Waste Reduction & Management Tony’s Pizza

Jay ReimerSalina, Kansas

September 14, 2007

About Me

• Kansas State University– Junior standing in Biological & Agricultural

Engineering– Expected graduation date: May 2009

• Career Interests– Bio-Medical Engineering

• Imaging Systems• Medical devices & technology

• Hometown: Beatrice, Nebraska– Raised on a dairy and crop farm

Project Flow Chart

Identify

Qualify

Quantify

Disposal

Reduce

Reuse

Recycle

• Projects:

1. Waste Water Treatment Plant (WWTP) Chemical Room Audit

2. Waste Control Project

Hazardous Waste Identification

1. Is the material a solid waste? • (40 CFR 261.2)

2. Is the waste specifically excluded form RCRA? • (40 CFR 261.4)

3. Is the waste a listed hazardous waste? • (40 CFR 261.30)• F-list, K-list, P-list, & U-list

4. Does the waste exhibit a characteristic of hazardous waste? (40 CFR 261.20)

• Ignitability, corrosivity, reactivity, toxicity

Rechargeable Batteries

Radio Battery Use

01020304050607080

2007* 2006 2005 Avg.Use/yr.

Years

Num

ber o

f Bat

terie

s

Nickel CadmiumNickel Metal Hydride

• Nickel-cadmium (Ni-Cad) and lead-acid batteries– Universal (Hazardous) waste

• 40 CFR 273

• Nickel metal hydride (NimH) batteries are NOT hazardous

• Disposal Method: Safety-Kleen recycles them

• Possible replacement battery chemistry– Lithium ion

Rechargeable Battery Recycling Corporation (RBRC)

• FREE battery recycling program

• Offer pre-paid and pre-labeled containers

• Cell phones ARE accepted

• No alkaline batteries

Implemented

Absorbents

• Used to clean up liquid spills– Pig-Mats--------------------------------------------149 Rolls– Pig-Socks/Other absorbing socks------------2000 Each– Corn Cob-------------------------------------------135 Gal.

• Proper Disposal Method:– If used to soak up non-hazardous/non-regulated liquids

• Thrown away in the trash

– Soak up regulated liquid (glycol, used oil, etc.)• Safety-Kleen

In Compliance

Aerosol ProductsTotal Annual Aerosol Product Usage (Excluding Spray

Paints)

0

1000

2000

3000

4000

5000

6000

7000

1

Num

ber o

f Can

s

2005

2006

Predicted 2007

• Current Disposal Method1. Punctured, then the liquid is drained into a 55 gallon drum2. Sent to the landfill

• Alternate Disposal Method1. Punctured, liquid drained2. Cans are recycled as scrap metal with Charles Heath, Jr.~1,600 lbs./160 cuf. diverted from the landfill (annually)

Aerosol Product Usage (2006-Present)

FMO 350JAX cleaner/degreaser Penetrating oilSS CleanerAerostripKool SprayLube TracLok CeaseClearexDaratheneDylekFoam InsulationUltra last 566 ss coatingDry Glide316 silicone sprayPurgel klear

In Progress

Mapp Gas & Leftover Paint

• Mapp Gas (1 lb. containers)– Disposal Methods

• Remaining gas is released to air• Empty containers are sent to the landfill

– Larger containers are not feasible

• Paints, Enamels, etc.– Disposal Methods

• Remnants are solidified– Becomes a RCRA solid waste (not regulated)

• Sent to the landfill

In Compliance

WWTP Audit Summary

*Quantities supplied by the Parts Room & the Purchasing Department

Material Amount Units Disposal Method Project Status

Aerosols 5328 Each Scrap Metal Recycling In progress 

Rechargeable Batteries 85 Each RBRC program Implemented

Paint, Stains, Enamels 243 Gallons Solid waste (landfill)  In Compliance

Spray Paints 248 Each Landfill In Compliance

Absorbing Socks 2007 Each Safety-Kleen In Compliance

Pig Mats (15"x150') 149 Rolls Safety-Kleen In Compliance

Corn Cob (absorbent) 135 Gallons Safety-Kleen In Compliance

Mapp Gas (1 lb. bottle) 175 Pounds LandfillNot Implemented; currently in compliance

• Compiled a notebook

• Contained each waste stream, brief description, & an MSDS

Parts Washer Solvent

• 3 Main Programs-----Hazardous Waste Code - D039– Continuous Use– Recycle-Kleen

• Recycling parts washer– Normal Use (what Schwan’s was doing)

Model Serial # Svc term (wks) Cost/service Annual cost51520 7574 16 $228.00 $741.00

52520 7575 18 $290.00 $837.78

52520 7576 18 $290.00 $837.78

52520 7577 52 $290.00 $290.00

52520 7578 18 $290.00 $837.78

53520 7579 4 $200.00 $2,600.00

         

33150  Transportation 12 $256.70 $1,111.00

   

Total   $7,255.34

Recycling Parts Washer

• Advantages – Clean Solvent on demand– Longer service terms– Eliminates hazardous

waste manifests– Helps reduce generator

status

• Disadvantages– More expensive

• Transportation Shop Quote- $172 more

– Disrupts current process– Gives off an odor during

recycling mode

Not Recommended

Continuous Use Program

• Advantages– Used solvent leaves as a hazardous product, NOT a

hazardous waste– Annualized cost is not increased– Changes only occur in paperwork

• Minimal change in current procedure

• Disadvantages– Amount of total solvent used remains the same

Implemented

Continuous Use Program

Solvent Use (2006-Present)

0102030405060708090

Month/Year

Qua

ntity

(Gal

lons

)

Main Plant

Transportation

• Annual hazardous waste reduced (2006 data)– Main Plant: 3,700 lbs. (552 gallons)– Transportation Shop: 1,000 lbs. (150 gallons)

Safety-Kleen Profiles

Waste Streams Hazardous Qty/yr. UnitsEPA Waste

Codes Cost ($/yr.) SK Profile #Oily water, propylene, shop

T. No 550 Gal. N/A $1,630.00 3419586

Used Oil No 4,350 Gal. N/A $0.00 3420495

Corn Cob (Absorbent) No 134 Gal. N/A $669.43 428016

Machine Tool Coolant1 Yes 116.67 Gal. DOO8 $683.05 40189494

Machine Rebuild Oil Yes 50 Gal. DOO7, D039 $176.36 2188639

Machine Tool Coolant Yes 475 Gal. D039 $3,022.73 2188640

Star Flex GCMI 90 No 119 Gal. N/A $0.00 3420457

Waste Paint Yes 37.5 Gal. D001, D005 $237.27 2279374

Used Oil No ----------- Gal. N/A $0.00 3420456

• Eliminated 4 active profiles (down to 5)1-Activated in 2007

Styrofoam

• Usage of Styrofoam products in break-rooms– Approximate disposal amounts and used landfill space

• Alternatives:– Recycle– Different type of product

Product Usage (wk) Usage (yr) Volume (cuf/yr)Cups 20,000 1,040,000 2,884

10" Plates 1,000 52,000 295

6" Plates 250 13,000 27

9" Plate 100 5,200 24

Bowls 800 41,600 47

6 oz. cups 100 5,200 226

       

Total 3,503

Styrofoam Cup Alternatives

Name Number/weekCost

($/1000)Cost

($/cup)Number of cups/year

Cost ($/yr.)

Styrofoam 20,000 $18.00 0.0180 1040000 $18,720.00

Eco-Wise Hot cups 20,000 $130.00 0.1300 1040000 $135,200.00

Sage Waxed Paper Cup 20,000 ----------   0.0272 1040000 $28,288.00

ECO-Hot Cups 20,000 ----------     ---------- 1040000 ----------

Not Recommended

Begin selling in October 2007

Styrofoam Recycling Machine

• TGL Chem. Machine– Loaded into top– Shredded– Sprayed with chemical

solution that releases the air– Gel is collected in a trash bag

• NEPCO– Front Loaded– Shredded– Forms a small cube– Minimum-250 lb/hr

In Progress

Waste Crust & Dough

• Roughly 2 million pounds thrown away each year• Current disposal method:

– Pig Farmer (Belcher Farms)– Landfill– $145,400 to dispose of waste crust– $15,000 for waste dough

Crusts for Bio-Fuel• Utilize waste crust and dough as an ethanol

feedstock• Advantages

– 80,000 gallons of ethanol by utilizing current waste stream

– Equivalent $120,000 of feedstock (corn @ $4.00/bushel)

• Challenges– Finding a company willing to partner with us– Processing the waste

• Drying• Size reduction• Mixing with ethanol company’s current feedstock• Transportation In Progress

Crust & Dough for Animal Food

• Garry Waldren has been working on this project– Found a customer that will partner with us

• Advantages– Schwans would dispose of its waste for FREE

• Challenges– Size reduction– Moisture control

In Progress

Summary of Waste Streams

Finishing the Internship

• Finalize decision/process for waste crusts• Written Project Report

– For Kansas State, Pollution Prevention Institute• Third-shift stacking• Rack Design

– Bread Racks– Silver Racks

3rd Shift Stacking

Acknowledgements

• Frequent contacts during internship– Jay Yarochowicz– Lynette Crawford– Greg Newton– Garry Waldren– Randy Simmons– Bob Padgett (Safety-Kleen)– Lori Baeza (Safety-Kleen)

• Internship was a great opportunity

Looking Back…

• Lessons Learned– Communication

• How to ask questions

– Taking the initiative– Sense of the business world

• How industry functions in comparison to a classroom

– Planning– Problem Solving

• Obstacles– Finding information

Questions?