A Cooperative Project
between the
U.S. Environmental
Protection Agency
and the
Printing Trade
Associations
Nationwide
October 1996
EPA 744-F-96-015
                          ONMB
                                                                          LITHOGRAPHY PROJECT BULLETIN 4
                   U.S.EPA
 BULLETIN
          HIGHLIGHTS
This Bulletin highlights
How to Find a Better
Blanket Wash for
Your Company

•The Blanket Wash Comparison
 Worksheet

• A Description of Nine Different
 Cost Categories
 ALSO IN T
         •iis BULLETIN^

'Hidden Costs of Your Blanket Wash

'Questions to Ask When You Call
 Your Blanket Wash Supplier

'What You Can Do to Compare
 Blanket Washes: A Checklist

•Use the Worksheet to Choose
 Other Chemicals for Your Shop
      A Worksheet to Help YOU
            choose  a Better Wash
There are many factors to consider when choosing a blanket wash or other press chemical
that is best for your shop. Perhaps the most obvious are purchase price and performance.
But there are other, less obvious factors that are just as important. How flammable is the wash?
Is it a regulated material? How hazardous is it to worker health or to the environment? Even
if it is cheaper to buy, a wash that is more hazardous, or one that is regulated, may have large
hidden costs that make it more expensive in the end.

The worksheet contained in this bulletin identifies many of these costs, both obvious and not
so obvious.  Use it to compare your blanket wash options - it may help  you find a blanket wash
that is better for your shop.
                           The Worksheet: How Does it Work?
                              The worksheet can help you compare test blanket washes to your normal wash. Complete
                              the worksheet after you (or your press operators) know how well the test wash works
                              (this may take a week or two of use). When you answer the questions and add up the
                              scores, the worksheet will tell you if the test wash may be a better choice for your shop.


                              All information  needed for the worksheet is available from:

                                 •  the press operators in your shop who have been using the test wash

                                 •  the Material Safety Data Sheet (MSDS) that comes with the blanket wash

                                 •  your blanket wash supplier
                        If the Final Worksheet Score Is...

                           Greater than zero

                           Less than zero

                           Equal to zero*
                          Then...
                             The test wash may be a better choice than
                             your normal blanket wash

                             The test wash may not be a better choice
                             for your facility than your normal blanket wash

                             The test wash is approximately the
                             same as your normal wash
                        * If the test wash appears to be approximately the same as your normal wash overall, look at each
                         individual category. Which is most important to you? Different scores in that category may still
                         help you decide which blanket wash is best for your shop.

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                                                                                                             ?
Could a  substitute blanket wash be  a better choice for your facility?
             Use the scorecard below to figure out whether a substitute blanket wash may be a better choice for your facility.

             Add the scores to see if the substitute wash is better, worse, or the same as your current wash.
             Test Wash:
             Supplier Name and Phone:



             Compare the test wash to the blanket wash you normally use for the following questions and enter the score of your

             answer in the column on the right:
Compared to your normal blanket wash,
                                                        -2
  Scores
-1       o
1
 1  Is the price per gallon of the test blanket wash:	Much more    More    Same   Less     Much less

 2  Is the amount of test wash used to clean each blanket:	Much more    More    Same   Less     Much less

\3\ Is the time required to clean a blanket with the test wash:	Much more    More    Same   Less     Much less

 4  What does the press operator think of the test blanket wash? Is it 	Much worse   Worse   Same   Better   Much better


             Consult MSDS forms and contact the blanket wash supplier to answer questions 5-9:


 5  Does the test wash contain hazardous chemicals as defined by Federal/State environmental regulations or OSHA? Yes = -2 No = 2


                                                                                 Scores

Compared to your normal blanket wash,                                     -2         -101          2

 6  Is the vapor pressure of the test wash: 	Much higher   Higher   Same   Lower   Much Lower

 7  Is the percentage VOCs of the test wash: 	Much higher   Higher   Same   Lower   Much lower

|8| Is the flash point of the test wash:	Much lower    Lower   Same   Higher   Much higher

 9  How does the test wash compare on any other factors: 	Much worse   Worse   Same   Better   Much better
Enter
Score
Below
                                Add all nine scores on this worksheet to get the total score for this test blanket wash.       I0t3l
                                                           Remember, when adding negative numbers -2 + 2 = 0.


What does the score mean?
            A score greater than zero means the test wash may be a better choice than your facility's regular wash,
            a score of zero indicates that the test wash is approximately the same, and a score of less than zero
            indicates that the test wash may not be a better choice for your facility.
                                                                                                         Design for the Environment B


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      Worksheet
Quest
o  n  s
                  What  Do They  Mean?
Purchase price: Compared to your normal blanket wash. Is the price per gallon of the
test blanket wash much more, more, the same, less, or much  less?
        The most obvious difference between two blanket washes is the cost to buy them. Compare
        the cost per gallon of your normal wash to the test wash. Answer "much more"
        if the test wash costs twice as much as your normal wash or "much less" if it is half the
        price or less. Factor in dilution ratios for those washes that  are shipped as concentrates.
Amount used  per cleaning:  Compared to your normal blanket wash. Is the amount
of test wash used to clean each blanket much more, more, the same, less, or much less?
        The more wash you use each time you clean a blanket, the more it costs you. Ask press
        operators how much of the test wash is needed to clean the blanket compared to the amount
        of normal wash. Answer "much more" if it takes twice as much test wash or "much less" if it
        takes less than half as much to clean the blanket.

Time to clean  a blanket: Compared to your normal blanket wash. Is the time
required to clean a blanket  with the test wash much more, more, the same, less, or
much less?
        Press downtime costs money. If the test wash takes twice as long to clean the blanket, answer
        "much more". Answer "much less" if the test wash takes only half as long as your normal wash.

Press  operator opinion: Compared to your normal blanket wash. What does the press
operator think of the test wash? Is it much worse, worse, the same, better,  or much better?
        Ask press operators to compare the test wash to the normal wash on odor, blanket swell, the
        time required for the press to come back to color, the effort required to use the washes, and
        any other factors they think are important. Combine these into an overall score for this ques-
        tion.
                                            Use the
                                            Worksheet to
                                            Choose a Better
                                            Roller Wash Too!
Hazardous chemicals: Does the test wash contain hazardous chemicals as defined by
environmental laws or the Occupational Safety and Health Act (OSHA)?
        Contact the supplier or manufacturer for this information.  A variety of environmental regula-
        tions apply to hazardous materials because of their potential dangers to people and the envi-
        ronment. Violations may result in large fines. At the very least, using a regulated hazardous
        chemical may increase compliance costs. Ask your blanket wash supplier if the blanket wash,
        or its waste, is considered hazardous under any environmental law (such as RCRA, CAA, CER-
        CLA, or EPCRA - Section 2, etc.) or under OSHA. Never mix hazardous and non-hazardous
        wastes. The hazardous chemicals in a blanket wash, as defined by OSHA, are usually listed in
        Section 2 of the MSDS form. If this section says "none", your test wash probably does not con-
        tain OSHA hazardous chemicals. But beware. The MSDS lists OSHA hazardous chemicals only.
        The blanket wash may still contain chemicals defined as  hazardous by other environmental reg-
        ulations.  If this section is blank, ask your supplier. See Questions to Ask When You Call
        Your Blanket Wash Supplier for more information.
                                                                                                Design for the Environment S

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Evaporation:  Compared to your normal blanket wash. Is the    I |f ,he test W3Sh l/apOr pieSSUIG (ill llllllHg) IS      Score
vapor pressure of the test wash much higher, higher, the same,
lower, or much lower?                                               More than ten times higher                        Much higher
         See MSDS Section 3 - Physical and Chemical Characteristics - for
        vapor pressure information. Vapor pressure is a measurement of
        how quickly a chemical evaporates. The higher the vapor pres-     Between 1 -5 times ni9ner and 1 -5 times lower          Same
         sure of a blanket wash, the quicker it evaporates. If a blanket       Between 1.5 times and ten times lower               Lower
        wash has hazardous ingredients, they can evaporate into the air in
              ,          ,   .      ,,        .       ,   „     ,          More than ten times lower                        Much lower
        your shop, enter the lungs of your workers, and pollute the sur-
        rounding environment.  If the vapor pressure of your test wash is
        less than the wash you are currently using, it may evaporate less in your shop. Vapor
        pressure is usually expressed in mmHg. Call your supplier if the vapor pressures of the
        washes are expressed in different units. 10 mmHg is usually a regulatory cut-off, but the
        lower the vapor pressure the better.

Environmental Regulations  and Worker Health:  Compared to your normal
blanket wash. Is the percentage VOCs of the test wash much higher, higher, the same, lower,
or much lower?
        Contact supplier or manufacturer for this information.  The amount of Volatile Organic
        Compounds (VOCs) in your blanket wash can affect your costs of complying with
        environmental regulations, especially CleanAir Act regulations on emissions from your shop.
        VOCs contribute to lower level  smog and may have health concerns.  If the test blanket wash
        has low or no VOC content, your environmental compliance responsibilities (and costs) may
        be lowered and the health and safety of your employees may be improved. You might need to
        contact your blanket wash manufacturer for this item (see Questions to Ask When You Call
        Your Blanket Wash Supplier  for more information). Score "much higher" if the percentage
        VOC content of the test wash is two times or more that of the normal wash or "much lower" if
        the percentage VOC content of  the test wash is two times or  more lower.  Score "same" if with-
        in 10%.

Flammability:  Compared to your normal blanket wash. Is the flash point of the test wash
much higher, higher, the same, lower, or much lower?
        See MSDS  Section 4 - Fire and Explosion Data - for flash point information. The flash point
        is one measurement of the temperature at which a chemical will ignite. In general, as flash
        point increases, so does safety. Even though the minimum flash point for flammability is 100° F
        and for hazardous wastes is 140°F, the higher the flash point the better. A less flammable chemi-
        cal may save you money on your property insurance as well as exempt you from costly storage
        and record keeping requirements of environmental and safety regulations such as RCRA and
        OSHA. Contact your insurance underwriter for a reappraisal to determine the cost savings from
        using a less flammable blanket wash at your shop. If the flash point of the test wash is two
        times lower than the normal wash, mark "much lower" on the worksheet.  If the flash point of
        the test wash is more than two  times higher, mark "much higher" on the worksheet. Score
        "same" if within 15°F .

Other:  Compared to your normal blanket wash. How does  the test wash compare on any
other factors? Much worse, worse, same, better, or much better?
        Compare the performance of the test wash to your normal wash on any other factors
        important to your shop. Some examples include acceptability of wash to commercial laundry,
        corrison of press parts, wash availability, dilution, and availability of recycled containers.
                                                                                                       Design for the Environment E

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Why a Worksheet?

The worksheet provided with
this bulletin gives you a place
to keep information about the
washes you try out at your
shop. Make extra copies of the
blank worksheet and record
information about each blanket
wash you test. After trying a
variety of washes, you can use
the completed worksheets to
compare them and find the
one that is best for your shop.
The worksheet is not a
scientific evaluation and
may not cover every potential
cost.  If a test wash scores
significantly better than
your normal wash, this
means the test wash  might
be a better choice, but
does not guarantee it.
The Hidden Costs of Your Blanket Wash
The environmental, health, and safety costs of blanket washes are often hidden.
If your test wash is less harmful to your workers or the environment, or is less
flammable than your current blanket wash, you may save money by using it even
if it costs more per gallon. Potential savings include:

                •> Decreased regulatory costs (such as disposal costs, pollution control
                   equipment, permitting, permitting fees, training, fines)

                > Improved worker health and safety

                •> Decreased insurance costs (such as workers compensation, fire, and liability)

                > Other decreased costs (such as energy)
Choosing a Better Wash — An Example
By testing a variety of washes you may be able to find one that is cheaper to use and better
for the environment. During the DfE Lithography Project (see page 6 for more information),
a vegetable ester wash was found that worked well and cost less than a petroleum-based wash.
Cost per wash was calculated based on price per gallon, time required to wash a blanket, number
of towels, and amount used.  Results showed the vegetable  ester wash was cheaper to use
per blanket than the petroleum-based wash at one facility, but was more expensive at another
facility. While savings may be even greater when factors such as those on  the worksheet are also
considered, these mixed results show how important it is to evaluate products in your own facility.
                     Use the Worksheet to Choose
                   Other Chemicals for Your Shop

   The nine  worksheet questions  can  be easily adapted  to compare other
   chemicals, such as roller washes, you test in your shop.  These nine questions
   are important to consider when making any chemical decisions for your facility.
                                                                                                              Design for the Environment E3

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What You Can Do To

Compare  Blanket Washes


Follow the checklist
below when testing
different blanket washes:


Test Blanket Wash for a Set
Amount of Time:

   n Discuss blanket wash
     tests with press operators

   n Set a trial period of one
     or two weeks with press
     operators

   n Record major observations
     during test period

Collect Information from:

   n Press Operators

   n Material Safety Data
     Sheets

      E> Vapor pressure
        information from
        MSDS Section 3

      E> Flash point
        information from
        MSDS Section 4

   n Blanket Wash Supplier

      E> Percentage VOC
        content

      E> Is  blanket wash
        considered hazardous
        under environmental
        regulations or OSHA?

Complete Worksheet:

   n Enter each score in work-
     sheet column

   n Add scores for final result

Complete Evaluation:

   n Does the final result
     indicate potential
     improvement?

   n Are there other benefits or
     costs of the test wash that
     are not on the worksheet?
     Don't Give Up
     Keep in mind that the process of choosing a better blanket wash will require some
     experimentation and an open mind. Not every blanket wash will work well at your shop
     right away, but some may work better as press operators become more comfortable with
     them.  For this reason, allow a set period of time for trying a blanket wash, and stick to it.
     For more ideas on cost saving ways to reduce pollution and waste at your facility, see other
     Design for the Environment (DfE) Bulletins for the Lithographic Industry.



     Questions to Ask When You Call Your Blanket Wash Supplier
     To complete the worksheet you will need to ask your supplier some important questions:
     (Some blanket wash manufacturers may supply this information on the MSDS, but they
     are not required to do so.)


        Jl Does the blanket wash contain chemicals deemed hazardous
          under any environmental statute or OSHA?
       C] What is the percent Volatile Organic Compound

          (VOC) content of the blanket wash?


          What is the Vapor Pressure of the wash in mmHg?
About the Design for the Environment Lithography Project

The goal of the Design for the Environment (DfE) Lithography Project is to provide lithographers
with information that can help them design an operation which is more environmentally sound,
safer for workers, and more cost effective.

Concentrating on the process of blanket washes, the partners of the DfE Lithography Project,
in a voluntary cooperative effort, evaluated 37 different blanket wash products.  Information
was gathered on the performance, cost, and health and environmental risk trade-offs of the
different types of substitute blanket wash. For more details on the
evaluations, please refer to the booklet, Evaluating Blanket Washes:
A Guide For Printers.
In addition to the Lithography Project, similar DfE projects are currently
underway with both the screen printing and flexography industries.
  To obtain additional copies of this or other bulletins and case studies, or for more information about
  EPA's Design for the Environment Program contact:
                   EPA's Pollution Prevention Information Clearinghouse (PPIC)
                                        U.S. EPA
                                  401 M Street, SW (7409)
                                  Washington, DC 20460
                                                     E-mail: ppic@epamail.epa.gov
                                                     DfE Web page: http://www.epa.gov/dfe
Phone: (202) 260-1023
Fax: (202) 260-4659

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