance including setting a good example for p2 and efficiency).

I1 - 8 MARCH 1996

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Slide 11-21 Prepress

RECYCLING ACTIVITIES

TONER AND TONER CARTRIDGES

ALUMINUM PLATES

0 PLASTIC PLATES

Certain prepress wastes can be recycled including :

0 toner and toner cartridges used in image processing,

aluminum plates, and

plastic plates.

Many vendors will recycle toner and toner cartridges. Once they can no longer be reused, aluminum plates can be sold as scrap. Recyclers will often pay you for your al-um plates.

You may have to pay a recycler to pick up plastic plates because their value is minimal.

I1 - 18 MARCH 1996


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Slides 11-22. 27

BEST MANAGEMENT PRACTICES

0 SMART MATERIALS MANAGEMENT

0 INVENTORYCONTROL

0 SCHEDULING AND MANAGING JOBS CAREFULLY

Press

Now, let's talk about the press step. In printing, the plate accepts ink from a roller and transfers it to a blanket and then to paper. Go to Slide 11-23 which shows a five-color press operating.

Successful lithographic printing requires the press operator to be thoroughly familiar with both the press equipment and how the inks and other materials behave. Ink, fountain solution, water, substrate and press adjustment all play a role in achieving the proper image. Go to Slide 11-24 which shows establishing product quality objectives by defining an acceptable color. Go to Slide II- 25 which shows a pressman adjusting and monitoring the press and its output. These are critical steps that must be taken to avoid bad runs (Go to Slide 11-26) which are costly and generate wastes.

Go to Slide 11-27.

Pollution-related problems in press operation focus on VOC emissions from inks, fountain

solutions and cleaning agents, generation of hazardous waste ink and the environmental and employee health and safety concerns associated with these emissions. Reducing and adequately managing press cleanup wastes, which present similar concerns, are discussed in the next section.

Low cost BMPs canbeusedto reduce inkuse and wastes. For example,

0 Keep ink containers sealed and contents leveled; place plastic or waxed paper on top of the ink to prevent oxidation and spray ink with an antiskinning agent.

0 If your facility is large enough, presses can be dedicated to specific colors or to hazardous inks only, decreasing the number of cleanings needed for each press.

0 Use a standard ink sequence for process colors.

. I I - 19 MARCH 1996

POLLUTION PREVENTION PRESENTATION n: POLLUTION PREVENTION TECHNIQUES TRAINING INSTRUCTORS' GUIDE

0 Schedule runs from lighter to darker colors to decrease the amount of cleaning necessary.

0 Improve accuracy in job estimation.

0 Carefully monitor inventory to assure that older inks are used in a timely fashion and inks are only ordered if necessary.

0 "Prethink" printing jobs and inform customers about the environmental impacts associated with particular color, paper or printing method choices.

[Instructors' Note: These BMPs are presented in the Iowa Waste Reduction Centerpublication listed in Appendix G.]

I"entingBMPst0reduceinksorto"iZe other wastes requires a commitment from facility management as well as proper employee procedures and training.

WhohasexpiemewiththeseBMPs? Whichones work best?

Next, we'll cover other P2 techniques in printing including using lower VOC inks, more efficient press equipment, and recycling.

I1 - 20 MARCH 1996


Slide 11-28 Press

MATERIAL SUBSTITUTES

0 VEGETABLE-BASED INKS

0 ISOPROPYL ALCOHOL (IPA) FREE FOUNTAIN SOLUTIONS

Substitutions in press operations are available for inks and fountain solutions.

0 Vegetable-based inks. These inks, including soybean and linseed oil- based, can significantly reduce VOC emissions. Soy inks have as little as less than 1 percent VOC content and are particularly useful for printers who must meet air quality agency permit requirements or who want to avoid having to get a permit triggered by a certain level of VOC emissions.

[Instructors' Note: Soy inks are comparable in price and quality to petroleum-based inks. All types of soy inks are available, including metallic and fluorescent. Inform your customers of the quality and benefits of soy- based inks. Some soy inks may not be as rub- resistant as oil-based inks and may dry more slowly. lYowever, many printers find that customizing dryers and using drying powders help them obtain good results. Examples of manufacturers are Western Ink, Soya, Gans Enviroset, and Kohl & Madden Ultrasoy 11.3

IPA-containing fountain solutions and help to reduce VOC emissions. Be sure to check if you can use IPA substitute solutions on your press equipment. You will probably have to adjust settings and watch the process closely until you are familiar with how the solution behaves (i.e., there is a significant learning curve associated with making major changes. You can often get help from vendors). Examples of non-IPA solutions are Suranol-Summit Fountain Solution and Prisco Alkaless R and Q Series.

0 IPA-free fountain solutions are more expensive than P A products. However, you will use less because they don't evaporate as much.

0 Indoor air quality improves by using low VOC products. Employees will be exposed to less air emissions.

What materials do you use that reduce wastes and emissions?

0 Fountain solutions that contain IPA substitutes can be as effective as

I1 - 21 MARCH 1996

POLLUTION PREVENTION TRAINING INSTRUCTORS' GUIDE PRESENTATION n: POLLUTION PREVENTION TECHNIQUES

Slides 11-29, 31 Press

EQUIPMENT MODIFICATIONS

a FOUNTAIN SOLUTION REFRIGERATION

a AUTOMATIC INK SETTERS

a AUTOMATIC INK LEVELERS

a INK AGITATORS

a WATERLESS PRESSES

Equipment modifications can often be made to your existing press. Most of these modifications function as press attachments, and include:

a Fountain solution refrigeration units reduce evaporation and maximize efficiency. Go to Slide 11-30 which shows a fountain solution refrigeration unit designed to recirculate solution to a four color press (the unit's covers are ofs but they should be on).

[Instructors' Note: Non-IPA fountain solutions do not need to be rejhgerated to reduce evaporation and VOCs (since there are no VOC emissions). However, printers have found that non-IPA solutions function better when chilled to a constant temperature.

Refrigeradon of fountain solution is not cost efsective for small printers.]

Go to Slide 11-31.

a Automatic ink setters reduce time and waste during the make-ready stage.

a Automatic ink levelers ensure ink is distributed evenly across the press ink tray.

a Ink agitators can be installed on the ink tray to prevent premature ink oxidation.

[Instructors' Note: Automatic ink levelers can be installed on most presses, but are most appropriate for large presses. Print facilities with small presses can eflciently spread the ink by hand.]

I1 - 22 MARCH 1996

POLLUTION PREVENTION TRAINING INSTRUCTORS' GUIDE PRESENTATION n: POLLUTION PREVENTION TECHNIQUES

0 Waterless presses are available which require no fountain solution or water, but involve a significant capital expenditure. Heat is used instead to transfer the image to the blanket. Manufactures include Water Mark Press, Thompson Litho, and Color Graphics. Equipment costs can be as high as $200,000.

[Instructors' Note: references on waterless presses. 3

See Appendix G for

What equipment modifications have paid off for you?

11 - 23 MARCH 1996

POLLUTION PREVENTION TRAINING INSTRUCTORS' GUIDE PRESENTATION II: POLLUTION PREVENTION TECHNIQUES

Slide 11-32

RECYCLING ACTIVITIES

e WASTE INKS

e INK CANS

0 LUBRICATING OILS

e PAPER

Press

Most wastes generated by the press operations can be recycled.

Waste inks are often considered hazardous wastes because of the presence of heavy metals. Waste inks should be manifested and sent to an energy recovery facility or a recycler. Very large printers, generating large volumes of waste ink, may find it cost effective to contract with a waste ink recycling firm who will arrange to recycle waste ink onsite with a e

certified mobile unit. Remember to segregate waste ink colors prior to recycling -

0

How many of you dispose of waste ink that is recovered as energy or recycled?

prevent recycling in many areas. Check with your local recycling company to see if they will accept these cans. Some may accept cans ifthey are washed and crushed. Can crushers that process 5-gallon cans and smaller cost about $1,500.

Press lubricating oils can be recycled. Any amount above a quart can be accumulated and recycled.

Most types of paper can be recycled. Separate your colored paper. Go to Slide 11-33 which shows a white paper recycling bin.

e Look into recycling ink cans. However, regulatory concerns about residual ink that remains on cans may

I1 - 24 MARCH 1996

POLLUTION "NTION PRESENTATION n: POLLUTION PREVENTION TECHNIQUES W I N I N G INSTRUCTORS' GUIDE

Slide 11-34 Press

REDUCING PRESS CLEANUP WASTES

PROCEDURAL IMPROVEMENTS

SOLVENT SUBSTITUTIONS

AUTOMATIC BLANKET WASHERS

b REUSING AND RECYCLING CLEANING WASTES

A well-operating press is critical to meeting pollution prevention goals. In addition to preventive maintenance, regular cleaning is also necessary to keep the many moving parts of the press operating. Cleaning solutions are generally petroleum-based and contain up to 100% VOCs. A single cleaner may not be the best way to clean rollers, blankets and the outside of the press.

control authorities. In addition to VOC emissions from cleaners, other wastes include waste cleaner with residual ink and shop towels. Waste solvents must be handled as hazardous waste. Shop towels that are heavily soiled with solvent and ink may be considered hazardous wastes. However, most shop towels can be laundered or disposed of as a nonhazardous solid waste.

Blanket cleaning uses approximately two-thirds of cleaners applied to the press. This is cleaning include: because blankets must be very clean to ensure

ink and dry quickly without leaving any residue. Solvents used for rollers should be less volatile so the solvent spreads over all rollers before evaporating.

Pollution prevention techniques for press

print quality. The cleaners must remove excess b Procedural improvements, such as:

- Clean presses as needed, not on a schedule. But, don't let ink build up on the equipment.

Press cleaning generates VOC emissions which expose employees to toxic chemicals. Dependmg on your emissions from inks and solvents, you may be directly regulated by air pollution

I1 - 25 MARCH 1996

POLLUTION PREVENTION TRAINING INSTRUCTORS' GUIDE PRESENTATION 11: POLLUTION PREVENTION TECHNIQUES

- Use a two-step cleaning approach (apply a cleaning solution with a higher VOC content as step one and immediately rinse with a low VOC cleaner as step two).

- Use the smallest amount of cleaner possible and apply cleaners with rags instead of pouring solvent over the parts.

- If cleaners must be poured over rollers or press parts, use a catch pan beneath parts.

0 Low (reduced) VOC solvents. These alternative solvents may increase cleanup time but provide the benefits of reduced VOC solvents. Follow "facturers' recommendations. Many low VOC cleaners tend to be water- soluble or water-miscible and often require a water rinse following application. Low VOC solvents do not dry as quickly as traditional solvents. These types of solvents have prices comparable to traditional solvents. If you have concerns about the ability of a 30% VOC solvent to clean your presses' blankets properly, experiment with a low VOC cleaner on your rollers first. Examples of these products are Varn California Wash, Ecolo Clean, Prisco Environmental Series, and Enviroklene.

0 Recycled solvents. Recycled solvents substitute for virgin products. Many vendors sell recycled solvent. Price

is similar to or lower than a virgin product. Quality may be inferior depending on how you use the solvent (e.g . , larger quantities may have to be used).

0 Automatic blanket washers may reduce how much solvent is used and reduce how much time is required for cleanup. This equipment is only cost effective for large presses.

Many cleaning wastes can be reused cost- effectively. Reuse activities include:

0 Using dirty solvents initially to cut heavy deposits, such as those that occur with varnishes. Clean solvents should be used for a final wipe down. Ensure that this method can meet your quality requirements.

0 Laundering shop towels used for cleanup. Many printers already get their shop towels from a commercial laundry service.

[Instructors 'Note: Most laundry services will accept shop towels with residual ink and solvent, but not shop towels soaked with solvent. You should have a container for your dirty shop towels that has a screen and drip pan on the bo#om so that solvent can drain from the shop towels and collect in the drip pan below. ]

0 Recycling cleanup solvents. [Instructors' Note: The waste solvent you generate will help you decide if onsite solvent recycling will save money or if using a vendor makes more sense. Mostprintersflnd it more

I1 - 26 MARCH 1996


cost efsective to contract with a vendor. Solvent distillation units are available in difserent sizes. The smallest units can handle 5 gallons of waste solvent per batch and cost $1,500 to $3,000. Most distillation units pay for themselves well within two years because you will save money in disposal costs and in virgin solvent purchases. of course, you need to consider some factors before deciding to install a solvent distillation unit, including the amount of solvents you use and the increased liabilities and regulatory requirementsassociated with onsite recycling.

r f you do not recycle solvent in your facility, you can pay a solvent recycling company to come to your facility to pick up your used solvent and have it recycled. Generally, 70% to 80% of used solvent can be recovered and sold back to generators at a reduced cost.]

I1 - 27 MARCH 1996

PRESENTATION n: POLLUTION PREWNTION TECHNIOUES POLLUTION PREXJENTION


Slide 11-35 Postpress

REDUCING AND RECYCLING POSTPRESS WASTES

LOWER VOC AND LESS TOXIC GLUES

WHITE PAPER

COLOR PAPER

CARDBOARD

Postpress includes binding and finishing. Printers apply glue and other binding materials (e.g., plastic spiral) to the products. Finishing involves any trimming that may be necessary. For example, when printing posters, there is usually some excess space on the margins that must be trimmed.

The primary wastes generated in postpress are paper trimmings and waste glue. Many glues generate VOCs. Of course, bindmg machines use electricity.

e Talk to your vendors and review material safety data sheets to identify lower VOC and less toxic glues that will work for you.

0 All types of paper and cardboard can be recycled.

I1 - 28 MARCH 1996

POLLUTION PREVENTION PRESENTATION III: IMPLEMENTING POLLUTION PREVENTION TRAINING INSTRUCTORS' GUIDE

Slide 111-1

PRESENTATION I11

IMPLEMENTING POLLUTION PREVENTION

I11 - 1 MARCH 1996

POLLUTION PREVENTION TRAINING INSTRUCTORS' GUIDE PRESENTATION 111: IMPLEMENTING POLLUTION PREVENTION

Slide 111-2

FOUR STEPS TO POLLUTION PREVENTION

COMMIT TO POLLUTION PREVENTION

IDENTIFY POLLUTION-RELATED PROBLEMS AND P2 OPPORTUNITIES

SELECT POLLUTION PREVENTION TECHNIQUES

ZMPLEMEjVT AND MONZTOR TECHNIQUES

In order to implement pollution prevention techniques, follow these four simple steps:

1) Commit to pollution prevention.

Since pollution prevention techniques may involve modifications to your operations, support&- - hmownersandmanagers are needed. Employees also need to understand the benefits associated with pollution prevention and support related operational changes. Also, informing your customers about products that employ P2 and their benefits is critical to implementing P2.

Owners, managers, employees and customers are motivated to support €2 in somewhat different ways.

For instance, owners may be mncerned most with the bottom line while employees may care most about health and safety issues and having a manageable workload. Customers want a quality

product at a reasonable cost (even though many will be willing to pay a little more for a product that helps protect the environment).

The key to implementing p2 is finding solutions that create win-win situations for everyone.

2) Identify pollution-related problems you want to address and associated P2 opportunities based upon a review of facility activities.

3) Identify, evaluate and select appropriate pollution prevention techniques. In general, the following business factors should be considered in selecting pollution prevention techniques. These factors can be considered pros and cons for P2 techniques :

technical feasibility equipment a n d m a t e r i a l

I11 - 2 MARCH 1996

POLLUTION PREXENTION PRESENTATION In: IMPLEMENTING POLLUTION PREVENTION TRAINING INSTRUCTORS' GUIDE

costs 1 a bor cos ts

waste management costs training efforts permit requirements health and safety issues product or service quality environmental benefits annual cost savings and payback period (if applicable)

and - remember, source reduction should be prioritized over recycling and reuse.

4) Implement the techniques and monitor their effectiveness.

Get help from trade associations and other organizations (e. g . , government technical assistance programs) and keep abreast of new developments.

111-3 MARCH 1996

POLLUTION PREVENTION PRESENTATION HI: IMPLEMENTING POLLUTION PREVENTION TRAINING INSTRUCTORS' GUIDE

Slide 111-3

POLLUTION PREVENTION EXAMPLES

Now let's practice what we've learned about pollution prevention by discussing a few examples of pollution-related problems and opportunities for P2 associated with facility activities.

The examples are:

problems and opportunities for P2 is probably preferable. If you choose to use your own examples, ask your audience earlier in the workshop (i. e., at beginning of Presentation 11) which problems concern them and then develop your a q l e s with this input in mind.]

Inventory control, and

Press cleanup wastes.

[Instructors' Note: Distribute pollution prevention examples and four copies of the checklist to each workshop participant. Use the instructors' notes to facilitate a group discussion on identiBing pollution-related problems and opportunities for P2 associated with the examples. For your convenience, business factors are highlighted for each possible P2 technique. Focus on presenting the fact situation and asking the questions, look to your audience for potential techniques and pros and cons. Use your instructors' notes only as needed to facilitate the discussion. Although these examples are probably appropriate for most audiences, developing your own examples based on your audience b

I11 - 4 MARCH 1996

Slide 111-4

POLLUTION PREVENTION CHECKLIST

FOCUS ON P2 TECHNIQUES THAT ADDRESS POLLUTION-RELATED PROBLE:

CONSIDER BUSINESS FACTORS

We'll use a simple checklist as a tool.

4s

The checklist can help you select the best P2 technique to address the pollution-related problems and opportunities for P2 you've identified. It is a tool to help you evaluate pollution prevention techniques by looking at a range of business factors.

Check off the factors that are important. The checklist provides an area to write down the problems and opportunities you are addressing. Determine which business factors may apply and make notes as necessary.

I11 - 5 MARCH 1996

POLLUTION PREVENTION I’FCESENTATION 111: IMPLEMENTING POLLUTION PREVENTION TRAINING INSTRUCTORS’ GUIDE

POLLUTION PREVENTION TECHNIQUE REVIEW CHECKLIST

POLLUTION-RELATED PROBLEMS:

POTENTIAL TECHNIQUES:

BUSINESS FACTORS TO CONSIDER FOR EACH POTENTIAL TECHNIQUE:

TECHNICAL FEASIBILITY:

EQUIPMENT AND MATERIALS COSTS:

LABOR COSTS:

WASTE MANAGEMENT COSTS:

TRAINING EFFORTS (for new procedures):

PERMIT REQUIREMENTS (new or modified permit or regulatory requirement):

HEALTH AND SAFETY:

PRODUCT OR SERVICE QUALITY:

ENVIRONMENTAL BENEFITS (reduced raw materials consumption, hazardous and solid waste generation, etc.):

ANNUAL COST SAVINGS (annual cost of current practice minus annual project costs)

PAYBACK PERIOD (capital project costs divided by expected annual savings):

WHICH TECHNIQUES CAN BE IMPLEMENTED IMMEDIATELY?

WHICH REQUIRE MORE INFORMATION?

WHICH ARE PROBABLY NOT PRACTICAL?

I11 - 6 MARCH 1996

POLLUTION PREXENTION PREsENTATION Ill: IMPLEMENTING POLLUTION PREVENTION TRAINING INSTRUCTORS' GUIDE

,

I11 - 7 MARCH 1996

c

PRESENTATION HI: IMPLEMENTING POLLUTION PREVENTION POLLUTION PREVENTION


INVENTORY CONTROL EXAMPLE

This lithographic printer, with 10 employees, has two offset presses. Photoprocessing is done in- house. The company uses aqueous plate processing equipment. Employees have open access to materials, including cleaning solvents, photoprocessing solutions, and inks. Inks purchased are premixed and ordered monthly based on a rough estimate of needs. Ink and solvent containers, as well as photoprocessing baths, are often left uncovered. The facility owner is concerned about high materials use, particularly expired ink that requires disposal, and increasing costs for solvent disposal.

What are the pollution-related problems generation. Also, waste ink and solvent associated with this example? generation can be reduced by using less

hazardous materials and increasing process 1. High materials use because of open access efficiency (e.g., scheduling runs from

to supplies and imprecise estimating lighter to darker colors to decrease the procedures. amount of cleaning necessary).

2. Significant hazardous waste disposal costs because of high materials use and expired ink.

3. Increased VOC emissions and impacts on employee health and safety and regional air quality because of uncovered containers and baths.

What are the potential P2 techniques that could address these problems? (taken in order by problem).

1. Implement a proper inventory control system including "prethinking" materials needs, mixing inks onsite or ordering them based on more accurate estimates, using a tracking system, assigning an individual to control access to materials (See pages II- 7,8, 19 and 20 for more ideas and specific information).

2. Inventory control will help reduce materials use and, therefore, waste

3. Cover containers and baths to reduce emissions (See pages 11-8, 9, and 18).

Business factors that should be considered to evaluate each technique (taken in order):

1. Materials costs (savings from reduced ordering, increased costs from ordering in smaller quantities, no bulk discount).

Waste disposal costs (savings from reducing amount of expired and wasted materials).

Labor costs (increased time to closely track materials needed).

2. Materials costs (savings from reduced ordering, increased costs from ordering in smaller quantities, no bulk discount).

Waste disposal costs (savings from reducing amount of expired and wasted materials). Labor costs (increased time to closely track materials needed).

I11 - 8 MARCH 1996

PRESENTATION HI: IMPLEMENTING POLLUTION PREVENTION POLLUTION PREVENTION


Product quality (negative impacts that could result from using alternative materials).

Training costs (to train employees on use of alternative materials).

Materials costs (potentially increased costs of alternative materials).

Waste disposal costs (savings fkom reduced amounts generated).

3. Materials costs (reduced materials needs because of less evaporation, spills).

Labor costs (minimal, if any, costs for properly covering containers).

Equipment costs (minimal costs for installing covers and lids on photoprocessing solutions).

Health and safety (less employee exposure to VOCs).

I11 - 9 MARCH 1996

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POLLUTION PREVENTION PRESENTATION 111: IMPLEMENTING POLLUTION PREVENTION TRAINING INSTRUCTORS GUIDE

PRESS CLEANUP WASTES EXAMPLE

This printer, with 25 employees, has four offset presses. The facility uses a petroleum-based cleaner with a 90% VOC content to clean both blankets and rollers. This printer generates a volume of emissions that the local air pollution control district is considering regulating. The printer's employees have complained occasionally about exposure to VOCs and heavy odors from solvents and inks.

What are the pollution-related problems associated with this example?

1. Local air district is considering regulating this facility.

2. Employees are concerned with exposure to VOCs in the press room.

What are the potential P2 techniques to these problems? (taken in order by problem).

1. Use a lower VOC cleaner for rollers or a lower VOC cleaner for both rollers and blankets.

2. Implement procedural changes: use the smallest amount of cleaner possible; use catch pans under the press parts; and a two step cleaning approach (applying a cleaning solution with a higher VOC content as step one to be immediately rinsing with a low VOC cleaner as step two).

[Each of the above techniques addresses the two pollution-related problems] .

Business factors that should be considered to evaluate each technique (taken in order):

1. Materials cost (low VOC washes are slightly more expensive).

Permit requirements (may eliminate need for air permit).

Training (employee training needed to use low VOC washes).

Health and safety (reduced exposure to emissions).

Waste disposal costs (no significant change, still handled as hazardous waste).

2. Materials cost (lower costs because less product use).

Labor cost (more time to implement procedural changes).

Permit requirements (may eliminate need for air permit).

Training (employee training and supervision needed to implement these techniques).

Health and safety (reduced exposure to emissions).

Waste disposal costs (lower because of reduced use of cleaners).

Labor cost (more time required to wash presses, increased drying time).

I11 - 10 MARCH 1996

Documents

Presentation II - Pollution Prevention Techniques …infohouse.p2ric.org/ref/27/26745.pdf · presentation ii: pollution prevention techniques training instructors’ guide slide 11-1