SEPA
                            United States
                            Environmental Protection
                            Agency
                    Solid Waste
                    and Emergency Response
                    (5306W)
         EPA 530-F-97-020
         August 1997
Waste  Minimization:
Increased  Profits and
Productivity
Harris Corporation
    S125K Savings
Annually

    Exempted from CAA
and EPCRA Section 313
Requirements

Implementing small projects
that demonstrated the result-
ing savings to management
established credibility and
opened the door to greater
funding for waste minimization
 What is the Harris
 Corporation?

    The Broadcast Division of Harris
 Corporation manufactures radio and
 television transmitters. Their manu-
 facturing process released several
 hazardous air pollutants and haz-
 ardous chemicals such as 1,1,1
 trichloroethane (TCA), methylene
 chloride, and methyl ethyl ketone
 that were used as cleaning solvents,
 thinners, and degreasers.


 What Did They Accomplish?

    Harris implemented a broad
 range of waste minimization initia-
 tives that reflect the company's envi-
 ronmental policy. Harris' savings
 resulting from all of its waste mini-
 mization efforts total about $125,000
 annually.


 Environmental
 Achievements

    Harris' pollution prevention and
 waste minimization program is
 broad in scope and has enjoyed
 numerous successes...

     Alteration of the paint mixing
     process to a batch process
     reduced wastes from 1/4 gal-
     lon to less than a cup per
     batch, contributing to a reduc-
     tion in waste paint generation
    from 3,000 gallons per year to
    about 900 gallons per year.

    Installation of a solvent distil-
    lation unit also contributed to
    waste paint reduction.

    Replacement of TCA with iso-
    propyl alcohol during circuit
    board cleaning eliminated
    waste TCA.

    Replacement of methylene
    chloride in the vapor degreaser
    with an aqueous solution elim-
    inated 25,000 Ibs. of air emis-
    sions per year.

    Implementation of a closed-
    loop water supply for a spot
    welder cut water use.

    Replacement of an old, larger-
    than-necessary compressor
    reduced overall energy con-
    sumption by 4%.

    Replacement of two 45 kw
    water heaters with a single gas
    heater slashed energy use.


Regulatory Relief

   Because they eliminated methyl-
ene chloride from their vapor
degreaser, Harris avoided the need
to apply for a Clean Air Act (CAA)
Title V Permit and is not subject to
Emergency Planning and
Community Right-to-Know Act

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 Waste Minimization: Increased Profits and Productivity
 Harris Corporation
(EPCRA) Section 313 requirements.
The company is now on its way to
being regulated as a RCRA small
quantity generator. Also, by not
using chlorofluorocarbons or Class I
ozone depleting substances, Harris
avoided the mandatory labeling
requirements under the CAA. The
elimination of methylene chloride
obviated the need  for additional
ventilation in the metal finishings
room.
The Implementation Process

   The driving force behind imple-
mentation of Harris' environmental
efforts was a corporation-wide
emphasis on the need for quality
environmental compliance. As those
efforts matured, Harris transited
from a regulatory-based approach to
waste minimization and pollution
prevention, whereby the environ-
mental health and safety organiza-
tions contribute to the company's
bottom line.

   Harris continuously evaluates its
waste streams and processes, and
performs annual formal evaluations
to develop three-year, rolling strate-
gic plans.  Pollution prevention and
waste minimization efforts are incor-
porated into the business unit's
overall annual operating plan. The
plan is considered a living docu-
ment and its goals are subject to
change. Current goals are to:

    Reduce solid and hazardous
     waste;

    Continue compliance with
     environmental safety regula-
     tions;
    Reduce toxicity of metal finish-
     ing chemicals;

    Reduce utility costs by 10% per
     year; and

    Increase quality.

   Most ideas were generated in
house. However, when the compa-
ny eliminated its methylene chloride
vapor degreaser and switched to an
aqueous degreaser, it contacted the
Illinois technical assistance program
for an analysis of available aqueous
degreasers.
Economics: Costs and
Payback

   Reductions in paint waste have
resulted in enough savings to pay
for the changes several times over
since 1992.  Reduction in water con-
sumption resulting from implement-
ing a closed loop system on the spot
welder has  saved about $14,000 in
water and sewage fees per year, cut-
ting the division's annual water
costs by 15%. The spot welder pro-
ject paid for itself in less than three
months. Savings in the electric bill
resulting from replacement of the
oversized compressor are about
$20,000 per year, representing 4% of
the division's electric bill.
Replacement of the two 45 kw water
heaters saves $5,100 per year.


Hurdles

   The biggest difficulty was in
securing project funding from upper
management. Manager of Facilities
and Environmental Compliance
Andy Edgar's solution was to estab-
lish the necessary credibility for
obtaining project funding. He
accomplished this by implementing
small projects that targeted "easy
money" and demonstrated the
resulting savings to management.
This established credibility and
opened the door to greater funding.


Words to the Wise

   Mr. Edgar advises that managers
wishing to implement waste mini-
mization focus on trying to add
value to the company. This helps to
keep the projects from being viewed
as a necessary evil.

   In addition, he is a proponent of
tapping non-management employ-
ees who "...have a thorough knowl-
edge of their job, and credible ideas
of how to develop and implement
improvements."
       WASTE
        MINIMIZATION
        NATIONAL PLAN
For more information about the Waste Minimization National Plan, call (800) 424-9346
or check the World Wide Web at http://www.epa.gov/epaoswer/hazwaste/minimize
                                          Reducing TOXKS m Our Data's Waste

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