SOLID WASTE MANAGEMENT IN THE






   HOUSEHOLD APPLIANCE INDUSTRY
U.S. ENVIRONMENTAL PROTECTION AGENCY

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SOLID WASTE MANAGEMENT IN THE HOUSEHOLD APPLIANCE INDUSTRY
    This open-file report (SW-47o.of) on work performed
under Federal solid waste management contract No. CPE 69-4
was prepared by LOUIS KOENIG RESEARCH, San Antonio, Texas,
       and except for minimal editing, is reproduced
              as received from the contractor
          U.S. ENVIRONMENTAL PROTECTION AGENCY
                          1973

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                               ABSTRACT


        Case  studies ware  made of solid waste management in nine establishments

with more  than one thousand employees in the household appliance manufacturing


industry which covers ranges, refrigerators, laundry, housewares, vacuum cleaners,


sewing machines and other household appliances.  Ihe industry is contained in


Standard Industrial Classification 363 with its seven four-digit subcodes.  Ihe


industry,  concentrated largely in the northeast, has about 670 establishments,


and 170,000 employees and has a total materials input of about 2.4 million tons


per year.  This averages a material input of about fourteen tons per year per

employee but  this figure varies widely among the four-digit codes from two to

twenty-five tons per year per employee.

        In the nine case studies the waste quantity ranged from 0.72 to 2.92


tons per year per employee, and it is not demonstrable from the data that the


waste quantity depends upon the materials input quantity.  Of the total scrap


and waste  generated^the plants studied found a commercial scrap outlet for 40


to 84 percent, but this scrap quantity does not include the scrap recycled within

the plant  itself.  Most plants( seven out of the nine) use an outside agency for


disposition of the waste.


        The investment (1970 estimated replacement value) for  equipment


associated with solid waste handling ranged from $38 to $102 par annual ton.  The

total cost of solid waste handling per ton handled ranged from $50 to $139 per


ton, and the total annual cost of solid waste handling per employee ranged from


$93 to $211 per year.  Most of the cost was in-plant own-force labor typically

making up  seventy-five percent of the total cost. That portion of the janitors'


time spent on solid waste handling contributed typically forty-two out of this
                                                            4/tt_
seventy-five percent.  External costs for contracts and fees is- typically only


thirteen percent of the total cost.  Amortization of equipment and operation


and maintenance of equipment make only minor contributions.
                                     ill

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        The impact of solid waste from these plants in the oonrounities in



which they are located is nil. The wastes themselves are not offensive, less so



than municipal refuse itself, and nationally the total quantity from the industry



is not more than a few tenths of a percent of the total quantity of all



municipal and industrial wastes.



        The plants surveyed have presented a wide spectrum of awareness of current



importance of solid waste management^and several had active studies underway



in one or itore phases of the subject.  Even in plants showing the greatest



awareness the solid waste management responsibility was quite fragmented.  One



of the recommendations of the study is that it would be beneficial if solid



waste planning, management, recordkeeping and coordination were more centralized



preferably in a single individual  in each plant.
                                       iv

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                          TABLE OF CONTENTS


Chapter


  1     Introduction                                            1


  2     Summary and Analysis                                    3


  3     Scope of Solid Waste Management                        17


  4     The Household Appliance Industry, Outline of           25
          the Industry


  5     Method Used in Interview Campaign                      45


  References                                                   47


  Appendix 1 - Case studies of nine establishments             49
                    •%-        ^    ^

  Appendix 2 - To Whom It May Concern Letter                  151




                            LIST OF TABLES


  1     Materials Input 4-Digit Codes                           5


  2     Condensed Plant Data                                    7


  3     Codes Per Plant by Employee Size Class                 28


  4     Directories Compared with County Business Patterns     29


  5     Materials by Kind                                      37


  6     Percentage of Establishments in 4-Digit Codes          39


  7     Percent of Establishments and of Total Materials       40


  8     Material Input Per Unit Produced, 1963                 41


  9     Percent of Total Employees in the North                43



                             LIST OF FIGURES


  1      Generalized Process Flow, Household Appliance          31
          Manufactures
                                    v

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                              CHAPTER  1



                             INTRODUCTION

     This study was one of several which had been  initiated  by  the  Office
              fAana.ye yhe?ri"t
of Solid Waste JPrograms for  the purpose of  obtaining  an  understanding  of the

practices and management in  solid waste handling in various  industries.  The

main content of this report  resulting  from  the  study  are nine case  studies

of establishments in the household appliance industry, each  with more  than

one thousand employees.  As  shown in the descriptive  chapter, this  industry

like most industries is highly  skewed  in its distribution by number of

employees, so that these nine establishments, a little over  one percent of  the

total establishments, have about ten percent of  the employees of the industry.

     At one stage of the project it was being considered whether a  larger

sample might be covered in such a way  as to be  able to project  the  total waste

generation of the industry.  Some of the work here reported  on  the  industry

characteristics, location, and  the materials pattern  in  the  industry was

developed with that aim.

     The initiation date of  the contract was May 1, 1969 but the

interviews were carried out  in  the spring of 1971  and refer  in  most cases to

1970 conditions and data.

     Appreciation is expressed  to the  staff members of the establishments

surveyed who were most hospitable and  cooperative  in  the study.  As will be

mentioned several establishments undertook  special studies and  tallies of their

operations in order to supply information for the  study.

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                            CHAPTER 2



                         SUMMARY AND ANALYSIS

     This  project investigated solid waste management in the household

appliance industry, Standard Industrial Classification Code 363.primarily by

two modes:

     1.  Characteristics and statistics of the industry, especially
     as related to solid waste management, data being obtained from
     statistical sources, and

     2.  An in-plant survey of nine establishments having more than 1,000
     employees providing case histories of the in-plant and out-of-plant
     management of solid wastes in these establishments.



                   CHARACTERISTICS OF THE INDUSTRY

     The industry, SIC 363, is divided into seven 4-digit codes:

          3631  Household cooking equipment
          3632  Household refrigerators and freezers
          3633  Household laundry equipment
          3634  Electric housewares and fans
          3635  Household vacuum cleaners
          3636  Sewing machines (includes industrial)
          3639  Household appliances not elsewhere classified

In recent years the industry has had about 670 establishments and about

170,000 total employees, most of the establishments being concentrated in the

northeastern part of the country.  Over the period 1963-1967 the increase in

number of employees and in total materials input to the industry was about

3.6 percent per year.

     A typical plant in this industry receives as input raw materials

metals, primarily sheet metal, paints and associated materials, enamels and

associated materials, plastic resin raw material, purchased parts and sub-assemblies,

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and packing and packaging materials, mostly corrugated kraft board.   In the period


1958-1967 the percentage of paper in the input materials doubled, from four to


eight percent, and this does not include the considerable paper brought in with


the incoming materials.


     The metals are fabricated in a fabrication department by operations


such as stamping, shearing, bending, and in some plants cast in iron foundries


or by die casting or investment casting.  The metal work pieces produced


by these operations undergo a number of finishing operations such as tumbling,


buffing, grinding ^and polishing.  After finishing, the metal work pieces may


be coated by enameling, painting or, rarely, electroplating and anodizing.  Where


the plastic parts are manufactured by molding and forming from the raw material


there is little plastic waste generated because the scrap is remelted and recycled


within the plant.  An important fraction of the plant waste results from the


packaging materials both incoming and outgoing, corrugated kraft, wood, etc.


This industry of course, like all industries, has the wastes from the support


functions such as cafeteria, custodial services, office work. and personal items


such as newspapers brought in by the employees.  A generalized flow sheet of the


process sequence related to solid waste generation is shown as Figure 1, Chapter  4.


     The various 4-digit subcodes differ in the amount of input materials,

      I****
which jX' the potential for solid waste generation, and also in the tons of
input materials per employee.  Condensed data of this sort are shown in Table  1


which are the data for 1967, differing little from those for  1963.


          The refrigerator code has the largest materials input, about 37 percent


of the total; the sewing machine code has the lowest, about 0.5 percent of


the total.  In laundry equipment manuf acture.the average employee is associated


with a material input of about 25 tons per year, while in the sewing machine


industry the average employee is associated with less than one-tenth of this


quantity.

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     The last column of the Table shows the pounds of material per unit.




Between 1958 and 1963 there was a considerable decrease in the pounds per unit




for ranges and for laundry equipment.  The other codes showed little change




between the two census years.









                          QUANTITATIVE DATA




          Table 2 summarizes the quantitative data obtained in the in-




plant surveys described in detail in the nine case histories in Appendix 1,




including some ratios not specifically computed in the Appendix chapters.




     All of the plants have a shutdown period of two to three weeks during




which they are engaged in inventoryjja^ periodic maintenance, etc. and are




not in production.




     The general mode of in-plant conveyance, from the waste generation




site to the disposition dock, is by fork lift truck or other power vehicle,




sometimes hauling trains.  However, three of the surveyed plants  conveyed by




man-power, two of these exclusively by man-power.




     The waste generation per employee, tye (tons per year per employee)




ranges from 0.7 to 2.9 tye, corresponding to cubic yards per year per employee




(cyye)^typically 2 to 7 for plants using compactors^and 12 to 26 for those




without compactors.  Special measurements allowed a determination of the compaction




ratio achieved with general plant trash in two of the plants, these being 4.65




and 4.60.   Measured figures for the compacted bulk density of general plant




trash in two plants were 500 and 429 Ib/cy.  Measured  data for the bulk density




of general plant trash as collected, in three plants, were 71, 107, and 117




Ib/cy.

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     Since scrap paper and corrugated is an important element  in the


plant waste,special attention was directed to its quantity. The scrap


paper as a percent of the total waste ranged from zero in  two  plants that


did not produce any paper scrap to 57 percent.


     The percent of the total scrap and waste which was utilized, i.e.


which was scrap, ranged from 41 percent to 85 percent, this not including  the


materials recycled within the plant.  This means that of the total materials


input to the plant.of that which did not leave as finished product or  the


packaging therefor, 40 to 80 percent found its way to the  commercial scrap


market and 60 to 20 percent had to be handled as waste.  The total scrap


and waste ranged from 1.2 to 9.5 tye.


     The last column in Table 2, instead of the absolute ranges here


being mentioned, gives the penultimate ranges, that is the range excluding


the highest and lowest values.  This range included seven  of the nine plants


and thus covers from the 11th  .to the 89th percentile.  The exclusion of the

                                                                      
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          The breakdown of these costs into cost categories as estimated by

the studies  is instructive.   Labor, that is own-force in-plant labor, quite

uniformly comprises the largest cost element,typically about 75 percent of the

total cost per ton.  And because this element is such a high percentage the
                                                                      '%•*'
variations among plants in the other three elements are also quite small in

absolute terms.

          A typical  (i.e.(near-median) Code 363 plant in this sample will

have the following breakdown of costs:

                    Labor                              75%
                    (Janitors only)                    (42}
                    Amortization of equipment           8
                    Operation and maintenance of equip. 4
                    Contracts and fees                 13

Many managers may have the impression that solid waste handling costs

are only incurred for contract disposal, dump fees, hauling costs,etc.

In general-in this sample only about one-eighth of the costs of handling

solid wastes occurs in such charges.  About 75 percent of the cost of

solid waste handling is own-force labor.  The remaining two elements,

amortization and operation and maintenance of equipment, make only minor

contributions to the total cost of waste handling.

          In this studyj own-force labor includes that portion of the janitorial

services concerned with the handling, collection^and in-plant conveyance of

solid waste, as distinct from other janitorial functions which do not  involve

solid waste handling.  Typically^these  janitorial services are the largest

contributor to the labor cost element and the largest contributor to the

total.  A  row  in Table 2 shows the janitor contribution to the total

cost of waste handling. In only three plants is the janitor cost less  than

50 percent of the total labor cost. Of course these figures depend upon the
                                       9

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management practices with respect to janitor services^as well as with respect




to other aspects of solid waste handling. If the janitors handle in-plant




conveyance as they do in some plants and if disposition and disposal operations




are handled by contract and thus do not appear as labor, then the janitor




cost will be a high percentage of labor cost. On the other hand^if special




power-vehicle operators handle the in-plant conveyance and if furthermore^




the disposition and disposal is handled by own-force labor, then the janitor




percentage will be low.




          In the individual studiesjestimates for the percent of janitorial time




spent on solid waste handling activities ranged from 30 to 60 percent, and in one




plant where a quite exact determination was possible the figure was 46 percent.









                            Accuracy of the Data




          For the investigators and authors of reports on solid waste management




in a real industry, it is difficult to convey to the reader an impression  of




the accuracy of the data which does not go either in one direction toward the




extreme of trust or in the other direction toward the extreme of distrust.  The




data obtained in this study, and presented in Table 2 to two decimal places are




just such data as can be expected when a competent professional investigation is




made on a survey basis in an area of plant operation which is notoriously neglected




and historically pushed back in a corner with respect to the operation itself and




much more so with respect to the maintenace of quantitative records.  Indeed^it




is a judgment of the author based on numerous contacts in this and other




industries, that the data here presented are more accurate than the data




ordinarily used by plant managements in studying and carrying out their own waste




handling operations.  It is gratifying to note that as described  later^this




attitude is changing.at least judged by the nine plants interviewed-but the
                                    10

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correctness of the judgement is attested by the number of situations in which


the data obtained were surprising to the plant management,or which caused


the plant management to revise its own prior estimates of the quantities involved.


In short,                         the data       are believed quite accurate


for the purposes of a general survey of solid waste management in the industry and


even for the purpose of waste management planning and costing in the individual


plants.


          On the other hand..                                 a considerable


improvement could be brought about if it were throught warranted.  The survey


technique did not intend or provide for an instrumented measurement to obtain


waste and related quantities.  Some measurements were made.however\by the


plants after the interview as a courtesy.  In general solid wastes are handled,


in this connection tallied and paid for, on the basis of loads or volume rather


than weight.  Secure weights are obtainable only if the disposal charge, for


example an incinerator charge, is based on weight^in which case the average


weight per load can be obtained from a sample.  Sometimes the accounting


department can provide the total annual charge for such dump fees from which


the annual total weight can be computed via the unit price.


          For the most part .however^solid waste quantity information must  be


obtained by frequency counts or estimates of loadsjtogether with volume


measurements and estimated bulk densities.  Frequency estimates must come  from


the plant managers or the operators.and it is gratifying how generally


accurate these are based on a few opportunities given in the study to check


the operator's estimates against.for example .the actual contractor's records.


It is very rare that a plant management will have summed and codified a fiscal

f>^'°i*
"pmrieeFTwaste quantities and expenditures.  To get such information in most


plants requires an audit of the accounting records and usually an adding up


of individual vouchers.  Sometimes this can better be done in the waste


contractor's records than in the company's own records.


                                    11

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                           INPUT-OUTPUT RELATIONS

          This project was  a case history study.  The sample  is not  one  from

which  statistical  inferences can be made concerning  the  solid waste  quantities

and other measures of the  industry as a whole.  Nevertheless, because  there

are some intriguing questions concerning input-output relations bearing  on

solid  waste management, some explorations are made here  treating the sample

as if  it was an adequate representative sample, and  also making the  assumption

that each plant had a tye of input materials which was close  to the  average

for that 4-digit code.

          The questions to  be explored are:

          1.  Is the tye of scrap and waste constant across the codes
          or does  it bear some relationship to the tye of input
          materials, and

          2.  Is the tye of waste alone constant across  the codes or
          does it  bear some relation to the tye of input materials ?

          If the nine-plant sample and the plants themselves  are representativej

then a plot of tye scrap and waste against materials input indicates that tye

of scrap and waste does indeed increase with the tye input.   A regression line

through all the points would have a slope of about one-third,  implying  that

typically one-third of the  weight of input materials appears  as scrap  and waste.

The band actually  runs from one-quarter to two-thirds, but the slope of  a regression

line if computed would definitely be significantly different  from zero.

          With the wastes alone^such a relationship is not so secure.  The

general trend of the plotted points is such that a statement  that waste  averages

one-sixth of the input would fairly well represent them numerically.  However,

the range and therefore the slope is quite small.and the highest input point

(about 25 tye)  has about a median waste tye so it is likely that a statistical

computation would indicate  a slope not significantly different from  zero.  After
                                    12

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all, eight of the nine plants have tye's of waste between 1.0 and 3.0.despite

the range of input tye from 2 to 25.  This is equivalent to saying that the

average employee produces about the same amount of waste regardless of whether

he is working on refrigerators or on electric shavers.  The question remains

unsettled.

          GENERAL OBSERVATIONS ON SOLID WASTE MANAGEMENT IN THE INDUSTRY

          The following admittedly subjective observations concerning the management

aspects of solid waste management handling result from the interviews.          , 4-
                                                     Dff-^e        .vu^*?^"7^
          Largely because of the activities of the Dm«»qu of Solid Wastej^-Programs,

there is a current wave of interest in solid waste management and it is interesting

to note that the plants in this survey lie along various portions of the wave.

Some of the establishments (used in the sense of the managers in the establishments)

had barely recognized the existence of solid waste management itself.  Others

were highly advanced in current studies seeking to improve their solid waste

management. Some of the plants were stimulated in this direction by their own

interest generated by this survey and the revelations of the survey itself.

          If there is one general comment that can be made on the level of

solid waste management in the pIantS surveyed^it is that at the worst it comprises

ignoring or merely tolerating solid waste management and sweeping it under

the rug; and at the best that the control, planningjand record keeping are highly

fragmented. Among the recognized management entities, solid waste management

is asking for a place on the roster.  Outsiders, especially in the profession

of solid waste management, would no doubt want to recommend that this place

be a rather prominent one in view of the wide public interest in the subject

at present. However, viewed from the inside it is not at all unreasonable that

the place on the roster, if any, be well down in the priority list.  After

all, this industry has a value of shipments of some $30,000 per year per employee,
                                      13

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 compared with a solid waste handling expense of some $150 per year per employee.


 Regardless of this disparity«if solid waste management is to be made


 respectable and responsive in an establishment,the following recommendations


 may be helpful.


          The working level cognizance over solid waste management, planningj


 and record keeping should be placed with a single individual, presumably in


 a staff position and with an engineering background.  This solid waste coordinator


 might be part of the general environmental services group already existing


 and might well have other duties of an engineering, environmental or industrial


 health aspect.  In his solid waste role^however~he should set up a system for


 record keeping on quantities and costs in the solid waste handling of the  plant.


 He should keep himself informed on solid waste handling technology,-from generation


 to ultimate disposal-and should keep under constant consideration how technological


 advances might be beneficially utilized in the plant.  He should review actual


 operations from the standpoint of good practice in solid waste management.


 He should plan for future facilities or practice changes as they are called


 for by advance of the technology or by changes in the plant's production processes.


 He should review and make comparative analyses of waste handling arrangements


with outside contractors with the view to obtaining the lowest cost and the


 most satisfactory ultimate disposal from the standpoint of environmental impact.


He should make an annual report to management on the  solid waste operations,


 quantities, and costs in his plant.





                            ENVIRONMENTAL IMPACT


          The environmental impact of solid waste from the household appliance


 industry is negligible.  In the first place the raw waste itself is not offensive,


 indeed less offensive than raw municipal waste in general.  Secondly, the quantity

                                                 is                J
of waste produced in the entire industry maste^M -extremely small compared with
                                                A



                                    14

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the total solid waste production of the country.  The latter is of the order




of several hundred million tons per yea^ while the Code 363 industry cannot




produce more than a few hundred thousand tons.  Thus the industry's contribution




is of the order of a few tenths of a percent of the total solid waste generation of




the country.




          As to the plants surveyed themselves, no instances of environmental




offense were found.  Storage of wastes awaiting disposition was minimal and




the few cases  of long-term storage were of materials such as oils and paints




in closed containers.  The ultimate disposal of the wastes in practically all




the instances was to  some municipal or contractor ultimate disposal facility




not under the control of the industry but presumably operated in accordance




with the local pollution control laws.since they were general facilities handling




much more than simply Code 363 wastes.  A few strict constructionists would




possibly object to one or two of the plant dumps as surveyed on the basis that




they were not covered each day.  However,the wastes being disposed of are almost




entirely inorganic or sealed in drums.  Several plants had formerly used incinerators




but had shut them down because they were too difficult to keep in operation




in a pollution-free manner.




          The major environmental impact observed in the survey was not the




impact of the industry on the environment but rather the impact of the environment




on the industry, namely that the increasing attention to and importance of




water pollution control is forcing the in-plant treatment of aqueous wastes




to remove the suspended solids, and these suspended solids thus become the




future responsibility of solid waste management.  Several plants were preparing




for this development at the time of the interview.
                                      15

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                                  CHAPTER 3





                       SCOPE OF SOLID WASTE MANAGEMENT


           This  Chapter attempts to describe the subject matter contained in
 solid waste management as token in this study and also explains some of the


 organization of  subject matter and terminology use.


           It is  not  possible  to give  a statement which will define the scope


 and coverage of  solid  waste management in such a way as to be simultaneously


 accurate,  logical, and reasonable.  If any one of these desirable characteristics


 is  pushed  to an  extremejOne or both of the others must suffer.   Accordingly the


 scope used in this study is a compromise toward these ideals and contains some


 arbitrariness.   No claim of universal applicability  is made for these arbitrary


 decisions.   They were  made simply  to  be able  to get  on with the study of solid


 waste management in  the household  appliance industry.


           This study includes as solid waste  handling all the activities which


 have  to be undertaken  because solid waste is  generated, and which would not have


 to  be undertaken if  solid waste were  not generated.   According to this, solid


 waste is generated and solid  waste jbMftdU«g**e management begins when a solid


 waste particle is generated in connection with a production or support operation.


 Thus  the dust generated in a  buffing  or polishing operation becomes solid waste


 when  it leaves the work.   It  may be conveyed  with a  pneumatic conveyer to a cyclone


 collector.   The  pneumatic system and  the cyclone conveyor are part


 of  the solid waste management facility.   And  the occasional cleaning out of
the collector and the conveyance of  the  collected  solids  to  a disposal point
a. *>A,i~~t o"f        yrtd7iltt,«j€rw eVlt*

are ..[solid waste 4i«MNhbikgjk In some cases  the  solid waste  is  not  entirely picked up


by the pneumatic system.  It may be  heavy or  sticky  and thus collect in the


polishing machine itself.  The  cleaning  out of  this  waste from the production
machine is taken as solid waste. handling.   It  is  an operation which would not
                               A


                                      17

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have to be conducted if solid waste were not generated, and the solid waste

begins its existence when it leaves the work.

          Some solid waste is collected as a slurry.  For example, a rake

classifier may separate the solid waste particles from the larger pebbles used

in a rumbling operation for deburring.  The rake classifier is taken as solid

waste handling equipment.since its purpose is to collect solid waste and

separate it from the working operation.  This solid waste is actually on the

borderline of being "solid" since it exists as a solid suspension in

a slurry and the entire slurry is sent to waste as a convenient means of

handling it.   Similar slurries occur in the wet scrubber and in sludges from

sedimentation basins.  They are usually conveyed by being shovelled into drums

and other discrete conveyance containers.  If they are pumpable and are

conveyed by pumping when the pumping operation has the primary purpose of

conveying the solids they are still considered solid wastes unless the pumping

merely carries the slurry to a sewer.  Solids disposed as slurries in sewers


                                   *-*
          Equipment for separating.solids from liquid streams is not necessarily
                     yvx VOL 3€.->v\ e "n. t.
classified as solid wastew-haiialing>  Where aqueous wastes are treated to remove

solids or remove chemicals prior to discharge^ such operation produces a sludge
are not taken as part of solid was teAhandliftg.
which itself is classed as a solid waste.  However, the liquid treating operation,
                                                  •yyt CL"V\
which may be expensive, is not considered in solid iTi~tr 1inniiiiliin|r tirnn~r its

primary purpose is to treat the liquors and make them acceptable for discharge

or reuse.

          ' 'Solid waste" may even include materials that are not solids at

all, for example waste oils and solvents from machining operations.  However,

these are classified with solid wastes because they are handled in discrete

containers like solid wastes and are not conveyed by piping like liquid wastes.

Also they usually have the same ultimate disposal fate as the solid wastes,


                                      18

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and their disposal is contracted for in the same manner and by  the same

contractors .

          This stpdy includes some janitorial and custorial activites  in  solid
  "> 1 \ (X 11 a C< c -
waste handling.  Some custodial services would be excluded from solid waste

management, these including cleaning lavatories, mopping floors, handling

lavatory supplies, polishing door knobs, cleaning windows and  the  like, but  a

considerable portion of the janitorial service consists of operations involving

the movement and handling of solid waste, these including emptying waste-baskets,

sweeping floors and aisles, in-plant conveying of wastes.  In  the  study an

attempt has been made to estimate that portion of the janitorial time involved

in solid waste handling of this nature.  The estimates vary  from 30% to 60%,

and one plant provided a quite accurate and objective job -by- job estimate of

46%.  A large fraction of the labor cost and a large portion of the total cost
         vnO-vv.^ t TH t X-L
of solid waste,.kaniliino in the study lies in the janitor cost.  A  philosophy
which excluded the janitorial services from solid wastejJ*ws*i*»g would  arrive

at low cost.  However, since one of the aims of this study  is  to call attention

to what it costs to handle solid waste, it is believed that  the purpose is
better served by including the solid waste* handling activities  of  the  janitorial

function.

          In earlier studies, e.g.  (1), the concept was created of  "scrap-

and -waste''.  This was defined as all the materials entering  the plant which

did not leave as the finished product or the packaging therefor.   It was  divided

into two categories, "scrap" and  "waste".

          The scrap was that portion of the scrap -and -waste  that found some

utilization.  Reference 1 explored  the various means of utilization. For  the

household appliance industry it is  sufficient to have two  categories : (l^f  scrap

which is recycled for use within the plant itself, and(?)  scrap which  is  sold

and given to an outside agency such that it enters the commercial  market.   Typical

scrap items are:

                                     19

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               Plastic recycled within the plant

               Steel and nonferrous metal scrap either returned to
               the vendor for credit or sold to a conmercial scrap
               operator.

               Paper and corrugated sold in the commercial market
               or given away, in the latter case also finding its way
               into the commercial scrap market.

          This study did not determine the quantity when the scrap was

recycled in the plant.  Scrap paper is given special treatment in the

study because paper is a prominent component of the general plant waste

(even when paper is salvaged).

          The purpose was not only to point out the importance of and the salvage

possibilities for paper and cardboard but also to allow projection of what the

total waste would be if paper was not salvaged.

          This study was directed to the waste and not to the scrap.  Therefore.

mention of scrap handling operations is only incidental.  The primary purpose

for collecting scrap quantity data was to assess the fraction of scrap and

waste which was utilized.



                         MATERIAL FLOW TERMINOLOGY

          The path of solid waste from the time of generation to the time of

ultimate disposal can be broken down into seven sequential stages:

               Generation                    Preparatory processing
               Collection                    Storage
               In-plant conveyance           Disposition
                                             Disposal

          Generation comprises the production or support functions which

produce the solid waste in the first place.  Examples are grinding and office

operations such as mail handling.  These are operations in which solid waste

first makes its appearance.
                                      20

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          Collection refers to the activities of gathering together  the  solid




waste from the generating points in a form preparatory to conveyance.




Collection includes the janitor emptying wastebaskets into a  larger  container,




a fork lift truck operator dumping waste from containers at the work site  into




mobile conveyance containers, pneumatic systems conveying waste to separators




such as cyclones and the cyclones themselves.




          In-plant conveyance signifies the conveyance of the  collected  waste




through the plant to a waste dock where it awaits disposition.  Storage  refers




to the period during which the conveyed waste is awaiting disposition.




          Preparatory processing or reduction refers to operations which may




actually occur immediately before or immediately after storage which reduce




the volume or weight of the waste preparatory to disposition.  Compacting




and incineration are two typical processing operations, of which only compacting




was encountered in the study.  Some of the wastes were incinerated but the




incineration occurred after the disposition stage and at the ultimate disposal




site and in this study it is lumped with the ultimate disposal operations.




          Disposition refers to the transfer of the waste, after conveyance




and after storage.if any* and preparatory processing, from the disposal dock to




the ultimate disposal or reduction facility.




          The disposition agent is the agent immediately responsible for the




disposition.   Possible categories are municipal or sanitary district,




contractor, the company itself at the the site^or the company  itself to  a




remote disposal point.




          Ultimate disposal refers to the ultimate and penultimate actions




of permanent  disposal of the waste.  Included are rirnnpjmQ, sanitary  landfilling,




incineration  with disposal of the residue, etc.
                                    21

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          The ultimate disposal or reduction facility may have various

categories of owners.  Included are municipal, the contractor, the company

itself, or merchant.  A merchant facility is one that is available for

use by a restricted or non-restricted group of ''customers".  A contractor

facility is one maintained by the disposition contractor for his own

exclusive use for disposal of the wastes for which he contracts.  It is

possible     that a merchant facility might be owned by the contractor.



                           CONTAINER TERMINOLOGY

          Terminology and definition in this study for the various waste

containers is as follows.

          There are three general types of containers involved:

          1.  Containers at the work site which are not used for
          in-plant conveyance but which are typically dumped into
          some other container for in-plant conveyance.  Included
          are fibre drums, trash cans, wastebaskets, and the like.
          (Wastebaskets are so common and obvious that they are
          taken for granted in the report.)

          2.  Containers primarily used for hauling waste from the
          -production points to some central disposition point,
          waste dock, etc.  These containers are typically larger
          than containers of Type 1 and typically are filled by
          being hauled from one work site to another and there
          receiving the content of the Type 1 containers. Such
          containers have various ill-defined names and forms in
          the various plants^including gondolas, trash tanks, cages,
          carts, and a special container manufactured by Roura
          Ironworks, 1401 Woodland Avenue, Detroit, Michigan,
          called a Roura hopper, or in this report a Roura.  One
          side of this container has something of a "S" shape.
          When the container is  lifted on a fork lift and rolled
          forward, it automatically upends itself on this curve and
          dumps clean.  In some cases-these Type 2 containers are
          spotted at the work site and are filled directly at the
          worksites, being hauled directly without transfer to the
          disposition dock when full.

          3.  Containers into which the waste, after in-plant
          conveyance, is dumped and in which the waste is conveyed
          to the disposal site.  Typically these are detachable
                                      22

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          packers, trailers, dump trucks, large tanks particularly for
          liquid wastes, etc.  Some of these disposal containers are
          being hauled away at frequent intervals such as daily so that
          the amount of ''storage'* in these disposal containers is
          minimal.  In a few situations, the disposal containers are
          hauled infrequently, such as once a month in the case of the
          closed containers for waste oils in some plants.  Such
          containers become storage vessels, pending the collection of
          a full load, but no problems incident to storage were
          evident^ since the containers in this study of that type were
          all closed.

          In this report containers of Type 1 and Type 2 above are called

"collection containers", the distinction between the stationary type and

the movable type usually being clear from the context.  Containers of Type 3

are called disposal containers.
                                     23

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                                 CHAPTER 4









                      THE HOUSEHOLD APPLIANCE INDUSTRY,




                          OUTLINE OF THE INDUSTRY




           The household appliance industry comprises standard industrial




classification Code 363 (2) comprising seven four-digit codes as follows:




                    3631  Household cooking equipment




                    3632  Household refrigerators and freezers




                    3633  Household laundry equipment




                    3634  Electric housewares and fans




                    3635  Household vacuum cleaners




                    3636  Sewing machines (includes industrial)




                    3639  Household appliances not elsewhere classified.




          In Code 3634 a wide variety of small articles is included, for




illustration: bed coverings, cigar lighters, food mixers, tooth brushes.




In Code 3639 there are included water heaters, dishwashers, floor waxers^and




garbage disposal units.




          In the period 1967 to 1969 the industry had about 670 establishments




and 170,000 employees.  Over the period 1963 to 1967*the increase in number




of employees and in materials input was about 15 percent, about 3.6 percent




per year.




          The major trade associations covering the industry are the Association




of Home Appliance Manufacturers (AHAM), The Gas Appliance Manufacturers Association




(GAMA), and the Vacuum Cleaner Manufacturers Association.  All three of these




Associations were contacted and informed of the study immediately upon its
                                       25

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 inception.  Coverage  of ARAM  includes  room  air  conditioners  which  based on




 their  manufacturing  and  selling  patterns could well be  classified in this




 code.  However, room  air  conditioners  appear  in another  SIC  Code associated




 with central air conditioning and refrigeration equipment.   The coverage




 of GAMA includes a number  of  items not in Code  363  largely having  to  do with




 central heating.




          The remainder of this Chapter describes  the  Code 363 industry,




 particularly in matters that  have some bearing  on  solid  waste management.









                            THE PURITY  OF CODE 363




          Establishments are classified in Code  363  if  the dollar value of  their




 Code 363 output is greater  than the  dollar  value of their product  output in any




 other code.  In such  cases the Code  363 products are termed  primary products




 and the other products manufactured  are termed  secondary products.  The




 degree to which this  occurs is measured by  the  primary products specialization




 ratio (%) which is:




                      Dollar  value of  primary products
          Dollar value of primary products + secondary products
                                                                         (100)
          It would be ideal for the present study  if Code  363  establishments




manufactured only Code 363 products, that is had a primary product




specialization ratio of 100%.




          However, even if that ideal condition were reachedjthls study,  confined




to the manufacturing establishments in Code 363, would not correctly  assess  the




waste management situation arising from the manufacture  of Code  363 products.




For in addition to the establishments in Code 363.there  are also other




establishments not classified in Code 363 but which manufacture  Code  363




products.  The degree to which this occurs is measured by  the  coverage  ratio




(percent)^which is:



                                     26

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          Dollar value of primary products manufactured by Code 363 estab.
          -- - - --  (100)
          Dollar value of Code 363 products manufactured by all industries


          It would again be ideal for this project if the coverage ratio of 363

establishments were 100%, that is if all Code 363 products were manufactured in

Code 363 establishments.  To the extent that they are not this study, confined

to Code 363 manufacturers , would not cover all of the manufactures of Code 363

products .

          However^it develops that the primary product specialization ratios and

coverage ratios in Code 363 are not very far from 100%. Data from 1963 and 1958

Census of Manufactures (3) indicate  that both the specialization and coverage

ratios for Code 363 for 1963 are 85 percent.  This means that in studying Code 363

we will be missing about 15 percent of the nation's total manufacture of Code

363 products, and also we will be including in our study to the extent of about
15 per cent 'products which are not Code 363 products.
          A
          The specialization and coverage ratios are tending to decrease from

1958 to 1963, indicating a tendency toward less specialization in Code 363

manufacturers and also more manufacture of Code 363 products by non-363 manufacturers,



                            EFFECT OF PLANT SIZE

          Since the logic of sample selection involved the possibility that the

sample be skewed toward the larger size establishments which produce most of

the product, and presumably have most of the waste, it became important to check

the possibility that the larger plants may have significantly lower specialization

ratios , that is that the larger plants might manufacture a broad spectrum of

products such that a sample of these plants would include significantly more

non-Code 363 products than do all plants.  To check this possibility^ use was
                                      27

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made of the state manufacturers directories from  14 states which happen  to present

data adequate for such an analysis.  Products  specified for Code 363

establishments were classified by SIC codes and the number of  such  codes for  each

plant tallied.  The establishments were then divided into employee  size  classes

and the number of codes per plant in each size class computed, the  results being

in Table 3.

                                   TABLE 3

                   CODES PER PLANT BY EMPLOYEE SIZE CLASS


               Employee Size Class           Codes Per Plant

                    1-10                          1.43
                    11-25                         1.19
                    26-50                         1.83
                    51-100                        1.54
                    101-200                       1.33
                    201-500                       1.50
                    501-1000                      2.00
                    Greater than 1000             1.50

That there is no trend in codes per plant with upper class boundary was

determined by regression analysis of codes per plant versus log of  upper class

boundary.  The mean for the entire sample was  1.8 codes per plant.

          The conclusion is that we are not likely to depart greatly from the

over-all Code 363 specialization ratio by selecting a sample weighted  toward  the

larger establishments.



                          DIRECTORY COVERAGE RATIO

          Since AHAM had expressed surprise that the number of Code 363

establishments was as great as 664 reported in County Business Patterns  (4),

it became of interest to determine just how many of these CBP  (County  Business

Patterns) establishments could be found in the manufacturers directories (which
                                    28

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at that time were the entries to the individual establishments).  To do this

the available directories supplying such information were searched for Code

363 plants^ and these also were classified as 363 only, 363 plus related

products, and 363 plus unrelated products.  All the establishments were

classifiable by the directory as true Code 363 establishments.  Table 4 compares

the number of 363 establaishments in the directory as compared with the number

given in the 1967 County Business Patterns.

                                   TABLE 4

                    DIRECTORIES COMPARED WITH COUNTY BUSINESS PATTERNS

          State          No. of GBP Establishments     No. of Directory Estabs.

          Washington                 7                             9
          Vermont                    0                             1
          Texas                     14                            11
          Ohio                      49                            29
          Louisiana                  3                             6
          Georgia                    6                             4
          Arkansas                   7                             6
          Missouri                  11                            14
          Mississippi                9                             5
          Massachusetts             24                            10
          Maryland                   4                             2
          Kentucky                  13                             5
          Tennessee                 30                            26
          Oregon                     5                             5
          New Mexico                 0                             1

          Considering that some of the directories were not current with the

CBP date, this indicates that in general the state manufacturers directories

achieve a rather high coverage of the CPB universe.



                        A GENERALIZED CODE 363 PLANT

          Despite the wide range of products in Code 363, all the way from

electric shavers to refrigerators and washing machines, the unit operations

carried out in Code 363 establishments are largely the same and differ only in
                                      29

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scale and emphasis.  Rather than describing the detailed operations and  flow




pattern in each plant interviewed an attempt is made in this section  to




describe a generalized Code 363 plant which will embody most of  the operations




involved in waste generation and in a particular flow pattern.   This  may




be thought of as similar to a composite photograph of the human  face  obtained




by overlaying the photographs of numerous individuals such  that  the result




brings out the main features of the human face.  In the same way the




generalized flow chart, Figure 1, brings out the common pattern of  Code 363




plants in a way such that by emphasis here, addition there, or omission




elsewhere the pattern can be made to represent almost any existing plant.




          At the top of the chart are shown the material inputs  to a  Code 363




plant, divided of course in a way that emphasizes their contribution  to  the




waste stream.




          The portion in the upper left describes the metal working operations




which are frequently called the  "fabrication department''.  In  some  plants.




"fabrication*' is confined to the major metal forming operations  such as




stamping, shearing, bending, etc.. and the large machines that do this are




termed "presses'' and the area the "press room''.




          Metals .if in large quantitiesAare typically received in  rail cars
                &                      ^



from which there is generated shoring and strapping waste.  The  press department^




of course.generates considerable quantities of cutoffs, punch-outs, and the




like-as well as reject pieces.  The oils and lubricants used in  these operations^,




as well as the solvents used in cleaning before or after the operations^




become " waste oil and solvents'' and these are sometimes  sold  for reclaiming.




          Other incoming metals may go to the iron foundry  or die  casting




departments .where a considerable amount of the scrap is reycled  and remelted.




Sand and investment material used in the casting eventually end   up as waste.




although in an iron foundry a large part of the sand is recycled.
                                    30

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•H
ix,

-------
          The metal work pieces produced by these operations may undergo a




number of finishing operations.  Small parts such as used in shavers, sewing




machines, etc. may be deburred by tumbling with pebbles.  The wear from the




pebbles and the burr material arefseparatedtjspmetimesiwith a classifier




and the waste solids removed from the recycling water by sedimentation.  Other




work pieces may be finished by buffing, grinding, sand blasting, etc.  These




operations generate fine-particle solid waste which usually requires considerable




investment in equipment for pneumatic conveying and air cleaning.  Before or




after buffing and polishing the work pieces may be plated or anodized-but




such solid wastes as are generated by these two operations are typically sent




to the sewer.  However.if there should be a large metal treating operation




such as bonderizing and if this requires treatment of the aqueous wastes for




discharge, then plating wastes may be sent to the waste water treating plant.




          A considerable amount of plastic parts a«- used ranging in size all




the way from refrigerator liners down to small injection molded parts. Most




of the scrap plastic is remelted, i.e.-recyled, but some of it appears in the




waste, none in the scrap.




          After the metal work pieces have been formed and finished^, they may




pass through operations which can be called "coating" i.e^ enamelling or




painting.  In enamelling.the incoming material is enamel frit which is milled




in ball mills, the waste being removed by sedimentation in pits usually under




the floor of the mill room.  The enamel then goes to a blending process to




achieve the proper color and composition and recycled




material.if any.is worked in at this point.  Enameling may be done by




dipping, by flow coating, or by spraying.  The first two generate waste




only to the extent that the reservoir containers are cleaned out
                                     33

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 occasionally.  In a water  curtain spray booth^the overspray  is  caught  in  a




 curtain of water and collects in a sump or is run to a pit.   In air booths  the




 air passes through scrubbers or filters to remove these solid particles.




          In painting, the incoming materials are paints,     thinners^and




 solvents.  They pass through a preparation room where the paints are mixed,




 blended and compounded*    some waste paints and solids are  generated  here.




 Painting may be by dipping or by spraying, the latter with a water curtain,




 with air flow, or electrostatically.  The air for the booths is cleaned in




 filters or scrubbers.  Most plants apply a release compound  to  the booth  walls




 so that occasionally the paint film that builds up there can be stripped  off.




 In the water curtain booths the slushy waste paint is skimmed off the  water.




          Painting is done on a moving line and the work is  usually carried along




 the conveyor line on metal paint hangers.  The overspray of  course, builds up




 on these paint hangers and eventually they have to be cleaned.   This is a rather




 tedious operation everywhere, involving transporting the paint  hangers to some




 stripping device and then returning the cleaned hangers.  The stripper may  be




 a hot aqueous salt and caustic or even molten salts and caustic.  The  paint




 sludge and also the waste salts and caustic are a special form  of waste




 associated with painting.




          Plants differ in the degree to which they completely  manufacture  their




products. Some plants make extensive use of purchased parts  and sub-assemblies.




Typical purchased parts are electric motors, refrigerator compressors, electric




wire pig tails and also such things as light bulbs, thermostats, switches.  The




unpacking of these purchased parts is a major source of cardboard and  paper




waste.
                                      34

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          Sometimes the unpacking is done in the receiving departments.  More


often it is done at the work site.  In the former case.the packaging waste is


generated in one place.  In the latter .it has then to be collected and brought


back to the disposal point.  Some plants make extensive use of cardboard


separators in the in-plant handling of parts, especially painted and enameled


parts.  Universally, corrugated cardboard from the incoming packaging or


packaging materials is utilized for this purpose, but eventually ,of course, all


the corrugated that comes in with the purchased parts must go out as scrap or


waste.


          Some large heat-transfer items such as ranges, refrigerators and


dryers require insulation, normally fiberglass bats, which are purchased.


The paper wrapping on this is a typical paper scrap or waste.  In addition.on


the assembly line where the fibrous insulation is installed special air cleaning


precautions are taken to free the ambient air of particulate waste.


          These operations provide the work pieces which are assembled in the


assembly line into the finished product.  Reject materials discovered during


assembly are discarded to the scrap or waste streams.  The assembled product


is then ready for packaging and shipping.


          Most establishments purchase pre-formed corrugated and assemble the


package.  Wooden bases as for refrigerators, may also be purchased.  This


assembly generates scrap and waste from punchouts and rejects.  In plants


employing separators .such rejects are also a source for the cardboard cutter.


          In addition to the process materials, raw materials generating waste


also enter the plant in support functions.  Food and food containers supply the


cafeteria and of course, generate cafeteria waste.  Janitor supplies such as
             *r         *

paper towels, sweeping compounds, etc. accumulate in the waste stream.  Some


food, containers, and personal items such as newspapers brought in by the


employees also contribute to the waste stream.  Office paper work generates


waste paper, punch cardsj and the like which may appear either as scrap or waste.



                                       35

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                   MATERIALS PATTERN IN THE A-DIGIT CODES

                  d
          The Mfftpil wastes generated by an industry arise from the materials


brought into the plants.  The process wastes from similar types of manufacturing


operations might be thought to bear something like a proportional relation to the


materials used.  For example, of two codes with similar manufacturing operations,


          one would expect that the code consuming a hundred thousand tons of


materials per year would have something of the order of ten times the waste of


a code consuming only ten thousand tons.  As will be shown.the data from the


case histories do not support this hypothesis.  Nevertheless, from a materials


handling standpoint,it is instructive to consider the actual materials consumption


pattern in the seven 4-digit codes in SIC 363.





                              MATERIALS USAGE


          The materials consumption is taken from the 1958, 1963jand 1967 (Prelim)


Census of Manufactures (3, 5).   The important categories are summarized in


Table 5 .  Not all of the items tabulated are directly available in the census


data.  However, they have been supplied by various means.  In some cases


missing items were supplied by a proportionality involving the total tonnage

               >^r\
in the code (ex.the missing item) and the total tonnage in the other codes for


which the item was not missing.  The tonnage of paper and paperboard containers


is not available but the delivered cost is.  This was converted to tonnage


by an average figure for the value of shipments in the paper industry, 1967,


where the tonnage of paper and paperboard was 43,049 kilotons and the value
                ^Ao^

of shipments, ex.pulpmills and building paper, 19,811 m$ (thousand dollars).
                F>

This is an average of $460/ton for the product mix of the paper and paperboard


industry and approximates the wholesale value.  This was increased by about


10 percent to $500/ton for the approximate delivered cost to Code 363


establishments.
                                       36

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Ranges
1967
Mill shapes 4 forms (except castings)
Carbon steel
Alloy steel
Copper & copper base alloy
Alum. 4 Alum. -base alloy
Castings
Iron
Alum. & Alum. -base alloy
Paper & paperboard containers
at $500/ton
GRAND TOTAL TONS
All Employees
1967 tons/employee
1963
Mill shapes & forms (except castings)
Carbon steel
Alloy steel
Copper 4 copper base alloy
Alum.S Alum. -base alloy
Castings
Iron
Alum.& Alum. -base alloy
Paper 4 paperboard containers
at $500/ton
GRAND TOTAL TONS
All Employees
1963 tons/employees
1958
Mill shapes 4 forms (except castings)
Carbon steel
Alloy steel
Copper 4 copper base alloy
Alum. SAlum.base alloy
Castings
Iron
Alum. 4 Alum. -base alloy
Paper 4 paperboard containers
at 5500/ton
GRAND TOTAL TONS
All Employees
1958 tons/employees


286
6
1
2

7
2

21
325
20
16


252
6
1
1

7


,300
,900**
,300
,000

,600
,150

,200
,819
,200
.291


,922
,870
,024
,546 .

,385
TABLE 5
MATERIALS BY KIND
Refrig. Laundry Housewares
and fans


691 ,400
4,900
15,800
23,600

28,100**
2,700

63,600
829,550
50,000
16.591


672,465
4,271
9,833
18,148

28,144
519** 1,716

8
278
19
14


244
3



7


6
262

,548
,815
,191
.528


,424
,308
487
600

,351
519

,000
,690
18,152
14.472

35,041
769,620
43,065
17.871


483,000
5,414
5,059
15,951

14,831
1,300*

19,444*
545,000
41,493
13.135


482,600
2,400
1,200
3,050

46,600
9,800

27,800
566,350
22,200
25.511


429,699
1,243
1 ,069**
986

34,228
5,271

22,674
495,171
18,343
26,995


361,258
1,548
1,807
1,892

28,948
5,066

18,530*
419,050
24,597
17.037


146,100
16,600
10,350
22,700

600
4,450

45,400
251,550
45,000
5.590


116,468
16.623
6,385
8,862

571
3,877

28,914
181,700
38,801
4.683


50,551
4,400
4,520
6,231

571*
4,552

11 ,522
82,348
29,150
2.825
Vacuum Sewing


34,900 10
700
1,450
1,650

1,691* 2
112*

12,800
57,641 14
10,000 6
5.764 2


22,504 8
728
962
1,313

998* 2
975

6,230
33,711 11
5,682 7
5.933 1


18,238 7
230
788
1,074

785* 1
2,050

3,100*
26,265 9,
5,871 9,
4.474 0.


,000
200
168*
278*

,300


972
,030
,400
.192


,023
184
98*
146*

,346
63*

513*
,372
,646
.487


,003
87
74*
134

,896
70*

329*
593
607
999
N.E.C.


323,200
4,300
2,850
1,700

8,800
2,300

20,200
363,350
14,400
25.233


297,334
2,088
2,595
1,845

6,118
1,807"

13,354
325,051
13,296
24.447


302,732
1,181
2,744
2,347

8,781
1,101

10,000
328,887
14,622
22.493
TOTAL


1,974
36
33
54

95
22

191
2,408
168
14


1,799
32
21
32

79
14

115
2,095
146
14


1,467
16
15



,500
,000
,118
,978

,691
,031

,972
,290
,200
.318


,415
,007
,967
,857

,789
,230

,175
,440
,025
.350


,206
,168
,481
28,232

63
14

68
1,673
143
11

,162
,659

,925
,834
,492
.665
Z


82.0
1.5
1.4
2.3

4.0
0.9

8.0
100.2




85.9
1.5
1.0
1.6

3.8
0.7

5.5
100.0




87.7
1.0
.0
1.7

3.8
.9

4.1
100.1


* Estimated
** Taken from previous  4 or 5 years data
                                                        37

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          In  total tonnage it is seen that there has been an increase of about

44 percent from 1958 to 1967, reaching approximately 2.4 million tons/year

in 1967.  The major single item is carbon steel mill shapes and forms  (except

castings), the percentage of which has been declining somewhat over the nine-

year period and now stands at about 82 percent.  However, this percentage

decline is solely a result of the increasing importance of paper and paperboard

containers.  Of the metal materials only, carbon steel mill shapes and forms

comprises a constant 90-91 percent over the nine-year period.

          The tonnage of paper used has increased by 180 percent in the period,

the percentage role doubling from about four percent of the total materials in

1958 to about eight percent in 1967.

          Of the total 1967 tonnage of Table 5jthe percentage usage for the

separate codes is as follows.

                    Code         Product          Percent of Total
                                                     363 Usage

                    3631       Ranges                   13.5
                    3632      Refrigerators            34.4
                    3633      Laundry                  23.5
                    3634      Housewares               10.4
                    3635      Vacuum cleaners           2.4
                    3636      Sewing machines            .6
                    3639      n.e.c. (not elsewhere
                                classified             15.1

          Shown also in Table 5 is the tye (tons per year per  employee).  Over

all codes this averages about 14.3 tye and has not changed since 1963.  This

measure varies greatly among the 4-digit codes, over more than a ten-fold range,

being about two tye for 3636, sewing machines and 25 tye for 3633, laundry

equipment.  This means that each employee is associated with about two tons/year

of materials in the manufacture of sewing machines and about 25 tons/year in the

manufacture of laundry equipment.
                                    38

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          During the course of the project an intensive study  (6) was made of the

statistics of the establishments in Code 363 with respect to geographical
                                                iAe
location, the number of employees and \rith »a»of»»fc to tons of  input materials

based on the tye's for each code from Table 5.  The material presented

here is a condensed version of that study, based on plots for  each of the

seven 4-digit codes showing the distributions of establishments and of

tons/year of materials used, by employee size class.  In Code  363.the

establishments of less than 100 employees contributed only five percent of the

tons/year of materials used.  Those over 5000 employees contributed 22 percent

of the total.  The thirteen establishments in size classes greater than

2500 use over 40 percent of the total materials used.  The extreme

concentration of the materials usage in the large size establishments is shown

in Table 6.

          About 82 percent of the total materials are used in  the four highest

size classes from establishments with 500 employees and up.  About 22 percent

of the total materials, 530 kilotons per year* are used by the  5000 and up

class .and this incidentally comprises only three establishments, all in Code

3632.

                                  TABLE 6

              Percentage of the Establishments in 4-Digit Code
            Which Use 50% of the Total Materials Used in the Code


               Code                          Percentage of Establishments

               363                                     3
               3631                                   16
               3632                                    3
               3633                                   10
               3634                                    7
               3635                                    6
               3636                                    3
               3639                                    8
                                     39

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          Table 7 shows the importance of the establishments with more  than

1000 employees, from which the case history sample was drawn.  For example,

in Code 3635 the approximately eight percent of the establishments over 1000

use 65 percent of the materials.  In Code 363 as a whole the establishments

over 1000 comprise about six percent of the establishments and use 62 percent

of the materials.



                                  TABLE 7

               Percent of Establishments and of Total Materials
             Used in Establishments with 1000 and More Employees

               Code                               Establishments with
                                                   greater than 1000

                                         % of estab.   % of materials in Code
               3632                          6.1                 34.7
               3632                         23.8                 91.7
               3633                         14.9                 69;.1
               3634                          5.9                 37.6
               3635                          7.9                 65.4
               3636                          2.4                 46.7
               3639                          1.9                 27.2

               363 Code                      5.9                 62.5
                     MATERIAL INPUT PER UNIT PRODUCT

          It is also instructive to consider the materials usage per unit of

product,  i.e. per refrigerator, per sewing maching, etc. The 1958 and 1963

Censuses (3) provide the tonnage of major materials used in each 4-digit

code together with the number of units produced.   Table 8 shows the

conversion to pounds per unit.  This cannot be a precise computation, since

either the number of pounds cannot be tied down to a specific number of units,

or else the "number of units" in an establishments must be allowed to be a

quite heterogeneous definition.  A range plant.for example^may manufacture

ranges and also thermostatap for ranges.  The total nyrterials input goes to

produce both the ranges and the thermostats.  But obviously the amount of

materials required for a thermostat is very much less than the amount

                                      40

-------
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                                                            41

-------
required for a range.  Accordingly  the  statistics  must  either ignore the

number of thermostats  in which  case the pounds  per unit will be too high

to a degree depending  upon the  ratio of ranges  to  thermostats,  or else they

must include the thermostats as unitSj in which  case the pounds  per unit for

ranges, which would be the assigned four-digit  code would be too low.   With

these reservations^Table 8 shows the expected relations that ranges, refrigerators^
                                •Witft
and laundry units are  heavy and general housewares, vacuum cleaners and sewing
                           J    ™                                   J
machines are relatively light.  The n.e.c.  (not elsewhere classified)  category,

Code 3639 includes such heavy items as  water heaters and  dishwashers.as well

as presumably smaller  items and thus the average is rather high.   Because

of the uncertain product mix in Code 3639. nothing  much  can be determined as to

the cause  of the significant decrease  in pounds per unit from 218 in 1958 to

130 in 1963.  A large  increase for  example  in floor waxers which are relatively

light, might have brought about the  decrease in  the ratio.   For regrigerators the
change in pounds per unit over the five-year period  is ^appreciable.   However,

for ranges and for laundry equipment,.there has been  appreciable  decrease in

the average pounds per unit, strikingly so in ranges.  Housewares  and  vacuum

cleaners remained about the same over the five-year  period.  Despite any

tendency toward lighter weights the total major materials  used in  the  seven-

code industry increased by a little over 20 percent  in the five-year interval.

Note that the major materials listed in Table 8 do not include the paper and

paperboard containers which had been included in Table 5.


                     REGIONALIZATION OF CODES

          It is noted that the great preponderance of activity in  Code 363
                                                   l&     j-   _.^
is in the North, and indeed the great part of that*in the  Jforth  east of the
     * l i ,X""7 l
 tlsippt and north of the Ohio and the Mason-Dixon Line.   Table  9  shows for

each code the percentage of the total employees in establishments  in the North.
                                      42

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                                  TABLE 9

            Percent of Total Employees in the North

                                                  % of Employees
                                                     in North

               3632      Refrigerators                 99.2
               3633      Laundry                       90.9
               3634      Housewares                    68.5
               3635      Vacuum cleaners               91.0
               3636      Sewing machines               98.9
               3639      N.E.C.                        50.5

               363       Total Code                    82.7
          It is seen that in some Codes over 90 percent of the total employees  are

in the North, even up to 98 and 99 percent.  For the Code as a whole about  83

percent of the employees are in the North.
                                     43

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                                 CHAPTER 5









                     METHOD USED IN INTERVIEW CAMPAIGN









          At the request of the Office of Solid Waste Management Programs,




preliminary contacts were made with the major trade associations in  the  industry,




which are the Association of Home Appliance Manufacturers,  the Gas Appliance




Manufacturers Association and the Vacuum Cleaners Manufacturers Association.




These contacts were helpful in obtaining an overall view  of  the industry,  in




obtaining preliminary statistical material about the industry, and in paving




the way for contacts with the establishments to be surveyed.




          Various state manufacturers directories furnished  identification of




individual establishments for the sample.  However, this  source was  replaced by




a Dun & Bradstreet listing on computer cards of establishments in Code 363




giving addressess, phone numbers and contacts, as well as  other statistical




information on each plant (7).  The final specification of  the sample issued by




the staff of the Office of Solid Waste Management Programs  specified that




only establishments with more than 1000 employees were to be included in the




interviews.




          After the establishments to be interviewed had been selected, letters




describing the project and asking permission to interview were directed  to




a high corporate executive of the firm, usually the president or the firm's




representative to the Trade Association.  In some cases the  letters were




followed up by telephone.and referral was made to a plant manager who would be




the main contact for the actual interview.  All initial correspondence contained




a "To Whom It May Concern" letter from the OSWMP (Office  of Solid Waste




Management Programs) officially describing the project—reproduced in Appendix 2.
                                    45

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          Contact with the plant manager was made mostly by telephone and




arrangements made for an interview date.  In some cases.the checklist to be




used was sent so that the plant manager could obtain and fill out some of the




information beforehand .  The checklist had been approved by the Office of




Management and Budget (No. 85S 68013, exp. 30 Sept. 1971).  Plant managers




differed in  the degree to which they wished to have and fill out the appropriate




pfrotions of the checklist beforehand, and also the degree to which they wished




to supply the information at the time of the interview.









          The interview itself was accomplished in one full day.  In some cases_^




portions of a second day could have been used.but because of the appointment




method of scheduling it was not possible to carry over into the second day.




However, the interviews were followed up with extensive correspondence and




telephone calls both with the persons who had been interviewed in the




establishment and also with new persons who had not originally been interviewed.




Persons interviewed included not only the establishment's employees but also




the contractors, local officials, and other outside parties who might provide




information.




          A rough draft of the Appendix Section on each establishment was sent




back to the establishment for review and checking.  All of the establishment




sections have been thus reviewed.
                                      46

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                                 REFERENCES

1.        Koenig, Louis and Wensley Barker, Jr.  Technical" economic  study of
           (olid waste disposal needs and practices.  Volume'II.  Industrial
           nventory (PtfS Contract PH 86-6&-163).  Sw^iilniim  Engineering, Inc.
          Windsor, Connecticut. Nov.  1967.       Cc'Mb
2.        Standard Industrial Classification Manual  1967.  Office  of  statistical
          jjtandards^USGPO.

3.        U. S. Bureau of the Census.  Census of Manufactures  1963. Industry
          statistics :household appliances, MC 63(2)-36B. USGPO. Mar.  1966.

4.        U. S. Bureau of the Census. County business Patterns  1967.  U.  S.
          summary CBP-67-1 ,USGPO. 1968.       -

       il-S'
5.     **\Bureau of the Census»1967 Census of Manufactures. Industry  series
          Preliminary Report MC 67(P)-36B-1 through  7. Sept. 1969  (7  reports
          one for each of the 4-digit codes) .

6.        Koenig, Louis. Materials Patterns in the 4-Digit Codes.  Portion  of
          rough draft intended for this report. Submitted to ^BSWM. April 1970.

          39 pt"
7.        Dun and Bradstreet.  Punched card listing of establishments  in  Code
          363. 1969.

-------
                       APPENDIX 1

          CASE STUDIES OF NINE ESTABLISHMENTS

These case studies are organized roughly in the following sequence:


SIC classification and product mix

Plant surroundings

Operating schedule

Number of employees, seasonal!ty

Waste management and operation responsibility

Scrap-and waste-generating operations in this plant

Primary collection containers

In-plant conveyance operation, organization and equipment

Modes of waste disposition, leaving plant

Storage

Disposition agent

Ultimate disposal facilities and distances

Disposition quantities, frequencies

Waste composition and paths from individual generating operations

Total waste quantity computations and basis

Total scrap quantity and fraction utilized

Waste handling equipment, cost

Waste handling labor, cost

Waste handling equipment operation, cost

Waste handling contractor and fee cost

Total handling costs

Future trends seen for this plant

                      SYMBOLS

tye       tons per year per employee
type      tons per year per production employee
cy        cubic yards
cyye      cubic yards per year per employee
                           49

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                                  PLANT 1


          This plant produces electric ranges and range tops, ninety-seven percent


of its value of output falling in SIC Code 3631.  It also produces components


for dishwashers and thermostats, this two percent of its output being  classified


in Code 3639.  Scrap sales and work for other company plants comprise   the


remaining one percent of its value of output.


          The surroundings are 90 percent light industrial and ten percent


residential.  It is located within a municipality and within a half-mile  of


the nearest builtup residential area.
                /<;

          It operates five days a week, most departments one shift, but some two


and three shifts.  There are nine holidays and a three-week shutdown in

                          £Vv*i

August, 237 operating days,, 49 operating weeks in a normal year.


          For the quarters of 1969 there was not more than a 1.5 percent


seasonality in the number of production workers, which averaged 1,480.


Nonproduction workers numbered 100 .  The number of employees in 1970  and in


the first quarter of 1971 has not changed appreciably from these figures.


However, the plant was down on strike for the fourth quarter.


          In the computations that follow quantity data obtained from  actual


1969 performance have been adjusted to the full year by assuming that


production occurred during 37 weeks, i.e..that no increase in quantities


occurred during a 15-week strike and shutdown period.


          The waste management responsibility is with the Manager of Materials


and the Manager of Manufacturing Engineering .who report to the Plant Manager.


Operations in the Materials Section are handled by a foreman of materials


handling,  whose jurisdiction includes plantwide trucking, scrap handling


and shipping and receiving.   In the Manufacturing Engineering Section,


operations are handled by a Supervisor of Maintenance .whose jurisdiction


included janitors and cleanup men and waste disposal.
                                      51

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          The scrap-and waste-generating operations in this plant are:

                    Stamping                      Shearing
                    Welding and brazing           Polishing and buffing
                    Electroplating                Porcelain enameling
                                                     flowcoat dip and spray
                    Painting, dip                 Rod  filling
                    Shipping and receiving      ,  Air cleaning and dust collection
                    Offices                       Cafeteria
                    Assembly

          The primary collection containers are:

                    No. 3 tote boxes 0.8 cy       Roura hoppers 1.4 cy
                    Wire-sided carts  3.2 cy

          In-plant conveyance to the disposal areas is by fork lift truck, various

areas being assigned to various truck drivers.  Containers are emptied at

least once a day by the assigned drivers and more frequently by request when

necessary.

          The waste proper leaves the plant in three modes, a 32 cy detachable

packer from a compactor, an 8 cy detachable gondola for enamel sludge^ and a

26 cy detachable open container for noncompactable rubbish.  Pending disposition

the materials are stored in these containers, which are at four separarate

locations in the plant.  Rare contractor construction jobs generate some waste
                                                       (*vJi it
not measured here, which is picked up from another docky^the responsibility of

the construction contractor.  The compactor is shared with an adjacent plant,

which contributes about 25 percent of the waste load going to the compactor.

Adjustments have been made in the corresponding computations.

          The disposition agent is a contractor.  One compactor load per day is

hauled ten miles to a merchant incinerator and sometimes the same distance

to a merchant sanitary landfill.  The open detachablec once a week at the

main plant and once a month at another building, are hauled to the same facilities.

The sludge gondola is hauled four times a week to a landfill seventeen miles

distant.  This plant also sells as scrap baled corrugated which leaves in trailers

about once each three weeks.
                                     52

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          The streams from the various  scrap and waste generating operations




are handled as follows.




          From the stamping of steel and aluminum and the  shearing  of  steel  the  scrap




is handled in No. 3 tote boxes and sold baled or loose.  The very small  amount




of contaminated non-saleable waste from these operations is collected  in Rouras




and goes to the open detachable container.




          In brazing there is a sandblasting unit  (Vac-U-Blast)  for cleaning  the




metal free of scale before brazing.  The waste  sand  and scale  is collected




in Rouras and goes to the open detachable container.




          The polishing is done on steel and chrome.  A pneumatic collection  system




takes the dusts to cyclones where the solids are collected in  Rouras and taken




to the open detachable container.




          The electroplating operation  is small and  the rare cleanout  is handled in




the sewer.




          The pjBocelain enameling operation generates solid wastes  in  a  multiplicity




of locations.  In the mill room the bags in which the enamel is  received are




stacked on pallets and go to the compactor.  The mill room is  underlain  with  a




sewer system which feeds two pits.  Sewers and  pits  are cleaned  once a month,




the material going to the enamel sludge gondola via  Roura. The enamel  dip tanks




are cleaned daily of sludge.which goes  to the gondola via  Roura.  In a ''grey




spray booth'' a base coat of enamel is  applied  to the metal.   The wastes and




residues from this booth are reused.  In the spray booths  for  white and  colored




enamels the scrapings from the walls and floor  are collected nightly in  Rouras




and go to the gondola.  In addition.each time there  is a color change  the booths




must be washed down to remove the prior color enamel.  The wash water  from this




is collected in five catch basins which are cleaned  once a week, the sludge




going to the gondola via Roura.  Finally there  are air scrubbers on the  enamel




booths which are dumped and cleaned once a week, the material  also  going to the




five catch basins.  While not producing the greatest quantity  of solid wastes,





                                     53

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the waste handling in connection with porcelain enamelling is considered the




most difficult and messy of the waste handling operations.




          Most painting except for a minor amount of touchup is done by dipping.  The




paint drippings that drip from the drying line are washed down and used for




makeup in the dip tank.  About twice a year the dip tank is cleaned of sludge,




which goes to the open detachable via Roura.




          The electric heating rods (Calrods) comprise a heating wire concentric with




a metal tube.  The annular space is filled with MgO powder which is put in a




vibrator hopper.  The MgO spills from this operation are cleaned out once a




week and taken via Roura to the open detachable container.




          In addition to the cyclones and scrubbers for polishing and enameling




there are Rotoclones for other air cleaning operations, particularly those




for collecting the glass or mineral wool fines from insulation in the assembly




area.




          Shipping and receiving does not unpackage the incoming material but




delivers them directly to the using departments in the incoming containers.




Therefore.very little waste is generated by shipping and receiving.  On the




other hand.assembly in this plant uses many purchased parts.  The cardboard




packaging from these, unpackaged at the assembly site, are placed in the wire




sided carts (20%) or skids (80%) and taken to the paper baler.  Cardboard for




baling must be corrugated and free from any metal contaminant or coating.




Therefore, considerable cardboard packaging from incoming material finds its




way to the compactor in Rouras and in carts.




          Office and washroom trash is of course collected in wastebaskets




and transported in drums or Rouras to the compactor.




          The cafeteria and the one snack area collect garbage and rubbish




in drums which are dumped into Rouras and taken to the compactor.
                                     54

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                            QUANTITY COMPUTATION

          The estimated quantities  of wastes  leaving  the  plant  in  the  full year 1970

are as follows:

                                            Per Year

                                    Loads       Cy       Tons

               Enamel sludge        196       1,660      1,660
               Compactor            177       5,660      1,420
               Open gondola          64       1,660        250

                         Total      437       8,980      3,330

               tye                                      2.11
               type                                     2.25
               Scrap corrugated as  % of waste 2.09

          The scavenger indicated that the average net  weight of a compactor

load was 16,000 pounds.  The computation is based on  32 cy  capacity and  237

loads per year, 75 percent of the loads assignable to this  plant.   The open

gondola quantity is computed at 64  loads per  year, 26 cy, and a bulk density

estimated at 300 Ib per cy on the basis that  the observed loads appeared

a bit heavy with metal and sludge.  The enamel gondola  has  approximately

eight inches of freeboard, the sludge is about 40 percent water and the

density is taken as 2000 Ib per cy.

          In the adjusted year 1969 there would have  been sold  as  scrap  aluminum,

steel, alloy, etc. 5600 tons. The corrugated  cardboard  is baled in 1.11

cy bales averaging 475 Ibs, 429 Ib  per cy.  A trailer load  averaging 18  bales

and 8500 Ibs is shipped about once  every three weeks.   Data from a seven —

month tally in 1971 compute  to 77  tons sold  as scrap for a 49-week year.

The total scrap is 3.6 tye and 3.9  type for the average employees

in that period.   These figures indicated that 63.0 percent  of the  scrap  and

waste was utilized.  The only recycled material was the enamel  from the

spray booth.
                                      55

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          As a courtesy to this investigation^this plant made a special

statistical study of the refuse going to the compactor over a ten-day period.

The results were:

                    Rouras     552           No. 3 boxes     184

                    Skids       36           Wire baskets    166

At the cubic yard volume each container type.this computes to a compaction

ratio of 4.65:1.  The total cubic yards of refuse in the collection containers

is 149 cy per day.  It has already been determined that the bulk density in the

compactor is 500 Ibs per cy, so the bulk density in the collection containers

is 107 Ibs per cy.  Each compactor leaving the plant represents 94 fork lift

loads.

                                   EQUIPMENT

          The equipment and estimated 1970 investment involved in waste handling is

as follows.

                    1 Compactor                      7,500
                    3 Fork lift trucks              36,000
                    50"Rouras                       10,000
                    100 Tote bins                    7,500
                    6 Enamel scrubbers             120,000
                    2 Cyclones at polishing         40,000
                    150 Drums                          300
                    Rotoclone at trim rings         12,000
                    2 Rotoclones in components       8,000
                    3 Rotoclones for wool fines
                         over assembly              36,000
                    Wet rotoclones at automatic
                         sandblast                  12,000
                    Enamel sump pits              not considered

                                      Total       $289,300

          This amounts to about $87 investment per annual ton of waste.  In

contrastjit was estimated that the equipment for handling scrap and paper

used jointly with another plant had a replacement investment of about $9.5
                                     56

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per annual ton of scrap.  Most of this investment was in the metal press

for scrap metal.

        The amortization of the waste handling equipment at 25 years and ten

percent would be about $31,800.



                                LABOR

        Estimated labor hours and costs for waste handling are as follows:

                                                  Hours Per Year

          3 Fork lift drivers                           6,000
          3 Cleanup men, pits and sumps                 6,000
          2 Cleanup men, enameling                      '4,000
                                             Subtotal  16,000
          20 Janitors, estimated one-half time         20,000

                                             Total     36,000

          Cost at $3.14 per hour @ 125% burden       $254,000 per year


        The janitor estimate is based on the judgment that there seemed to be

more floor dirt being generated in this plant than in a plant of another

type where the janitor percentage estimate was 33 percent.



                      EQUIPMENT OPERATION AND MAINTENANCE

        The cost of equipment operation and maintenance is estimated as:

                                                     $ Per Year

          Energy for compactor, 500 operations per
               week, (the 75% ignored)                     50
          Maintenance at 4% of investment              11,600
          Energy for Rotoclones and scrubbers           1,970
          Energy and supplies for fork lifts              350
          Janitor supplies                             not est.

                                             Total    $13,970

        The computation of Rotoclone energy is based on 14 units averaging

10 horsepower operated eight hours per day at an energy price of one cent

per KWH.
                                      57

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                              CONTRACT DISPOSAL

        The  costs for contract disposal are as follows:
                                                        $ Per Year
               Compactor at $100 each  (75 percent)        17,700
               Enamel gondola, 1,600 cy per yr
                    <§ $6.60 per cy                        11,000
               Open gondola, 64 per year, 26 cy
                    @ $2.80 per cy                         4,700

                                             Total       $33,400

        Tho contractor rate on the compactor is $3.12 per cy.


                              TOTAL COST

        The total of the foregoing cost elements is as follows:

                                             $ Per Yr  Percent of Total

                    Labor                     254,000       76.3
                    Equipment amortization     31,800        9.6
                    Contractor                 33,400        9.9
                    Equipment operation
                      and maintenance          13,970        4.2
                                    Total    $333,170      100.0

                    Per ton of waste          $100.

        By the time the waste passes off the plant property, $100 per ton has

been spent on it.



                                   TRENDS

        The management forsees major changes in equipment and operations necessary
             711 
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                                      PLANT 2

          This plant produces ranges and cook tops and the door and knob

sets for them in the form of kits which are used to assemble a variety of

finished models by the local sales distributors.  In 1970 they produced about

half as many kits as complete ranges and tops, about 95 percent of the output

being in the range code (3631) and about five percent of the output in

dishwashers.

          The surroundings are light industrial, the plant being located

inside a municipality and within two hundred feet of the nearest builtup

residential area.  It operates five days a week, two shifts and with a few

people in the paint department and in housekeeping and maintenance on the

third shift.  There are seven holidays and a two-week shutown, thus 244

operating days, 50 operating weeks in a normal year.

          For the quarters of 1970 the number of production workers was practically

constant, deviating at the most only about three percent from the average

which was 935 production workers.  There were 258 office employees in

addition for a total of y93 employees.

          Solid waste management responsibility in this plant is very simple.

It is in the hands of a single individual who also handles plant safety and

bears the title " Safety Director.''  All waste and cleanup operations report

to him.

          The scrap and waste generating operations in this plant are:

          Stamping and shearing
          Milling (only in the tool and die room, negligible)
          Welding and brazing (only for maintenance, negligible)
          Polishing and buffing
          Porcelain, spray and dip
          Painting, electrostatic dip and spray
          Material handling
          Shipping and receiving
          Offices, cafeteria.and snack areas
                                       59

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          The primary collection containers are:

          55-galIon drums
          Wooden flatbed carts
          Wheeled "tanks", 1 cy and 2.5 cy, "trash tanks'* or
               "trash carts"
          Also fibre drums and trash cans

          In-plant conveyance to the disposal areas is by  man-power, no

powered vehicles being used.  The conveyance schedule is random as the

vehicles are filled.  However, the janitorial function is highly organized.

This plant is remarkable in the extremely high degree of organization of work

tasks, approaching regimentation, and yet an equally high degree of  personnel

involvement and motivation at all levels. As an example, each of the 18

janitors has a task sheet outlining the tasks he is to perform each  day.

Two of these are shown on the following pages as a sample of the detail.

From these sheets and an intimate knowledge of the activities of each

janitor the manager was able to estimate individually the number of  hours
                                       Til.. \^m\f-,---t^-,\~t
that each of the 18 spent in solid waste haii«tliu% (e.g. sweeping and

moving trash) as distinct from other janitorial duties (e.g. washing bowls,

mirrors, filling paper holders, etc.)  The estimate was 46.5 percent of the

total time.  Also each production worker  having a work station, e.g. a

shear, a press, etc., spends 10 minutes per day, on schedule, in cleanup

work around his station.

          The waste leaves the plant in three modes, a 40 cy detachable

packer from a compactor averaging one load every three working days, a

dump truck for sludge drums once a week, and a five-ton dump truck daily  for

pallets and crates.  In addition, corrugated board is separated and  is

given to a local volunteer organization  ( a charitable rehabilitation

organization)-grfraTremoves it in a van truck.  There are three loading

locations.  Pending pickup and disposition the wastes are  stored  in  the

compactor, the 55-gallon drums, and in the wheeled  "tanks".  The pallets

and crates going to the five-ton dump truck are uncontainerized.


                                     60

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                            JANITOR # 3 SALVAGE 0152
                            STARTING TIME £>:30 A.M.

 i,  Ch.iuf.e factory entrance trash bag - as needed

 2.  Empty trash tanks once a day or as needed nnd sweep tanks area

       a.  Shipping floor
       b.  Receiving floor by scales

 3.  At 1:30 use trash tank and pick up

       a.  Model Shop three c;ins
       b.  Empty trach rnit by vending machines second floor office by
           elevator #2.
       c.  Pick up out of cafeteria

 4.  Sweep thiiv»g«r following three ramps on Tuesday and Thursday.

       a.  Two ramps leading from crated range conveyor to assembly.
       b.  Ramp from Inspection Office down to P^int Stock room.

 5.  Sweep r.etal covered aisle, east of Personnel to and around  fire
     truck Wednesday and Friday.

 6.  Cut up scrap cardboard north side of ramp in assembly where vending
     machines are located.

 7.  Empty trash cans in Replacement Parts inot trash tank daily.

 8.  Clean men and womens rest room - Replacement Parts

       a.  Clean bowls, nirrors, toilet stools ?nd seats both sides, urinals.
       b.  Sweep and mop floor as needed - d,- ;1y if necessary
       c.  Fill paper holders, toilet paper, ^oap containers, towels,'etc.
       d.  Dust off all areas
       e.  Empty all trash or waste containers

 9.  Clean men and womens rest room - Office Services
        (Some as above)

10.  Empty trash cans (3) from Purchase stock room when directed from Safety
     or Guards office.   Purchase parts men will set them on elevator and
     send down.  Janitor unload into trash tank and send trash cans up on
     elevator.

11. -Empty scrap metal from Model Shop as directed from Safety or Guards
     officf.

12.  Sweep Jown East and West office stairway on Tuesday and Thursday and
     hand scrub as needed.

13.  Friday sweep out all five blev?tors

14.  Collect  Brsss c'ind Scrap wire froa Li?mp Assembly when directed from
     Safety or Gu.srrl Office.

     IlLI'Lli-H^.: 8V.50 to £:40    Lunch _Tlp?_;  11:00 to 11:30   Bre.nk. Tinier 1:00 to -1:10

     'Chit xchfedult will be. changed and adjusted as needed as other janitor
       •   * •>         i •  ..  i   .\
                            f  _;
                                       61

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              JANITOR if 6  PRF.SS  SHOP CLEAN t'P  0151
                      STARTING TIMK 7:00  A.M.

 1.    Sweep out and empty waste baskets  in the following offices daily
      a.   Press shop
      b.   Welding
      c.   Tool Room

 2.    Empty Aih tray daily
      a.   Press shop (2 trays)
      b.   Paint 1st floor (1  tray)

 3.    Empty paper boxes daily or  more often if necessary
      a.   Press shop (3 boxes)
      b.   Shear line (1 box)

 4.    Empty trash cans daily  from
      a.  .Press shop
      b.   Tool Room

 5.    Empty trash cans Monday, Wednesday  and Friday
      a.   Welding

 6.    Install new trash bag daily or as  needed in Press Shop vending
      area

 7.    Pick up dirty rags and  used gloves  daily

 8.    Run vacuum sweeper daily

 9.    Empty one (1) trash tank ati'         ^ gate two (2) times daily

10.    Clean railroad area between Press  shop and Shear line and
      between two (2) overhead doors doily

11.    Clean all of yeard area from West  overhead door to Boiler house
      cross over
                                                v
12.    Salt back door area tc*v      -;Avenue as needed in winters

13.    Salt walk way in yard (railed off)  south side of Tool Room as needed
      in  winter months

14.    Sweep Shear line main aisle (North  and South) two (2) times weekly
      or  daily if needed

15.    Sweep off scrap and paper from shelves (scrap loader) in Die Storage
      area

16.    Sweep up scrap and paper in Die Storage area daily

17.    Clean area around scrap cage        Avenue).  Keep all scrap off
            Avenue

18.    Clean area by Tool Room time clocks
      Clean area by Tool Room time clocks entrance (air block)

19.    Operate machine that removed slugs, metal, etc., from Press Shop
      floor every two or three weeks (as  required)

                               -62

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                               - 2 -
20,    Leave point dcwn from F;
-------
In addition the segregated cardboard is stored on the wooden carts at the




dock awaiting pickup by the volunteer association.




          The disposition agents are a contractor, the volunteer charitable




organization, and the company itself via the five-ton dump truck.  The compactor




and the drums are hauled by the contractor five miles to the county  sanitary  >•




landfill.  The volunteers' van goes to the organization's collection point.




The company's dump truck -mask /combustibles \delivers.jteheg across the  street to




the company's own burning site on company property.  The disposal operation




at the company site is described on the Land Disposal Site Investigation




Report form on the two pages  following;.




          Only combustible material is hauled to the site so that quite clean




burning is obtained and the residue is simply wood ashes contained in the




burning pit.  The site is not fenced.but unauthorized dumping is fairly well




controlled, first because of the motivation of all plant employees and




secondly because the pit is located next to the garages, parking lots and




playing field of the plant.




          The streams from the various scrap-and waste-generating operations




are handled as follows:




          Stamping and shearing produces only an incidental quantity of




material other than metal scrap.  It is deposited in drums and  trash carts.




There is no waste oil and solvents.  Drawing compounds  are removed in the




enamel pickling and go to the enamel sump.




          There is only one small belt polisher and a vacuum collector in




the polishing operation.  The vacuum collector is emptied about once a
          The .on nmo ilfbng spray lines have water  curtains.   Both  the  enamel




room and the paint room are pressurized by blowers  and  air filters  which




supply clean air to the rooms and also supply the   air  flow through the
                                   64

-------
DEPARTMENT OF
HEALTH. E 'UCATION. AND WELFARE
 •UBLIC HEALTH SERVICE
                                                                                             Form Approved
                                                                                             Budget Bureiiu  No.  6<
                                           COMMUNITY SOLID WASTE PRACTICES
                                  LAND DISPOSAL SITE INVESTIGATION REPORT
                                                                                                                    L
. STATE 2. COUNTY
2 3
4. NAME OF SITE

11 12 13
7. NAME OF PERSON COMPLETING FORM
Louis Koenig
| 3. SITE LOCATION (Political J uriadiction) \
456
S. ADDRESS OF SITE


7 8 8 10
. B. DATE OF SURVEY
DAY MONTH YEAR

8. TITLE
14
1
3
f 717
15 16 17 18 19 2O
9. ORGANIZATION AND ADDRESS
10. POLITICAL JURISDICTIONS SERVED BY LAND DISPOSAL SITE
NAME OF
POLITICAL JURISDICTION

21



22 23


29 SO 31
L


37 38 30
1



24

32

40

48 46 47 48
ESTIMATED
PERCENTAGE OF
JURISDICTION
SERVED BY SITE

'
* '
x
*


,


29


33




28

34
I
41
42
1
49
BO
i- ••.,-



AVERAGE DISTANCE
OF SITE FROM
CENTER OF SOURCE
AREA (Miles)



'- :'.
' \ '

27 28

38 3«

43 44

SI 52
•&
•.-."-
..- V.- .



FOR ADDITIONAL ENTRIES. CHECK HERE Q <83» AND MAKE ENTRIES IN ITEM US
11. SITEOPERATED BY
| 1 PUBLIC AGENCY
hl^PRIVATE AGENCY
12. SITE OWNED BY
Q PUBLIC AGENCY
Jjjfl PRIVATE AGENCY
 3.  IS OPERATION
    REGULATED BY A
    WEALTH AUTHORITY?
                       RYES
                                            IF YES. INDICATE LEVEL
                                            OF PRINCIPjAU AUTHORITY
 4-  C.ENERAL CHARACTER OF
_J QUARRY OR BORROW PIT
~] GULLY-CANYON
 ] LEVEL AREAS
] COMMUNITY    [1 STATE
                                       1 HILLSIDE
                                     r~] MARSH. TIDELAND
                                        OR F^OOD PLAIN    I
                                                               15. YEAR SITE PLACED IN OPERATION
                                                                s. ANTICIPATED LIFE REMAINING
                                                               17. TOTAL AREA OF SITE (Acres)
                                                               '•• AREA TO BE USED FOR LAND
                                                                  DISPOSAL (AcrJa)
                                                                                                         64   68   66  67
                                                                                                         68   09   7O
i».  ZONING/LAND USE SURROUN0ING FACILITY (Chuck predominant type only)
                           ZONING  ^.
                                    J^INDUSTRIAL
                                    [^AGRICULTURAL
                                    [~] OTHER
    I ID NONE
        RESIDENTIAL
        COMMERCIAL
                                                  (Specify)
                                                                                      LAND USE
                                                             |__J RESIDENTIAL
                                                             Q COMMERCIAL
                                                             [^INDUSTRIAL
                   C7] AGRICULTURAL
                   [  I OTHER.	
                                                                                                           (Specify)
20. ISUSEOF       f  YES     IF YES. CHECK      RECREATIONAL  piLIGHT
                   L- '                         '—'AREA OR PARK   L -Jr-nusT
   COMPLETED                 PREDOMINANT
   SITE PLANNED?  SjfnO      USE ONLY
                                                                  p.                r" 1 Ar-oir-ii. TIIOF  I   jUSENOT
                                                        OR PARK   L J CONSTRUCTION  L. J *GR ICU LTURE  | _ ] DE JERM|N £D
21.
23.

' ^
KILL PUBLIC AGENCY CONTROL
COMPLETED SITE USE'
* HEQUENCY
OF COVER
« 'heck one only)
X-NE
[ 1 DAILY (EnS. NUMBER OF DAYS DISPOSAL SITE COULD NOT BE USED BECAUSE OF WEATHER CONNECTED CONDITIONS (Enter average f  i
                                                                                                       per year) | /
   GENERAL CHARACTER OF OPERATION (Judgment evaluation - check appropriate categories)
•PPCARANCE

.y
/VIGHTLY
ISIGHTLY
'"
IS BLOWING PAPER
CONTROLLED?

|^YES
L-lHO

is BLOWING PAPER
CONSIDERED TO BE
A NUISANCE'
CJ YES
XNO
17J
ROUTINE BURNING

[ ] NONE
[~ ] UNCONTROLLED
l^fPLANNED AND
^L,M,TEO
is!
65
                                                                                  ARE THERE SUR-
                                                                                  FACE DRAINAGE
                                                                                  PROBLEMS?
                                                                                                1
                                                                                                     ARE THERE
                                                                                                     LEACHING
                                                                                                     PROBLEMS?
                                                                                                                             2
                                                                                                                             14
                                                                                                                   1 - 1
                                                                                                                   1

-------
                           LAND DISPOSAL SITE I NVESTIGATION REPORT (Page 2)
27. CONTROL PROGRAMS
                                              28. I', LOWEST PAKT OF FILL IN WATt"
                                                                  -	-   __  	

                                                          TIMES FIRE CONTROL EQUIPMENT            I /
                                                          ED AT SiTE IN THE PAST YEAR        W-p "--,--LfjJ
                                                 IS SALVAGING PERMITTED'
                                              33  ESTIMATED NUMBER OF LOADS DEPOSITED DAILY
                                                                FROM P Rl V A TE
                                                                COLLECTION
                                                                VEHICLES
34  ART QUANTITATIVE RECORDS  .	.
   KEPT IN ANY FORM'         '	'
   YES
                                       D°
                                       no(
                                       use  47
35. QUANTITIES OF SOLID WASTES RECEIVED ANNUALLY
TONS WEIGHED
TONS ESTIMATED
CUBIC YARDS
                      48  49  50  51  52  53  54
                      ^^^rimg
                      55  56  57   68  !9  60  61
     _J	L
                   S2   63  64  65 66  67	6B  89
36. GENERAL  CLASSIFICATION OF SOLID WASTES
   ACCEPTED AT DISPOSAL SI T E (Check those accepted)
  1HOUSEHOLD  H^^
               72
   :OMMERCIAL
[  JlNSTITUTIONAL
74

i—| INCINERATOR
-,, RESIDUE ONLY
                                                                            r

37. CHECK ANY ITEMS LISTED BELOW WHICH ARE
   EXCLUDED FROM THE DISPOSAL  SI T C
                                                 ALL
                                                 PUTRESCIBLES

                                              »^T|ALL
                                              )|KL NON-COMBUSTIBLES


                                              [~|ALL
                                              1	1 COMBUSTIBLES

                                              [jXcARBAGE

                                                'DEAD
                                                 ANIMALS
                                                 'ASTE
                                                'OIL
                                                                                   TIRES
                      iEWAGE
                      SOLIDS

                      BUNKED        Aj^HAZARDOUS
                      AUTOMOBILES   ^WATERIALS
                                   28

                      APPLIANCES    OTHER (SpecHy.)
                                   29

                      DEMOLITION
                      WASTES
jgl WASTES        [7JOTHER (Specif/)
A^ CONSTRUCTION  3'
KJi
                                         1 DEBRIS
                                                                    SWEEPINGS    n°THER Specify)
                                                                                 33
                                                L_   C
38. EQUIPMENT AVAILABLE
   (AvarciQe utilized daily)
DRAGLINE OR SHOVEL-TYPE EXCAVATORS
SCRAPERS (Self-propelled)
TRACTORS (TrBck or Rubber Tire)
         (Bulldozer or Hl&h Lilt Loader)
TRUCKS
OTHER  *f r*W\
OTHER
      Do
      not
      use  43
      Do
      not I	
      use  46
             NUMBER
                                       35
                                       37
                                          OS-
                       TOTAL NUMBER »F EMPLOYEES ON SITE (Av
                                                      erage daily)  \
                    40. HOURS OF DAILY
                       OPERATION
                       (On a 24-hour clock)
                                                                                    END
                                           38
                                              41.
                                                 NUMBER OF DAYS OPERATED PER WEEK
                                           42
                    42. ANNUAL OPERATING COST
                       (Including supervision and
                             t maintenance)
                                                                          IIEIIZWS
                                                                            56  57   58  5')  60  61  62
                                       44   45
                                              43. IS THIS A SANITARY LANDFILL7
                                       47  48
44. IF SOURCES OTHER THAN REPORTER DESIGNATED IN ITEM 7 WERE UTILIZED IN COMPLETING THIS FORM, INDICATE BELOW
   THE SOURCES USED AND ITEM NUMBERS
NAME OF PERSON




TITLE




ORGANIZATION




ITEM NUMBER(S)




                                                  66

-------
 enamel  and paint  spray  booths.   There  are  five  such  systems  in the enamel
                               yjrfcV (t          Of
 section and  three in  the paint,,total  capability^134,000  CFM.   The airflow

 in the  workrooms  is downward  rather than upward and  this  achieves  such a low

 dust count in the  ambient air that  the state  industrial hygiene department

 no longer runs regular  inspections.  There  are  about  300  square feet  of

 filters on the blowers  and these are changed  monthly,  the filter material

 going to the trash carts.  The spray booths in  both  the enamel and paint

 lines have water  curtains which  catch  the  overspray.   In  this  plant, the

 overspray from the color coat lines  is skimmed  from  the water  and  recycled

 by blending  into  the  ground coat (the  colors  being disguised to a  grey by

 addition of  lamp black).  This reduces the  amount of  enamel  waste.  The

 over-spray waste material is  shovel/ed into 55-gallon  drums  and hauled by

 trash cart to the  drum-loading dock.   There are three  enamel milling  sumps

 which are cleaned  of  solids every two weeks.

          The paint spray booths have  a release coating on the walls.   This  is

 stripped when the paint deposit builds up.  The electrostatic  booths  have

 the water curtain  and water bottom  from which skimmings are  removed.   Both

 types of waste, together with that  from the paint mixing  room  are  placed in

 55-gallon drums, about seven  drums per week.

          In this industry^ there is considerable moving of parts on carts, etc.

 from one operation to the other.  Where this  is  done by hand,  protection is

needed to keep the parts from scraping one another.  For  some  parts^special

wooden racks are provided.   For other parts, particularly small parts,  there

 is extensive use of cardboard separators in tote boxes, etc.   In this  plant.

 the cardboard is prepared from scrap corrugated by a cardboard cutter

 operation performed by some of the janitorial staff at several locations
                                    67

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throughout the plant.  As  the cardboard  separators  are  discarded  through


use the larger pieces are  sorted to the  cardboard scrap,  the  smaller  into the
   r

' 'tank carts".


          This plant does  not have a shipping warehouse but shares  with a


sister plant a warehouse and distribution  center about  eight  miles  distant.


The receiving operation does not unpack  the incoming material;  this is


done at the point of use.  The corrugated  packing material is sorted  and


segregated as scrap on hand-trucks.  Paper and  other compactible  material


•*^ deposited in the "tank carts".  Wood  and other combustible


non-compactible material *«• transported  by tank carts to  the  dump truck


dock from whence ifc'irr taken to the open burning site.


          Wastes from offices, cafeteria .and snack  areas, the latter  two  in


plastic bags  deposited in wastebaskets. and drums., are  collected  in the tank


carts and go to the compactor.





                            QUANTITY COMPUTATION


          As a courtesy to this study  the  plant, after  the interview, made an


extended tally of the trash carts delivered to  the  compactor.  The  study


covered sixteen compactor  loads over a period of fifty  working days.  For each


compactor load, of 40 cy,  the number of  1  cy and 2.5 cy tank  carts  was


tallied, and the cubic yardage of waste  in the  carts was  computed for each


compactor load.  The average of the 16 compactor loads  was 184 cy,  an


average compaction ratio of 4.6.  For  two  other plants  in this study  .the  bulk


density of similar material in compactors  was 430 and 500 Ibs/cy.  If the bulk


density for this plant is  taken as the average  465  Ibs/cy, this indicates a


bulk density in the tank carts of about  100 Ibs/cy.


          The 16 data points allow some  statistical Interpretation.  The


(reciprocal of the) number of uncompacted  cubic yards in  a 40 cy compactor,
                                     68

-------
expressed as the compaction ratio, was log-normally  distributed with  a median

of 4.4 compaction ratio and a sigma ratio of  1.28  (ratio  of  the 84th

percentile to the median, equivalent to the standard deviation in  log

units).  Each compactor load represents about 93 deliveries  of the carts •
                0*f£
60 of the larger. 33 of the smaller.  Thus there are about 30 deliveries

per working day'-about 19 of the larger and 11 of  the  smaller, on  the average.

          The estimated waste quantities are  as follows:

                                                          Per Year
                                                   Loads      cy          tons

          Enamel, paint & other sludges in drums     50        480         410
          Compactor                                  79       3,100         730
          Dump truck                               244       5,300         270

                                      Total        373       8,880       1,410

          tye                       1.18
          type                      1.51
          Scrap paper as percent
               of waste             3. 3
The 35 drums per week of sludges are computed at a specific  gravity of  1.0.

The compactor loads are computed at 465 Ib/cy, the average of  compactor bulk

densities in other plants in this survey. The dump truck has a 30  cy  body

hauled three-quarters full, and an estimated density of 100  Ib/cy, the  loads

being crates, boxes, and other bulky wooden items.

          The plant in 1970 sold 3295 tons of metal scrap, and 12  tons  of  paper

(punched cards).  Thirty-four tons of corrugated were taken by the volunteer

association.  Of the scrap and wastea70.5 percent was utilized.

-------
                                 EQUIPMENT

          The equipment and estimated 1970 replacement investment involved in
               AAJt
waste handling is*, as follows:

               20 Tank carts                           Rented
               150 Trash drums and cans                    750
               55-gallon drums                           Scrap
               1  Dust collector on polisher              3,000
               1  Compactor                               Rented
               1  Lift for compactor                      5,000
               1  Industrial vacuum                       2,000
               1  Dump truck, 1/3 share                   3,000
               5  blowers and filters on enamel rooms    76,000
               3  blowers and filters on paint rooms     24,500
               3  enamel milling sumps                  not included

                                             Total    $114,250

This amounts to $81  investment per annual ton of waste.

          The amortization of the waste handling equipment at 25 years and
10 percent would  be about $12,600 per year.  The major items are the blowers
and filters on the enamel rooms and paint rooms,


                                 LABOR

          Estimated labor hours and costs for waste handling are as follows:

                                                  Man-hours/yr

               Paint lines                             830
               Enamel sumps                          1,040
               Enamel lines                            780
               Janitors - 18 @ 46.5%                16,700
               At work stations                      4,000

                                             Total  23,350

               Cost at#3.76  /hr for 75% burden   $154,000/yr


                           EQUIPMENT OPERATION

          The cost of equipment operation and maintenance is estimated
according to:

                                                  $ Per Year

               Maintenance @ 4% of investment        4,500
               Energy for compactor and lift            50
               Janitor supplies                      not est.
               Energy for blowers                    1,500

                                             Total $ 6,050

                                     70

-------
          The energy for the blowers is estimated from the CFM capability

operating eight hours a day, against four inches of water pressure drop

and at 60 percent efficiency and an energy price of one cent per KWH.



                            CONTRACTOR AND FEES

          The cost for contract disposal is:

          Rental, tank carts @ $8/mo               1,920
          Rental compactor, $375/mo                4,500
          Hauling compactor, $73.5/load            5,700
          Hauling sludge drums, $85.5/wk           4,300

                                      Total      $16,420



                                 TOTAL COST

          The total of the foregoing cost elements is as follows:

                                       $ Per Year      Percent of total

               Labor                      154,000      ,     81.4
               Equipment amortization      12,600            6.7
               Operation and maintenance    6,050            3.2
               Contractor                  16,420            8.7

                                   Total  189,070          100.0

               Per ton of waste -$134
                                   TRENDS

          The management sees no forthcoming changes that would affect

solid waste quantities or practices.
                                     71

-------
                                  PLANT 3




          This plant, part of a multiplant complex, produces household refrigerators




and is classified in SIC 3632.  It also produces room air conditioners,




which are in SIC 3585, about 25 percent of the units produced being air conditioners.




Of course from the standpoint of the manufacturing processes involved and the




solid wastes generated there is a considerable similarity between refrigerator
                      >'



manufacture and room air conditioner manufacture.




          The plant is located within a municipality and half a mile from the




nearest built-up residential area.  The surroundings are 100 percent light




industrial.




          It operates five days per week, mostly one shift, some operations




two shifts, and plastic extruders and vacuum forming three shifts.  There are




nine holidays, a one-week shutdown for inventory and a one-week shutdown at




Christmas, thus a 242~day, fifty-week year.




          Some of the quantitative data to be obtained applies to the 1968-




1969 fiscal year.  Other data apply to the period immediately before the  interview,




that is the ending months of 1970 and the beginning months of 1971.  The average




total employment in the 68-69 fiscal year was 4f100, the average employment




in the period just preceding the interview 3640.  The offices and the engineering




department serve not only this plant but also several sister plants.  It is




estimated that about 300 people are involved in offices and engineering, thus




giving about 3J300 employees associated with production and 3600 total employees.




The 1968-69 quantities used in computations are adjusted downward to the 3600




figures.




          Responsibility for waste management planning and engineering is with




the Superintendent of Manufacturing Process Development.  In actual operations^,




the janitorial staff is in the maintenance department*    the solid waste hauling




contractsjas well as the scrap negotiations^are handled under a material control




function in the purchasing and distribution department.






                                     73

-------
           In  addition,  this plant has  the practice  that  the production machine

 operators  are to spend  a nominal fifteen minutes per day cleaning up at  their

 work stations, and this is a responsibility of the  production department.  At
         <*•>
 the multi-plant level,  there is a Director of Environmental Services whose
         V
 function is the overall coordination of operations  involving pollution control

 in air, water, solid waste, noise, and industrial health.  The Director  of

 Environmental Services  has particular  cognizance over  the extensive plant sewer

 and liquid cleaning operation.

           The scrap and waste generating operations in this plant are:

           Stamping and  shearing              Electrostatic and spray painting
           Milling (as a machining operation) Plastic molding
           Welding and brazing                Vacuum forming
           Broaching                          Air cleaning
           Tube expanding                     Coal burning
           Tumbling                           Liquid cleaning
           Anodizing                          Receiving
           Porcelain enameling(spray and dip) Offices,  cafeteria and snack areas

 This is the only plant  among the nine surveyed that burns coal.


           The primary collection containers are:

          Waste baskets
           Fibre drums
           55-gallon steel drums
           4.5 cy trash wagons
           1 cy ''V-buggies'' used for sludges

           In-plant conveyance to the disposition areas is by fork lift truck

 in trains  of up to five wagons or buggies and also  by  flat bed power vehicles.

 This is done under a precise schedule, the schedule being shown for illustration

 on the next two pages.  This scheduling incidentally was worked out in an

 industrial engineering study performed by an engineering trainee, actually

an engineering college student in the five—year cooperative education program

sponsored by the company.   As an illustrationythe schedule shows that on

the first shift, having two power vehicle operators and  49 trash wagons

at their disposal there must be hauled between 6:48 and  9 a.m. four trains
                                       74

-------
                                             1ST SHIFT
     DRIVERS 2  -  49 WAGONS




          6:48 — 9:00




[RAIN NUMBER




     1.






     2.






     3.






     4.
    5.






    6.






    7.
    8.






    9.
   10.
          9:10 —  11:00
          11:30 —  1:30
1:40 -- 3:00




M W F






T TH
1
PICK UP AMD DELIVERY ORDER
N-73-1
N-96-2
N-66-1
N-73-1
M-47-2
M-61-1
L-74-1
L-96-1
C-90-1
F-96-1
F-73-2
F-88-1
E-98-2
L-113-1
N-68-1
N-96-2
M-47-2
M-61-1
J-15-1
0-105-1
N-90-2
N-90-2
N-70-1
0-71-2
M-56-1
M-60-1
L-88-3
L-8P- J
C-80-2
C-90-1
F-84-1
F-86-1
L-102-1
L-102-1
N-71-1
N-73-1
M-56-1
M-60-1
E-21-1
F-30-2
N-96-2
N-73-1
0-71-1
N-70-1
M-60-1
M-56-1
L-96-1
L-14-1
D-70-1
C-80-2
F-86-1
F-84-1
L-113-1
E-98-2
N-73-1
N-71-1
M-60-1
M-56-1
F-30-2
E-21-1

N-73-1
N-66-1
M-61-1
M-47-1

F-96-1
D-70-1
F-88-1
F-75-2

N-96-2
N-68-1
M-61-1
M-47-2
0-105-1
J-15-1
3-Insulatlon Street 1-Duco House 1-Provinp, Test
1-Proving Test 1-Paint House 3-Insulation Street
Pick Up
Deliver
Pick Up
Del ivei
Pick Up
Deliver
Pick Up
Deliver
Pick Up
Deliver
Pick Up
Deliver
Pick Up
Deliver
Pick Up
Deliver
Pick Up
Deliver
Pick Up
Deliver
Pick Up
Deliver
                                              -  75

-------
                                            2ND SHIFT
    DRIVERS 1 - 50 WAGONS




         3:18 -- 5:30




'RAIN NUMBER^




    1.






    2.






    3.
         5:40 -- 7:30
    4.
    5.
    6.
         8:00 -- 10:00
    7.






    8,






    9.
         10:10 -- 11:30
PICK UP AND DELIVERY ORDER
   10.
D-30-2
J-69-1
J-72-2
J-94-1
L-48-1
L-73-1
N-73-1
N-96-2
N-69-1
N-73-1
M-47-2
M-61-1
M-96-1
H-45-1
H-96-1
H-96-1
H-68-1
H-68-1
L-75-1
L-96-1
J-56-1
J-61-1
J-84-2
J-84-2
L-56-1
L-67-1
N-90-2
N-90-2
N-71-1
0-71-2
M-56-1
M-60-1
L-47-1
H-42-1
H-88-1
H-88-1
H-67-1
H-62-1
L-88-3
L-88-3
J-61-1
J-56-1
J-94-1
J-72-2
L-60-1
L-60-L
N-96-2
N-73-1
0-71-2
N-71-1
M-60-1
M-56-1
L-45-1
L-45-1
H-84-2
H-84-2
H-57-2
11-51-2
L-96-1
L-75-1
J-64-1
P-30-2

L-67-1 L-73-1
L-56-1 L-48-1

N-73-1
N-69-1
M-61-1
M-47-2
H-42-1 H-45-1
L-47-1 M-96-1
H-72-1
H-72-1
H-48-1
H-48-1

Pick Up
Deliver
Pick Up
Deliver
Pick Up
Deliver
Pick Up
Deliver
Pick Up
Deliver
Pick Up
Deliver
Pick Up
Deliver
Pick Up
Deliver
Pick Up
Deliver
Pick Up
Deliver
                                                  76

-------
of the 4.5 cy trash wagons.  The location designations are posts  (roof-support

posts) numbered in an alpha-numeric grid.  Train No. 1 is to pick up one wagon

from Post N 73, two from N 90,and two from N 96.  The driver then proceeds

to the disposition area, unloads, and on the return delivers the wagons, in

this case in the reverse order, two to Post N 96, two to N 90 and one to N

73.  He then proceeds to the second train at Post N 66.  At 9 a.m. he has  a

ten-minute break and then resumes with train No. 5 at 9:10.  It will be noted

that there is a second pickup at Post N 73 in the second train and a third

in the eighth train.  This Post is also revisited in the fourth and fifth trains
                                                                  ho. i' c
on the second shift.  The frequency and the number of trash wagons -fees- been

worked out according to the industrial engineering study,which determined the

average frequency of fill at each Post.  Considerations of optimum routing

and also of space available for retaining the wagons at the work  site determine

whether to have a single wagon and frequent pickups or a number of wagons and

infrequent pickups.

          This industrial engineering study reduced the required  total number

of wagons from 142 to 107.  Pickups are now made at 25 posts thrice daily,

at 52 twice, and at 26 one, and at 15 once every two days,_a total of 212 pickups

per day. about 71 pickups per driver day, about one every 6.75 minutes. The

main building in which this activity occurs is about 1700 feet long and the

disposition dock is at one end of it.  However the layout and the aisle housekeeping

allow  rapid movement.

          Waste leaves the plant in the following modes:

          Compactor, 42 cy
          Dump truck, 5 cy
          Open detachable container, 40 cy
          Tank truck, 5000 gallon
          Hopper truck (for fly ash) , 5 cy

Also some wastes are taken directly to the company dump in V-buggies or flat-

bed power vehicles.
                                        77

-------
           The  disposition agents  are  two contractors and the company itself.

 The  latter involves  the hauling  to  the  company dump  on the plant grounds of

 the  V-buggies  and  the  flatbed  power vehicles  and the trips to the company dump

 by the  dump  truck, hopper truck,  and  the tank trailer.   In addition the compactor

 loads are  hauled 2.5 miles  to  one contractor's establishment by the company

 in company trucks, averaging seven  loads per  day.  The other contractor handles


 the  open detachable  container, two  loads per  day,  hauling it four miles to

 the  merchant dump  owned by  the contractor.

           The  company  dump  is  described  on  the following Land Disposal Site

 Investitation  report.


           The  material from this  plant  taken  to the  merchant dump is burned

 in an "air  curtain destructor'', a forced  air burning pit where the wood waste

 comprising the load is burned  in  an operation which  has the approval of the

 county  pollution control  agency.

           The  contractor,  actually  a  paper  broker  who takes the compactor

 loads segregates the paper  and corrugated,  mostly  the latter, by hand picking

 from a  conveyor belt.  It  is then shredded, pneumatically  conveyed to a baler

 and  compacted  into 1000 pound bales which are sold by the paper broker.  The


nonsalvaged material is compacted in  a  compactor truck and taken to the County

incinerator.   It is difficult to  say  just where the  solid waste management of

the  company ends and the  solid waste  management of the paper broker begins.

The  company pays the broker J6$/ton  for handling, the broker pays the county
                    .-~~~~^.  <                           pCfCgyCt
incineration fee of ^7.90\  $//ton for  the  approximately 50j£vtaken to the incinerator,

and he  sells the other 50 percent as  waste  paper.  Because of the payment to

the contractor, in this study it will be taken that  the compactor loads comprise

waste for  the  company and not scrap.
                                     78

-------
1EPARTMENT OF
 EALTH. EDUCATION. AND WELFARE
 •UBLIc'lEALTH SERVICE
                                                      Form Approved
                                                      Budgot  Bureau No.
                                                                                                               68-S-b8C
                                           COMMUNITY SOLID WASTE PRACTICES
                                  LAND DISPOSAL SITE INVESTIGATION REPORT
 .  STATE

                              2.  COUNTY
                                    T
                                                               i 3  SITE LOCATION (Po I it icfi I J uzi •
   5.  ADDRESS OF SITE
                                                                                                       _ _[_ 7	
                                                           i  >NTH     YEAR
                                                                                         IS   10    17   18    19   ZO
 . NAME OF PERSON COMPLETING FORM
                    JJL
                                                                          9. ORGANIZATION  AN O ADDRESS
 0. POLITICAL JURISDICTIONS SERVED BY LAND DISPOSAL SITE
                     NAME OF
             POLITICAL JURISDICTION
                                    45   46   47   48
                 ESTIMATED
             PERCENTAGE OF
                JURISDICTION
              SERVED BY SITE
                                                                         AVERAGE DISTANCE
                                                                            OF SITE FROM
                                                                         CENTER OF SOURCE
                                                                             AREA (Ml In a)
                                                                                       7
         FOR ADDITIONAL. ENTRIES. CHECK HERE  (_J (S3)   AND MAKE ENTRIES IN ITEM t45
                                                                                                It. SITE OPERATED BY
                                                           PUBLIC AGENCY
                                                               PRIVATE AGENCY
                                                                                                12. SITE OWNED BY
                                                                                                       PUBLIC AGENCY
                                                                                                       PRIVATE AGENCY
13. IS OPERATION
   REGULATED BY A
   HEALTH AUTHORITY?
IF YES. INDICATE LEVEL      [-] COMMUNITY    ["1 STATE
OF PRINCIPAL AUTHORITY
     (Check one only)
                                                                        ]5g£
                                     cOUNTY
                                                      OTHER.
                                                                                                          (Snecity)
14. GENERAL. CHARACTER OF SITE (Chock one only)
d] QUARRY OR BORROW PIT Q HILLSIDE
~| GULLY-CANYON FH MARSH. Tl DELANO
-i OR FLOOD PLAIN
^^LEVEL AREAS
(Specify) Do
not
use


B. ZONING/ LAND USE SURROUNDING FACILITY (Check predominant
ZONING v>
LJ NONE QSjNDUSTRIAL
^RESIDENTIAL [^AGRICULTURAL
| ] COMMERCIAL ("""] OTHER
*— ' (Specify)

15. YEAR SITE PLACED IN OPERATION
i«. ANTICIPATED LIFE REMAINING (Years)
17. TOTAL AREA OF SITE (Acres)
'»• AREA TO BE USED FOR LAND
DISPOSAL (ACT3a)
type only)
LAND USE
LJ RESIDENTIAL TJAGRICU
[7] COMMERCIAL [71 OTHER
J^^INDUSTRIAL
19


C4
L

6!

6B

^
98

62
3
66

^
60
/
83
0
67
/
68 69 70 71
LTURAL
(Specify)


72 73
0.  IS USE OF
   COMPLETED

   SITE PLANNED?  [  ] NO      USE ONLY
                               IF YES. CHECK   P"! RECRE*TIONAL
                                               1 — 'AREA OR PARK
                               P R E OOMI N A N T
                                                                       IGHT
                                                  PARKING LOT
                           ONSTRUCTION  [ _ 1 AGRICU L ruRE  Lj DETERMINED

                                          [_~ ~| OTHE:R	
                             1 CONSTRUCTION
''• WILL PUBLIC AGENCY CONTROL

   COMPLETED SITE USE'
LJ YES
                                           NO
                                                                                                        (Specify
                                                 22. MATERIAL USED    []NONE    [_"_] OTHER
               FOR COVER
              (Check one oily)
                                                                            EARTH
                                                                                                        (Specify)
Z3. FREQUENCY      [ J NONE
   OF COVER
                              (En
                    LI DAILY '^-^'
   [31 DAILY (Except
      OTHER
                                                       (Scily)
                            24. IS SPREADING AND COMPACTION
                               OF REFUSE HANDLED IN APPROX-

                               IMATELY TWO-FOOT LAYERS OR LESS'
                                                                                                               NO
 •S. NUMBER OF DAYS DISPOSAL SITE COULD NOT BE USED BECAUSE OF WEATHER CONNECTED CONDI
                                                      TIONS (Enter average f
                                                                per year)
 .6.  GENERAL CHARHCTER OF OPERATION (Jutl&nent evaluation - chock appropriate categories)
APPEARANCE

%^f
1/fSlGHTLY
JNSIGHTLY
'-1 1
IS BLOWING PAPER
CONTROLLED?

QjYES
	
lal
IS BLOWING PAPER
CONSIDERED TO BE
A NUISANCE?
OES
i 	
I7l
ROUTINE BURNING
& X
|XLNONE
L j UNCONTROLLED
,- i PLANNED AND
L- ' LIMITED
18 1
ARE THERE SUR-
FACE DRAINAGE
PROBLEMS?
DYES
5KNO
• '. I
ARE THERE
LEACHING
PROBLEMS?
r i YES
\ffNO
?n! j
                                                                 79

-------
                               LAND DISPOSAL SITE INVESTIGATION REPORT (Page 2)
2 CONTROL PROGRAMS

RODENT CONTROL
PROGRAM
(
FLY CONTROL
PROGRAM
BIRD CONTROL
PROGRAM
DUST CONTROL
PROGRAM
ODOR CONTROL
PROGRAM
_,__.._, 	 1
| YES 1 NO j
! ,* j
NEEDED ! "j iS :2
| '-- X :
PROVIDED j | [jfj i
NEEDED ~] jj/j 2
PROVIDED \J (Jfl 2<
NEEDED ~ yf] 2!
PROVIDED ~~ ' J/) 2t
NEEDED kp \ } 2-
PROVIDED ~" jjjfj 2f
NEEDED [*J jy^f 7?
PROVIDED ~ JST *
3J ARE QUANTITATIVE RECORDS , 	 . .,,-,- t:^ -. °
1 1 YES BT NO not
KE;JT IN ANY FORM' ' — ' *V>
0o ! W0T£r /*9
not 2H. ' LOWEST t AT-, T OF FILL IN WATER
use J
I 	
-I
1
J
,



47
3' QUANTITIES OF SOLID WASTES RECEIVED ANNUALLY
T .NS WEIGHED
T NS ESTIMATED
C BIC YARDS
62

48 49 10 51 b2 53
"rimzzni
55 56 57 E6 59 60
1 ^A
63 64 65 66 67 68
	
54
6 1
69
3( GENERAL CLASSIFICATION OF SOLID WASTES
ACCEPTED AT DISPOSAL SI T E (Check those accepted)
l ^HOUSEHOLD MS-TRIAL" [~ ] 1 NST ITUTION AL
72^ 74
COMMERCIAL |-|AGf"CUU- r— , I N C IN ER ATOR
\, • 7yTUR L 75 RESIDUE ONLY
3- EQUIPMENT AVAILABLE
(Avcraftv utilized daily)
DRAGLINE OR SHOVEL-TYPE
SC RAPERS (Salf-ptopetled)
T FACTORS (Tf^ckorKubber T
THJCKS
NUMBER
EXCAVATORS
35

37



41
Do
O !" HER nnl
(Specify)
07 HER
(Specify)

36

38

40
/
4?

use 43 44 45
Do
not

use 46 47 48
^TABLE- j , YES | NO
~9 Jtvl" "NCNE j WAT^J I ^. ^^
t '.FIREBREAK j | O T h^JlCW/l« f_ •f^T'^'^f^'
30. NUMBER OF TIMES FIRE CONTROL E
WAS REQUIRED AT SiTE IN THE PAST
3 1.
IS SALVAGING PERMITTED'
32.
IS SALVAGING PRACTICED'
(
QUIPMENT 1
r YEAR I-J5 ' 34-^-3%— '
. YES Jt'NO
i Y E S ^J N O
33 ESTIMATED NUMBER OF LOADS DEPOSITED DAILY (Average)
FROM PUBLIC FROM PRIVATE
COLLECTION COLLECTION^
VEHICLES VEHICLES X^
(Enter ^ T~ T (Enter \ 1
number) j J 1 number) 1 	 [
~"J8~ 39' ~4C>~ 4~! ~t
j FROM OTHER VEHICLES
// ' r-W,/;/ "
"T-fej,, ["TJ~
"2 ^3~| 44" ^"45" ~4G
37. CHECK ANY ITEMS LISTED Bbi OW Wt.iCH ARE
EXCLUDED FROM THE DISPOSAL SITE
rN^ALL ^yfSEWAGE
J^NPUTRESCIBLES ^SOLIDS
t- i ALL rV^JUNKED
l-el NON-COMBUSTIBLES Lj(^AUTOMOB|
i —i ALL .^f LARGE
[^GARBAGE ^-.DEMOLITIC
^8^ 24
1^ DEAD [ -, CONSTRUC
J/yANIMALS ^ J DEBRIS
p .WASTE j^/STREET
39' TOTAL NUMBER OFEMPLOYEES ON Slil
40. HOURS OF DAILY QCr-,.,
OPERATION BEGIN
(On a 24-hour clock) 51
41' NUMBER OF DAYS OPERATED PER W
42. ANNUAL OPERATING COST ,

43. IS THIS A SANITARY LANDFILL'
*-j
^JT,RES
LES 1-P^MATERI ALS
28
_s ' OTHER (Specil e,0 61 62

| ] YES
PS^io
44  IF SOURCES OTHER THAN REPORTER DESIGNATED IN ITEM 7 WERE UTILIZED IN COMPLETING THIS FORM, INDICATE BELOW
   THE SOURCES USED AND ITEM NUMBERS
       NAME OF PERSON
                                           TITLE
                                                                     ORG ANI Z ATION
                                                                                             ITEM NUMBERISI
                                                                                                                    r
                                                                                                                    \	
                                                                                                                    L
                                                          80

-------
          The streams from the various scrap and waste generating operations


are handled as follows.


          The wastes from stamping, shearing, milling, welding and brazing,


broaching and tube expanding are placed for the most part directly in the

                                                      / S
trash wagons.  The metal scrap from these operations a*« hauled to a rail


dock at one side of the plant where it is loaded on open rail cars.  Steel


scrap is returned to the vendor for salvage.


          This plant has an extensive system for handling aqueous wastes


partly from anodizing and pickling, described beyond under liquid cleaning.


The oils used in broaching are filtered and recycled.  The cutting and


lubricating oils and compounds used in other metal fabrication are placed in


55-gallon drums, about eight per week.  On occasion it has been possible to


sell this waste oil to a reclaimer.  However, if not saleable the oil can


be taken to a waste oil burner in a separate building and burned.


          The tumbling or Hotofinish operation for all parts is very minor.


Only one drum is used, three inches by thirty-six inches.  It is dumped on

                    OJVL-

a screen, the pebbles.reused and the wash water goes to the plant sewer and


holding tanks.  It is only used about 20 percent of the working hours.


          From the porcelain enamel spray booths the overspray is scraped up


and placed in V-buggies, about two to three cy per booth being obtained on


the weekly cleanings.  The 8,000 Ibs/week of such scrapings plus the occasional


cleanouts of the dip tanks^ are taken directly to the dump in a train of five


or more V-buggies.  In addition.there is a 100,000 cfm bag filter for dust


collectioiubut this material is recycled for reuse in enameling  the backs


of the liners, i.e.,jthe portion that is not seen and does not come in contact


with the  refrigerator contents.
                                          81

-------
          Painting is both electrostatic and  spray with water  curtain.




Paint preparation is in a separate building,  the waste paint and  solvents




being piped to one of the holding tanks described later.




          The strippings from the electrostatic booths are placed  in  trash




carts and taken to the compactor.  There is extensive purging  of  the  paint




lines due to color changes.  About 50-60 drums per month from  purged  paint




are taken in drums on flatbed power vehicles  to the dump where they are deposited




with the drums. Paint thinner is reclaimed  .  Sludge from that operation, about




8 drums per week, is also taken to the dump on flatbed.




          Paint hangers for stripping are taken by truck to a  separate building,




about five to six truckloads a day.  There are five aqueous caustic stripper




tanks.  One of these is dumped each week to a sump and pumped  to  one  of the




holding tanks about once a month.




          The only cementing and bonding is of gaskets, the very  small amount




of waste being placed directly in the trash wagon.




          Plastic molding and vacuum forming  are extensive but all possible




plastic, cutoffs.etc.*is remelted.  The small quantity of residual waste is




placed in trash wagons.




          There is no waste from refrigerant  charging because  the delivery




of the refigerant is in bulk.




          Except for the bag filter mentioned above practically all of the




"air cleaning" comprises the flue gas cleaning in the power  house described




later  under coal burning.




          This plant has an extensive waste liquid collection  and cleaning




system, the liquid waste  coining from various process streams  including pickling




and anodizing.   There are seven primary settling tanks, 20,000 to 50,000 gallons
                                     82

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each. some underground.  Sludge, 1,450 cy in 1970, is removed from these

holding or settling tanks by a contractor  and trucked by him to the plant

dump.  The partially settled liquor is pumped to a secondary settling basin

of about five acres and   eight feet deep, located across a highway about 500

yards from the plant building.  This secondary settling basin also receives

the drainage from a city storm sewer which serves about a 100-acre drainage

area from an industrial area adjacent to the plant.  This secondary settling

basin at the time of the survey had been in use for about four years, and approximately
20,000 cy of sludge, 12-18 percent dry solids, had. collected.  A dredging contractor

was at that time pumping the sludge, averaging about 3 percent solids as pumped,

to an adjacent sludge drying bed of about 1.6-acre area and eight feet deep.

This sludge pit had just been placed in operation.  It is anticipated that

the material will require about one year to dewater and then will be draglined,

disposition as yet undetermined.   The resulting overflow from the secondary

settling basin is discharged to an  adjacent river and meets the requirements

of a local pollution control district.

          The receiving operation generates scrap and waste from incoming packaging.

In a location central in the plant and adjacent to the rail dock, incoming

clean corrugated and also kraft paper from wrapping of incoming insulation
         air e
materials ±9- shredded and baled. The output is three 800 -pound bales per day

which includes about two tons per month of kraft.  Some corrugated is also

placed on skids and bound.  The scrap is sold on a batch bid basis and removed

by the buyer.  About 200 skids  (pallets) are generated per day.  About half

of these are sold (for ten cents each) .  The other half go to the open detachable

container for wood waste.  Of car shoring^about 250 2x4's and 50 4x4's are

sold each week to the steel vendor, this being 30-40 percent of the total incoming.

The remainder of the shoring is taken to the open detachable.
                                       83

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          Wastes  from  offices are  collected by  the  janitors  in the  trash




wagons.  Confidential  material  is  placed  in a special  container and taken once




a week directly to the County incinerator by Company personnel.




          The cafeteria operation  is  catered, i.e.^the prepared food is  brought




in.  The wastes are deposited in trash cans.thence  to  trash  wagons  and to the




compactor.  Snack area waste is placed directly  in  the trash wagon.




          From all of  the above operations general  plant  trash is flowing via




the trash wagons  to the compactor.  In addition  to  the corrugated and paper




•wliiHili	"to salvaged by the contractor the compactor material contains  such nonsalvagable




items as old gloves, uniforms,  oil- contaminated ABS cutout  scraps,  some broken




skids by mistake, glass reinforced plastic, damaged vinyl door seals, urethane




foam parts, sweepings, etc.




          In various stages of  fabrication and assembly ..reject parts are generated.




If such large parts as cabinets are not too far  along  in  the assembly process,




they are returned to the vendor in rail cars via a  dock at the site  of the




building adjacent to the assembly  line and opposite the main scrap  dock.  The




cabinets are insulated by injecting urethane foam between the  liner  and  the




outside shell.  If rejects occur after this operation or  after the wiring has




been installed then they are not usable directly by the vendor but  are loaded




on rail cars and shipped about fifty miles to a  Prolerizer operation in  which




they are converted to  No.  1 scrap.




          A captive coal-burning power plant serves this  plant and  several




other plants of the corporation nearby, the only coal-burning  plant  encountered




in the study.   About 30 percent of the power plant  is attributable  to the




manufacturing plant under study.   The power supplied is steam  only,  used




for space heating, vacuum ejectors, and heating  plating and  metal cleaning




solutions.   The power  plant burns  about 100,000  tons of pulverized  coal  per




year and generates about 10,000 tons of fly ash  and bottom ash.  About 70
                                     84

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 percent  of  this  ash  is  collected  in unpowered  cyclone  collectors.  A hopper  truck

 takes  the collected  ash from  the  hopper and  transports it about  100 yards  to the

 company  dump.  There about  once a week a  contract bulldozer bulldozes  the  ash into

 the  pit  and covers it with  clay.  The truck  makes five trips per day.   The remaining

 30 percent  of  the fly ash is  lost in the  stack effluent.  The  company  is taking

 steps  to recover this as is described in  the section bSlow  titled  ''Trends'*.

          The  power  plant also softens its feed water  by the lime-soda processy

^generating {thereby 150,000 gallons per week of  sludge.   A five-thousand ..gallon tank

 truck  is used  in sole service to  haul this sludge to the company dump  150  yards

 distant.

                              QUANTITY COMPUTATION

          The  estimated quantities of these  various waste streams for  the  year

 1970 are as follows:

                                                     Per year
                                             Loads       cy      Tons

               Compactor                    1,694      71,100    7,300
               Open  detachable                  484      19,360    1,936
               Enamel buggies                  50        200       200
               Paint line wastes                130        280       189
               Waste oil and  solvents               very  little
               Sludge drying  bed  (net,
                     this plant)                 --        1,740       845
                                \J
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 The  compactor  quantities  are  computed  from  seven  loads  a  day,  42  cy  each,




 4.3  tons  each.  The bulk  density  therefore  is  only  204  Ibs/cy,  because the




 compactor is not  run up to full pressure.   The  open detachable  is  computed




 from two  loads per day and estimated bulk density of  200  Ib/cy.  The enamel




 buggies are computed from the  8,000 Ib/wk and  estimated 2,000  Ib/cy.   The paint




 line wastes are based on  87 drums/mo from purging and thinner  reclaim, 50 to




 60 drums/mo from  purging  and  8 drums/wk from thinner  reclaim,  and  8  drums per




 load and  a specific gravity of 0.8.  The coal  ashes are computed from five




 loads a day, 30 percent attributable to the plant under study,  the loads being




 carried in a 5 cy hopper  truck.   The bulk density from  these figures becomes




 2,310 Ib/cy-which is reasonable.  The  softening sludge  is computed from the




 10 truckloads/wk, 30 percent attributable to this plant,  25 cy/load  and a




 specific  gravity  of 1.0.




          The output from the sludge drying bed is  computed as  follows.




 In four years the secondary lagoon has accumulated  20,000 cy of sludge at 12  to




 18 percent solids, say 15 percent average, and  a specific gravity  of 1.0.




 This corresponds  to 2,530 tons of dry  solids in the four  years  or  634 tons/yr.




 In the sludge drying bed  this sludge will have  about  50 percent moisture,




 thus the  annual increment of 50 percent moisture sludge is 1,268 tons/yr.




With sewage sludge.the volume of dried sludge,as on sludge drying  beds.




 is about  35 percent of the applied volume.  If  the  moisture as  applied is




 taken at  90 percent ±hen  1 cy of  the 90 percent moisture  sludge will have a




weight of 1,690 Ib and contain 169 Ibs of solids.   Dried  to 50  percent




moisture,this one cy will have a volume of 0.35 cy  and  weight  of 338 Ibs,




 thus a bulk density of 965 Ib/cy.  Thus the 1,268 tons/yr of 50 percent




 sludge in the sludge drying basin will have a volume  of 2,620  cy/yr.
                                         86

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However, the secondary settling basin also receives the storm water

concentration from the city storm sewer draining about 100 acres. The annual

runoff at the plant site is about 12 inches^and at 1,000 ppm total suspended

solids in the storm sewer runoff .this would amount to 136 tons/yr of solids

in the street washing.  This is 21.5 percent of the 634 tons/yr total solids

collecting in the sludge lagoon.  In addition the managers estimated that of
the contributions to the lagoon, one percent we go from an adjacent plant and

10 percent from an adjacent building not connected with the plant in this  study.

In all. about two- thirds of all the sludge in the sludge lagoon can be attributed

to the plant under study and this gives the 1,740 cy/year and 845 tons/yr  as

contributed by the plant itself.  This involved computation is roughly  confirmed

by the figure of 1,450 cy of sludge cleaned out from the seven holding  tanks

by the contractor in 1970, solids concentration unknown.

          Because of two unusual features coal burning and the scrap paper
                        •*•* ^
salvage by the contractor, this plant requires special manipulations to  arrive

at quantities comparable with the other plants.  In the first place^ there

is no doubt that coal ashes and softening sludge resulting from  the power  plant

are actual wastes generated by this plant and the costs of handling them are
                   VH-''
solid waste -ita«diiag costs.  On the other hand they increase the total  tonnage

by about 50 percent. and since coal burning is the exception the figures would

not be comparable with the other plants. ( Coal»burning manufacturing establishments

are quite rare.  The author and associates over the past ten years have surveyed

some 600 manufacturing and non-manufacturing plants on various projects and

this is only the second coal— burning plant encountered.)  On the reduced  basiSj

the tye is 2. 92. and the type is 3.17. while for the total wastejincluding  those

from the power plant the tye is 4.37 and the type 4.77.
                                       87

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          The scrap paper actually salvaged by the plant amounts to 290 tons
                                                    Ju^/'^t,^
per year, about 2.8 percent of the subtotal waste,ex>power plant. However,

the 50 percent of the compactor waste salvaged by the contractor brings the total

scrap paper from this plant reaching the commercial salvage market up to 3,920

tons.  If the amount salvaged by the contractor is subtracted from the subtotal

tonnage then the paper salvaged by plant and contractor becomes 57.5 percent

of the remaining waste, i.e.-the waste that would have been generated if the

plant itself had salvaged all the paper that is salvaged.

          Of metal scrap«about 60 percent of that emanating from this multiplant

complex results from the activities of the plant under study and this is 23,300

tons of metal scrap per year.   The total scrap (including the paper salvaged

                v                              '  ,V<3
by the contractor) then is 27,220 and the waste.exi power plant and W& paper

salvaged by the contractor is  6,840 tons/yr.  Thus.total scrap and waste.exe/uJ i wo

power plant.is 34,060 ty.and therefore .80.0 percent of the scrap and waste

generated finds utilization.



                                 EQUIPMENT

          The 1970 estimated replacement cost for the equipment used is:

               30  V-buggies @  $250                  $  7,500
               107 Trash wagons @ $350                37,500
               3 Compactors &  dumpers,
                    conveyors, pads                  200,000
               6 Compactor containers                 30,000
               2 Trucks, hauling containers           18,000
               1  5 cy dump truck                       9,000
               Waste oil burner                       25,000
               1  Flat bottom cart                        350
               2 Fork lift trucks                     24,000
               5 Paint hanger  strippers                30,000
               Sludge drying basin      ,,             14,000
                                  c\u^
                        Subtotal ex. power  plant      $395,350
                                        88

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          1 5 cy hopper truck at powerhouse            1,800
          3 Mechanical collectors                     75,000
          5000-gallon tank truck                       1,200
               (All at 30%)
                                             Total  $473,350

This amounts to $30.1#per annual ton for the grand total and including the

power plant tonnage.or $37.80per annual ton for the subtotal excluding the

power plant tonnage.

          The amortization on this total investment at 25 years and 10 percent

would amount to $52,100 per year.

                                   LABOR

          The labor cost involved is computed as follows:

                                                       Hours per year

               Compactor operator                           2,000
               2 Truck drivers                              4,000
               52 Janitors at 40%                          41 ,500
               3 PTO operators                              6,000
               Truck driver and janitor, power plant(30%)     600
               65 Production operators 15 min/day           2,000
               Cleaning enamel booths                       2,000
               Hauling paint hangers                          750

                                                  Total    58,850

               Cost @ $3.00/hr + 130% burden             $406,100/yr
                                     89

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                    MAINTENANCE AND OPERATION OF EQUIPMENT

          The costs for maintenance and operation of equipment are computed

as follows:

                                                            $ Per Year

          Equipment maintenance at 4%                         18,800
          Fork lift trucks, fuel, oil, and supplies               250
          Trucks hauling compactors
               fuel,  oily and supplies                            500
          Hopper truck, dump truck^ and paint hanger truck
               fuel,  oil,and supplies                             50
          Compactor operation                                    100
          Janitor supplies                                     not est.

                                                  Total      $19,700


                             CONTRACTOR AND FEES

          The cost for contractor and fees is computed as follows:

                                                            $ Per Year

               Paper broker                                    43,800
               Open detachable @ 40 cents/cy                    7,750
               Rental, open detachable                          1,800
               Cleaning, primary holding tanks                 13,000
               Bulldozer at dump                                1,500
               Dredging secondary basin                         7,000
               Future dragline and disposal of
                    dry sludge,  est.  @ $3.00/ton                2,500

                                                  Total        77,350


                             TOTAL COST SUMMARY

          The foregoing costs  are summarized as follows:
                                             $ Per Year      Percent of Total

              Labor                          406,100              73.1
              Equipment  amortization          52,100               9.4
              Equipment  operation  & maint.    19,700               3.6
              Contractor and  fees             77,350              13.9

                                   Total     $555,250             100.0

              Per  ton    $35.3D
                                        90

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        However the costs in this table are those for the entire plant.

including the powerhouse.  When powerhouse costs and quantities are removed

the total cost summary is as follows:

                                       $ Per Year 'Percent-' of Tota

          Labor                         395,000             74.3
          Equipment amortrization    43,500   .7         8.2    ^J
          Equipment operation & maint.   16,700              3.1
          Contractor and fees            76,600             14.4

                                   Total $531,800          100.0
          Per ton - $50.80

        This cost table is more comparable with those for the other plants
which do not burn coal.
                                TRENDS

        Since the date of the survey this plant has installed a larger size

compactor and -fehoy intendsto segregate cardboard by sorting it from the conveyor

belt to the compactors.  Also they have purchased five 40 cy open detachable

containers.

        The company has plans to install electrostatic precipitators on the

power plant stacks which will completely eliminate the pollution by the loss of

fly ash in the stack gases.  When that is done they hope to sell 60 percent of

the fly ash for light weight concrete which will cut in half the quantity of fly

ash now going to the company dump.

        This company has been instrumental in initiating an industry-wide

movement to standardize the sizes of pallets, skids, cartons, and other packaging

systems so that the packaging material may have a much greater degree of reuse

and interchangeability among vendors and customers.

        The company is voluntarily supporting the work of the local pollution

control agency and participates in the work of the Water Quality Committee.  It

intends to continue these activites.
                                       91

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                                  PLANT 4
          This plant produces household refrigerators  and  freezers  and  is
 entirely  contained  in  SIC Code  3632.
          The plant is  located  within a municipality and 500 feet from  the
 nearest builtup residential area.  The surroundings are 75 percent  light
 industrial  and 25 percent residential*
          It operates  five days per week.  The plastic molding operation
 runs  three  shifts,  the  fabrication  (stamping, forming, etc,) two  shifts,and
 assembly  and other  departments  one shift.  There  are nine  holidays  and  a
 three-week  shutdown—two weeks  in August and one  week  at Christmas.  Thus
 there  are 49 working weeks and  237 working days in a calendar year. For
 the four  quarters in 1970 there was not more than a one percent  variation
 in the number of direct hourly, indirect hourly,  non-exempt.and  exempt  employees.
 The direct  hourly and  indirect  hourly taken as equivalent  to production
 workers average 1,337  employees.  The non-exempt  salaried  employees average
 156 for a total of  1,493.  The  non-exempt salaried employees include secretaries,
 clerks, stock clerks,  etc., a few of whom should  be classified as associated
 with  factory production.  The exempt salaried workers  include engineers
 and executives.
          Responsibility for waste management planning and engineering  is
 with  the  manager of manufacturing engineering.  This plant is housed in
 two groups  of buildings wfaiate^yr-e separated by a  city  street and crossed
 only by two conveyor and personnel bridges.  The  waste handling  on  the  two sides
 of the street is separate.  The operating organizations on the two  sides
 of the street are separate but  parallel, in this  plant under two positions-
 one a general foreman of production control but having responsibility for
materials handling, trucking, sanitary services and the janitors; the other the
maintenance foremen who also handle special solid waste operations  such as cleaning
filters.  Sales of scrap and management of the contract with the disposal contractor
                                    93

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are handled by the purchasing department.  Railroad contracts are via

Production Distribution in the Traffic Department.

          The scrap-and waste-generating operations in this plant are:

          Stamping and shearing                   Plastic molding
          Welding and brazing                     Vacuum forming
          Anodizing                               Refrigerant charging
          Porcelain enameling, dip and            Air cleaning
            spray, & enamel milling               Offices, cafeteria & snack areas
          Painting, electrostatic and manual

          The primary collection containers are:

          Fibre drums and trash cans
          55-gallon steel drums
          No. 2 tote boxes (1.0 cy)
          Roura hoppers (1.4 cy)
          Wire-sided carts (3.2 cy)

          In-plant conveyance to the disposal areas is by fork lift truck*

sometimes hauling containers in trains.  The pickup sequence and schedule is

unspecified.

          Solid waste leaves the plant primarily from a single location, a rail

dock.  Baled cardboard and a small quantity of baled aluminum leaves from a

second dock.  Baled metal scrap leaves from another rail dock across the

street.  This second rail dock is also used by an adjacent sister plant

manufacturing a different product.  There is some overlapping of the waste

streams at this second rail dock jointly used.  The study has attempted to

separate out the waste from the two plants at this dock.  The foremen estimated

that about 25 percent of the waste leaving in a compactor operated

by the sister plant aqj^tally is generated and delivered by this plant.  A

very minor quantity of waste leaves in the sister plant's gondola not accounted

for here. In addition to the shared compactor handled by one contractor.there

is only one other mode of disposition—open rail gondola cars.  The disposition

agent is the railroad and another contractor.  The plant orders the gondola cars

delivered from the railroad -and prepays the freight^and consigns them to the

contractor at the disposal location 40 miles away.  At the disposal site the


                                    94

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contractor incinerates the combustible material, the incinerator residue going



to a landfill.  The damaged refrigerator cases as well as the styrofoam and

                            OSUL
urethane insulation material *«• crushed down with a bulldozer and buried at



the disposal site. Both incinerator and landfill are merchant facilities



wholly owned by the contractor.  The shared compactor loads are taken to a



merchant incinerator 10 miles distant.



          The main gondola siding holds two cars and since the turnover is about
                                                t9


1.7 cars per working day this means that the storage pending disposition in
these cars is less than a day.  From the second rail dock there ts. shipped waste


paint and solvents from the paint mixing room.  These are stored for  about six


months in the drums outside until a gondola car load has collected.


          The average monthly shipment for 10 months in 1970-71 was 36.3  cars


per month, about 1.7 per work day for the adjusted year.  The cubic yardage in


the cars varies from as little as 55 to as much as 125.  However the  average


cubic yardage in all gondola cars from all customers of the contractor  (about


350 per month) is 81 cy.  The weight limit on shipment in this switching  area


is 30 tons per car.


          The streams from the various scrap-and waste-generating operations


are handled as follows:


          Only sheet metal is handled in the stamping and shearing operations,


generating scrap but very little waste.  There are no cutting oils used and


therefore no waste oils.  In the drawing operation. a drawing compound is  used


and the incoming steel is oil coated.  These materials are washed to  the  sewer


and do not appear as solid waste.
                                    95

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          The brazing operation consists of soldering copper tubes, the residual




going to scrap.




          The very small amount of anodizing sludge is sent to the sewer.




          The enamel line has one roll filter and one bag filter.  The roll




filter is discussed with the paint line roll filters beyond.  The bag filter




is cleaned with a vacuum cleaner about once a month yielding only about two




pounds of cleanout each time.




          In the porcelain enameling the base coat is dipped, the cover coat




sprayed.  The enamel mill room wastes are collected in a pit.  The sludge from




the pit and the overspray is disposed of with the much larger quantity of




like enamel wastes from the sister plant, and is not accounted for separately




here.




          The paint line has both electrostatic and manual spray painting.  Some




of the manual booths have water curtains, some use air.  From the water curtain




booth there is obtained a sludge called "slush'' which is shoveled into




55-gallon steel drums^about two per week.  These are stored in the yard and




about two times a year a gondola load of drums^along with the waste paint drums




and stripper sludge is shipped to the contractor.




          The paint line is served with five roll filters having blowers of




various sizes from 25 to 50 HP.  In addition,there is a similar roll filter in




the enamel line.  The filters have an average of about three rolls per unit, 48




and 54 inches wide and about 24 feet long.  The design advance rate is 12 to 16




inches in 24 hours but sometimes this has to be supplemented with a manual




advance.  Thus the filters are changed about once every three weeks, being




removed and placed in Rouras and sent to a gondola not described here.




          There are three stripping tanks for stripping paint hangers by the




hot solution method.  About every three to four months.each tank is decanted
                                       96

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and the sludge drained and shoveled out into covered drums which  are  sent  to  the




storage area with the paint drums, about four drums from each  tank.




          From plastic molding and vacuum forming all the scrap material,  which




is polystyrene, is remelted and reused.




          Incoming materials are not unpacked in the receiving department,-but




this is done at the work site.  Cardboard is segregated in the wire carts  and




sent to the cardboard baler where it is re-sorted before baling to remove  any




plastic.  The oak skids used for handling steel are sold as scrap.  Waste




wood pallets and metal strapping are collected and conveyed in Rouras.  Copper




tubing is received in long wood boxes which are conveyed by fork  lift to the




rail cars.  All shipping is from a large warehousejand no waste is generated.




However, packaging of the product for shipment, in corrugated  board,




is a source of scrap through damaged cartons.




          The processes of fabrication and assembly yield some damaged  and reject




cabinets which are bulky and cannot be sold as scrap.  These are  conveyed  on




pallets to the waste dock.




          Waste from offices, cafeteria .and snack areas is collected  in




wastebaskets, drums and trash cans and conveyed via Roura.




          Considerable handwork is involved at the waste loading  dock in fitting




material compactly into the gondola cars.  An attempt is made  to  stack  and pack




damaged refrigerator cases, pallets, and large wooden boxes so as to  occupy




the minimum space.  One man is engaged in this loading operation.
                                   97

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                            QUANTITY COMPUTATION

          More than 90 percent of the waste leaves in the rail cars and

therefore it is unfortunate that the quantity estimation depends strongly on

the visually estimated bulk density of the waste in the cars.  Since this

is a stacked waste with a man assigned to assure compaction^ the estimated

bulk density of the material as seen in the survey is taken as 225 Ib/cy.  It

is difficult to arrange for the weighing of railroad cars,but a set of

weighings on a series of cars of measured volume is the only means to a more

accurate estimate of the bulk density.  The total number of cars is quite

well established from the actual contractor's tally of 10 months.  The average

cubic capacity of the cars could be considered insecure but as mentioned

it has been arrived at by the measured average of some 350 cars per month

in the historical records of the contractor.  The cars are assigned by the

railroad as they become available, and there is no reason to suspect that this

particular plant receives cars larger or smaller than the average.  The

compactor share is computed as 25 percent of the total figure as operated

by the sister plant.  The filter belts also find disposition in one of the

sister plant containers,but the quantity is inconsequential.

          The quantities thus arrived at are:

                                                          Per Year
                                                   Loads      cy         tons

               Rail cars                            408     32,640      3,670
               Compactor, share (25 %)               60      1,890        470
               Filter belts                                    100           5
               Enamel sludges                          none accounted for
                                         Total      468      34,630       4,145
               tye                    2.76
               type                   3.10
               Corrugated scrap as
                 percent of waste    14.40
                                     98

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          In 1970 there was sold as scrap and baled steel, aluminum etc.^2,732

tons, six tons of oak skid boards and 595 tons of corrugated cardboard .^JP^
             *
total of 3,33&.tons.  These figures indicated that 44.5 percent of the scrap

and waste was utilized.  The only recycled material was polystyrene from the

plastic operation.
                                 EQUIPMENT

          Equipment and estimated 1970 investment involved in waste handling

   as follows:

                    Compactor (25 percent)       $  2,500
                    2 Fork lift trucks             24,000
                    1 Sweeper                       6,000
                    50 Rouras                      10,000
                    50 Tote bins                    3,700
                    150 Drums                         300
                    6 Moving filters               90,000
                    1 Bag filter                   14,000
                    3 Paint strippers              30,000
                    Enamel pit                     not considered

                                          Total  $180,500

This is $43.6ftinvestment per annual ton of waste.

          The amortization of the waste handling equipment at 25 years and
10 percent would be about $19,800 per year.

                                   LABOR

          Estimated labor hours and costs for waste handling are as follows:

                                              Hours Per Year  $ Per Year
                    2 Fork lift drivers            4,000
                    1 Sweep operator               2,000
                    1 Loader                       2,000
                    Paint & filter cleaning,
                       misc.                       1,000

                                      Subtotal     9,000

                    Cost @ $3.5/hr + 125% burden                 70,900

                    29 janitors, est. 1/3 time    19,333
                    Cost (9 $3.06/hr + 1002 burden               118,300
                                          Total                $189,200

                                       99

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                    EQUIPMENT OPERATION AND MAINTENANCE

          The cost of equipment operation and maintenance is estimated as:

                                                     $ Per Year

                    Maintenance @ 4%                    7,300
                    Energy & supplies for fork lift       250
                    Energy for filters                  3,700
                    Filter belts                        4,900
                    Janitor supplies                    not est.
                                              Total   $16,150

The energy for the filters is based on the average horsepower per filter,

operated eight hours per day at an electric energy cost of 1 cent/KWH.  The

filter belts average $50 each.



                            CONTRACTOR AND FEES

          The cost for contract disposal is as follows:

                                                     $ Per Year

                    Compactor share (25%)               5,900
                    Rail cars, $45 each                18,400
                    Freight, $65 each car              26,500

                                             Total     50,800

The total of the contract fee and freight for the rail cars is $110 per car

or about $1.36/cy.



                                 TOTAL COST

          The total of the foregoing cost elements is as follows:

                                               $ Per Year  Percent of total

                    Labor                       189,200          68.6
                    Equipment amortization       19,800           7.2
                    Operation and maintenance    16,150           5.8
                    Contractor and fees          50,800          18.4

                                      Total    $275,950          100.0

                    Per ton of waste             $66.6Q
                                   100

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As has been seen in the comparative summary of the plants surveyed .this  is  an

unusually low $/ton cost for solid waste handling.  The percentage  of  the

four cost elements fits the pattern of the other plants.but  the  total

$/ton is low.  This could occur if the estimated bulk density of  the rail

cars were too high.  If the actual bulk density were about 150/cy instead

of 225 the $/ton costs would be in line with the other plants.   Also it

is noted that the waste:employee ratio for this plant is about double  the

average of the other plants, which again would be brought into line  if  the

bulk density were 150 Ib/cy.



                                   TRENDS               ;
                                          r^a 11 ;,./•>. t-vv.e 7 r
          Extensive changes in solid wastei-handli'Hp, and an increase in the

total quantities *«_ forseen within the next two years in this plant because

of the restrictions being placed on the discharge of solids  to sewers.  There

will be an increase in waste water treatment facilities and  operations

to take the solids out of the wastes now going to the sewers or  to  recycle

and to reuse some of them.  Included is the removal of soluble and  insoluble

oils from the present sewers.

          At the time of writing a compactor was being installed at the

rail dock to reduce the rail car shipments.

          In addition,steps are being taken which will somewhat  consolidate
                                   wt t v, t~
the responsibility for waste.hanalfatg, operations.  This was  to have  been

one of the recommendations of this survey.since the responsibility,  as

surveyed, both for operations and for record keeping was  rather  fragmented.
                                     101

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                                   PLANT 5



          Plant 5, classified In SIC Code 3633, manufactures primarily household



dryers.



          The plant is located in a light industrial area about 200 yards


                                                                        *-

from the nearest municipal boundary and 500 yards from the nearest builtup
                                                                       A


residential area.



          The plant operates five days per week, two and three shifts.



          Production worker statistics for 1970 show an average for the



four quarters of 1156.  The 308 non-production workers bring the total


              /W
employees to  H04.  The second quarter was 14 percent below that average,



the third quarter 24 percent above it.  The production worker man-hours



followed a similar fluctuation.  The explanation is that dryer production



is seasonal, picking up in the summer months.  In addition,there is a two-



week shutdown period comprising the last week in the second quarter and the



first week in the third quarter. The plant has nine holidaysyso the normal



number of working days in a calendar year is 242 and working weeks 50.  The



normal shift arrangement is that  during the first half of the year the assembly



department works one shift and the fabrication departments two shifts; during



the second or busy half of the year the assembly goes to two shifts and most



fabrication departments to three.



          Responsibility for solid waste management, comprising both operation



and planning is spread rather widely in this plant.  Part of this.especially
            s                                                    '


in the planning may be only apparent and temporary since management has been



making a quite intensive study of solid waste management on two fronts--one



on the question of disposal methods (especially in conjunction with plans for



another of the company's plantsL the other on the collection aspect by  the
                                        103

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industrial engineering department.  These studies are being conducted under

the Manager of Industrial Engineering by industrial engineering personnel

and under the Manager of Plant Engineering by environmental engineering personnel.

For actual operations there are three responsibility centers. The disposal,

that is the dealings with the contractor, are handled by the Purchasing Department

through the steel buyer and planner in raw material purchasing.  This group

handles the scrap resale of course and therefore also the somewhat similar

operation of waste disposal.  One group of janitors is the responsibility

of the Manufacturing Director and another group, plus the  maintenance staff,

is assigned to the Maintenance Superintendent.  At the corporate level in

the headquarters office there is a Director of Environmental Control.

          The scrap-and waste-generating operations in this plant are:

          Stamping                                Plastic molding
          Shearing                                Liquid cleaning
          Milling (only in tool room)             Shipping and receiving
          Welding, brazing and soldering          Offices
          Tube expanding and bonding (very minor) Cafeteria
          Electrostatic, flowcoat, and spray
            painting

          The primary collection containers are:

               Drums (55-gallons, some fibre, but mostly metal)
               Pallets
               Wheeled gondolas (2.7 cy)
               Racks (8 cy but designed specifically to hold 16
                    damaged cabinets)
               Rouras (1.4 cy)

          In-plant conveyance is by fork lift truck and "mule''.  The fork lift

handled by one man per shift takes gondolas, pallets and racks. The

productivity is one fork lift load  each 10 minutes.  A recent industrial

engineering department study showed A3 lifts per day on the first shift,
                                   104

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34 on the second and 21 on the third—a  total of 98 lifts per day.  The "mule'




is a standup motorized buggy operated by one man, one shift, pulling a Roura.




He transfers plant and office trash (in plastic bags) into the Roura, the




productivity being two mules per hour.  In addition .there are occasional trips




to the waste dock by men from each department.  Pickups of the mule and the




fork lift truck are unscheduled.




          There are four disposal locations..the paint mixing room, the




paint stripping building, at the scrap dock in the fabrication department,




and the main waste or sorting dock.  A fifth and minor location is the water




treatment plant settling basin.




          The disposal containers at the paint mixing room and the




stripping building are 55-gallon metal drums .which are discarded along with




their contents.  Those from the paint stripping operation are hauled in a




metal pan (bucket) to avoid spills in transit.  Those from the paint mixing




room are hauled by dump truck.  Tank trucks are the conveyance vehicle for




sludge from the water treatment plant settling basin.  Waste oil and solvents




from fabrication are hauled in 800-gallon waste oil bucket.  At the main waste




dock .there are three types of disposal containers into which material is sorted




by the contractor's employees as described later.  A 45 cy trailer takes the




sheet metal, miscellaneous salvageable metal being piled on the back of the




sheet metal trailer loads.  A 72 cy trailer takes the corrugated board for




salvage.  A 40 cy detachable container in 1971 takes the remainder of the




wastCjincluding the waste pallets.  However, in 1970 this had been a one-and-




one-half-ton dump truck with sideboards estimated to hold 23 cy.




          The disposition agent is a contractor with whom the arrangement is




rather complicated.  On permanent assignment at the main dock ±he contractor
                                     105

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has two men for two shifts and one man for  four hours on  the  third  shift.


These men do the sorting and  loading into the  contractor's vehicles at  the


dock.  The contractor's equipment and drivers  make  the pickups  at all docks,


except the water treatment plant, and make  the hauls to the city sanitary


landfill.  The company reimburses the contractor for the  dock labor at  $3/hr


for the first half of 1970 and $5/hr for the second half.  The  operation at


the main dock is both a scrap operation and a  waste operation.  The contractor


pays the company for the metal but he is given the  corrugated cardboard that


he salvages.  However, the company has paid for the sorting and loading labor


for the cardboard and metal as well as the waste and presumably these considerations


enter into the negotiated price for the service.  The contractor also loads


and hauls from the other four locations.


          The two scrap operations at the waste dock are  only a minor part


of the total scrap.  The main scrap outlet  is  via rail cars at  another  dock.


          The major scrap, almost entirely  steel, is in two categories — •*' 'clips' '


which is baleable steel, and  "bushlings" which is steel of  such small sizes


that the pieces can be put in a bushel basket  and is not  baleable.


          Another contractor handles the sludge from the water  treatment plant


in tank trucks.  All waste hauled by both contractors finds disposal in a


municipal sanitary landfill two miles distant.


          The streams from the various scrap-and waste-generating operations


are handled as follows.


          The stamping and shearing operations in the metal fabrication department
are of course, the major sources of scrap.  Such small quantititahR  of process
   5         /                                                A

waste that may be generated are collected in drums and Rouras with  the plant


trash and go to the waste dock by mule or fork lift.
                                    106

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          Waste oil and solvent (trichloroethylene) from fabrication is collected




in drums and conveyed to the 800-gallon waste oil bucket outside.  About five




bucketloads per month are hauled to the sanitary landfill.




          Milling (as a tool room operation), welding, brazing and soldering,




and tube expanding and bending generate only small quantities, handled in




drums and gondolas with plant trash.




          Waste solvents and paint from the paint mixing room are collected




in 55-gallon metal drums.  An average of three dump truck loads per month,




20 drums per  month, is hauled by the contractor from the paint dock directly




to the sanitary landfill.  Strippings from the paint spray booths are placed




in drums and go to the waste dock.




          The cleaning of the hangers for the paint line is a complicated




operation, carried out in a separate building.  When the paint line operators




notice a paint hanger on which the paint has built up (so as to endanger the




finish on the work), they remove the hanger and place it in a No. 3 tote box




which when full is taken to the maintenance dock.  The tote boxes are taken




to the stripper building by a flatbed truck, about one-half man-hour per day




being occupied in this transfer and in the return of the clean hangers.  The




operation consists of immersing the coated hangers in a molten salt caustic




bath at about 950*F.  The paint is burned off as the hangers are immersed




in the bath.  After the immersion the hangers are removed, washed off with




water,and returned to the paint line.  The molten salts in the units are continuously




circulated through a side tank where the sludge settles out.  About two pounds




of salt are used for removing one pound of paint and this generates 1 to




1.5 Ibs of sludge.  The sludge, of course containing large quantities of the




salts also, is dumped into 55-gallon drums weighing about 700 Ibs per barrel.




About eight drums per week are hauled to the sanitary landfill by the contractor,




in two loads per month.
                                        107

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The drums are placed in a metal tray with high sides to avoid spillage in

transit.  The stripping operation itself requires about 1.25 man-days per

day, one operator per unit.

          Practically all the scrap from plastic molding is recycled, the small

quantity of waste going in with the plant trash.

          Refrigerant charging does not generate waste because the refrigerant

is delivered in bulk.

          The water treatment plant is set up to take the chemicals  and solids

out of plant sewer water, most important being the liquor used for phosphate

metal preparation.  Soda ash and lime are used in the treatment.  About twice

a year the sludge is pumped to tank trucks of a contractor hired solely for

this purpose and trucked to the municipal sanitary landfill.  In 1970, 160
                                wu
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                            QUANTITY COMPUTATION




          Quantity data for some of the waste streams wa» available on a




per week or per month basis.  Some of the major quantity information^however,




was only available for the five-month period August-December 1970.  The




total production man-hours expended in 1970 was found to be 2.093 times the




number of production man-hours in the August-December five-month period.  This




factor was used to adjust five-month quantities to 12- month quantities.




          Of residual trash from the waste dock .726 loads were hauled in  1970




in the 23 cy container.  The contractor estimated a weight of four tons per




load-but this was found grossly in error.  From a three-month tally in 1971yit




was estimated that the average load in the 1970 truck was 1.34 tons, a total




of 975 tons in 1970.




          The recoverable corrugated salvaged by the contractor, 930 tons,




is computed from an average tons per month given for the five-month period,




which checked (3 percent) an estimate resulting from a tally for three months in




1971.




          The waste oil and solvent from fabrication is computed from the five




loads per month and an estimated density of 7 Ib/gal.




          The paint stripper sludge is taken from the eight 700 Ib drums  per




week figure.




          The paint and solvent  waste is computed at an estimated specific




gravity of 1.0 from the twenty 55-gallon drums per month.




          The water treatment plant sludge is computed from the recorded  number




of loads and gallonage and an estimated 9 Ibs/gal.
                                  109

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          The computations result in the following quantities:

                                                         Per year
                                                   Loads      cy         tons

               Residual trash                       726     16,700       975
               Waste solvent and oil                 60        240       168
               Stripper sludge                       25        109       140
               Paint and solvent                     36         65        55
               Water treatment plant                 30        800       720

                                           Total    877     17,914     2,058

               tye                 1.40
               type                1.77
               Paper salvaged as
                 % of waste       45.2

          In 1970, there was sold as metal scrap 9,900 tons(and an estimated

350 tons  (based on one months weighing) were taken by the contractor

from the waste dock.a total of 10,250 tons.  Together with the corrugated \the

total tonnage of scrap salvaged is 11,180 tons so 84.5% of the scrap and waste

is salvaged, not including the recycled plastic.
                                 EQUIPMENT

          The estimated 1970 investment for equipment is as follows:

               One fork lift                     $12,000
               1 Stripper facility, incl. bldg   100,000
               1 Mule                              2,000
               100 Metal drums                       400
               50 Fibre drums                        100
               80 Wheeled gondolas                16,000
               1 Roura                               200
               Water treatment plant              not included

                                      Total     $130,700

This is 63.5
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                                    LABOR

          The estimated labor requirement for waste handling is as follows:

                                        Man-hrs/wk      Rate & burden    $/wk

          Fork lift PVO                    120         est. 3.50 + 180% 1,176
          Mule                              40         est. 3.50 + 180%   392
          Department men on trips     not counted
          Janitors 
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          The summarized totals are as follows:
                                                      $ Per Year
               Main contractor                         29,800
               Water treatment plant contractor         2,400
               City fee on residual trash               3,630
               City fee on stripper sludge                300
               City fee on waste oil                      720
               City fee on waste paint                    200

                                             Total    $37,050
                                  TOTAL COST

          The total cost of the foregoing cost elements is as follows:

                                             $ Per Year     Percent of total

               Labor                          220,700            79.4
               Equipment amortization          14,300             5.1
               Equipment operation & main.      5,920             2.1
               Contractor & dump  fees         37,050            13.3

                                   Total     $277,970            100.0

               Per ton of waste  • $135.10


                                   TRENDS

          Since this plant is already purifying and clarifying its waste water

before discharge,its solid waste management will not be subject to the
                ?
forthcoming changes which are occuring in plants now required to eliminate

solids from the sewers.

          However, as indicated .the engineering staff had made an analysis
                               7
and a recommendation for an incinerator in another of the company's  plants.

As a result of the interest and information developed out of the present survey

of the plant under this project,they have given intensive study to solid waste

management problems in this plant with the result that major changes are being
                                      112

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undertaken.  To the maximum extent possible paper and cardboard will be sorted




from the collected waste, shredded, baled and sold directly by the company.




The rest of the waste including the oils and solvents from fabrication and from




the paint department.will be incinerated in an incinerator of the type already




developed for the other plant.  In this incinerator.,the paint hangers will




also be stripped by combustionjthus eliminating the molten salt paint stripping




operation.




          Management control and record keeping for solid waste will be




concentrated now to a much greater extent in a single individual.  This action




anticipates the intended recommendation of this survey that management and




control be more concentrated than was found.




          Judging from the apparent composition of the residual trash, if the




paper is to be sold as shredded rather than merely as corrugated board, and




especially if some segregation at the collection points can be practiced instead




of sorting at the dock after collection, then the author estimates that the




present yield of the salvaged paper and corrugated could be increased by




about 50 percent and the tonnage of residual trash to be disposed of




correspondingly reduced by about 25 percent.
                                      113

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                                 PLANT NO.  6



           Plant 6,.classified in Code 3634,,manufactures primarily electric shavers,
                  )                        *

 about 90 percent of the units produced here,  and also a relatively few other

 small housewarest  about 10 percent.

           The plant is within a municipal  boundary and across the street from

 builtup residential areas.  The surroundings  are 30 percent light industrial,

20 percent commercial, 30 percent residential, and 20 percent parks.

           The plant operates five days per week, mostly one shift, with about

 80 employees on the second shift and 10 on the third.  The plant has nine

 holidays and a shutdown period in December and January during which assembly

 is shut down for one month, heat treating  and machining for two weeks, and

 office work not shut down.  This gives the offices 50 weeks, 251 days in the

 year; machining etc. 50 weeks, 244 days; and  assembly 48 weeks, 234 days.
                                        flfc*£x
           The production and employment 4es definitely seasonal with a slack

 period from May to  August, a peaking from  August to about December 15 for

 the Christmas rush, the shutdown in December  and January, and a smaller peak

 in the spring.   Based upon estimates for 1970^the monthly total employment

 for each month, (man-months per month) in  1970 was as follows:


           Jan       700            Feb       1300      Mar       1300
           April    1200            May       1200      June      1200
           July     1200            Aug       1500      Sept      1700
           Oct      1800            Nov       1800      Dec        900

 This includes an office and nonproduction  worker employment of about 250 during

 the peak months and 230 in the slack periods.  Over the yearithe average

 production employment was  1,140, the nonproduction 240.and the total employment

 1380.
                                       115

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          Solid waste management planning and engineering responsibility is

with the Manager of Plant Engineering who reports to the Plant Manager.  The

relatively few janitors including a small night cleanup crew.are assigned

to a supervisor whose main duties are elsewhere, actually classified as

"Electrical Lead Man".  The production employees assigned to cleanup are

the responsibility of the Manager of Plant Engineering.  The purchasing

department handles scrap sales, contracts with the disposal contractors,

and contracts with the janitorial service.

          The scrap-and waste-generating operations in this plant are:

               Stamping                           Cementing and bonding
               Milling (as a machining operation) Air Cleaning
               Welding and brazing                Shipping and Receiving
               Polishing and buffing              Offices
               Electroplating                     Snack Areas

          The primary collection containers are wastebaskets, fibre drums and

55-gallon steel drums.  These are conveyed in-plant to the disposal dock by

hand trucks.  Fork lift and powered vehicles are not used because the narrow

aisles are not convenient for their operation and result in damage from

collision and scraping.

          In 1970^there were five modes of waste disposition leaving the plant:

a 30 cy open detachable for general plant trash destined for the incinerator,

a 20 cy open detachable for pallets and other wood items not acceptable in

the incinerator, 55-gallon drums containing waste oils, others containing

solvents, and a small gondola at a crusher used for breaking up trade-ins and

rejects. In addition .there were ferrous and nonferrous metal scrap categories.

          The disposition agents are a number of contractors, one for  the

30 and 20 cy open detachables, another for the steel scrap and the gondola

at the crusher*and a third and fourth for the waste oils and solvents  in

drums.  In addition .there are two contractors for the nonferrous scrap.

Two of the disposition agents are not regular contractors.  The commercial

-------
salvage firm that handles the steel scrap picks up the gondola at  the




crusher and disposes of it without charge as a courtesy.  Also.the vendor




for the solvents picks up the waste solvents and disposes of them  as a




courtesy.




          The 30 cy detachable is taken to a municipal incinerator, and  the




20 cy detachable with nonburnables and the gondola at the crusher  are taken




to a municipal open dump both located at the same site about two miles distant,




The city fee for the incineration was $5/ton and for the open dumping $5/load.




          The 30 cy detachable was hauled six times per week, the  20 cy  three




times per week.




          The streams from the various scrap-and waste-generating  operations




are handled as follows.




          Wastes from stamping, milling and welding,and brazing are collected




in the drums or trash cans and conveyed to the disposal dock by the janitors.




Metal cleaning and degreasing is done with trichloroethylene and




tetrachloroethylene.  The waste and dirty solvents from these operations are




collected in drums and stored for occasional removal by the vendor of the




solvents. Waste heat-treating salts are flushed to the sewer.




          Polishing and buffing wastes are collected by pneumatic  systems  and




separated by two cyclones.  When cleaned out by the production cleanout  men.




the solids are put in drums and the janitors convey them to the disposal dock.




          The metal grindings in the circulating grinding oils are




collected by magnetic separators^of which there are twelve in the  plant/




and the non-magnetic grindings are removed by centrifuges^of which there




are 10.  These are handled by production cleanup men, the metals going




to salvage, the non-metals to waste in drums for conveyance to the




disposal dock.  The waste oils from grinding and other machine operations
                                      117

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are placed in drums and stored in the yard for pickup by the contractor.

          On the electroplating line there is a purification tank .but this

is seldom cleaned out and then generates only a handful of sludge.

          Since there is no painting or enameling the air cleaning

devices are only the cyclones on the polishing and buffing previously

mentioned.

          The only cementing and bonding is for name plates on the product

which have a heat sensitive adhesive backing and which generate only

small quantities of wastes, handled in the regular trash drums.

          The products are placed in the shipping containers directly on

the production line,and little waste is involved.

          The receiving operation generates corrugated waste both at the

receiving site and at the unpacking sites.  These materials are placed

in the regular collection containers,and some of the corrugated and

paper is sorted and baled by the janitors at the disposal dock.  Both

the baled and the loose material is put into the 30 cy detachable

destined for the incinerator.



                            QUANTITY COMPUTATIONS

          The waste quantities are computed as follows:

                                                   Per Year
                                         Loads         cy            tons

               30 cy detachable           300        9,000           450
               20 cy detachable  (wood)    150        3,000           525
               Waste oils                  25          220             16
               Gondola at crusher          12            24              3
               Waste solvents                 Not available, small

                    TOTALS                487          2/4           994

               tye   .72
               type  .86
               Paper salvage, percent of waste  0

The computations are based on an estimated bulk density  as  found  for general
                                       118

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plant trash of 100 Ib/cy, an estimated bulk density for the wood waste of
                                                                         i
350 Ib/cy, oil density of 7 Ib/gal and bulk density of the crushed rejects
and trade-ins 300 Ib/cy.
             A
          In 1970 there was sold as scrap 660 tons of steel and 15 tons of

non-ferrous for a total of 675 tons of metal scrap.  Thus 40.5 percent of the

scrap and waste found utilization.
                                EQUIPMENT

          The estimated 1970 investment for equipment is as follows:

               Hand trucks                                 $ 	
               100 Drums                                       400
               12 Magnetic separators on grinders           12,000
               10 Centrifuges on grinders                   14,000
               1 Cyclone on polishing 5 HP                   6,000
               1 Cyclone on buffers 25 HP                   20,000
               1 Paper baler                                 3,000

                                                  Total    $55,400

               Per annual ton $54.70

The amortization of this waste handling equipment at 25 years and 10 percent

would be about $6,100 per year.
                                         119

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                                   LABOR

          The estimated labor requirement for waste handling is as follows!

                                                     Manhours/year

                    3 Janitors                           6,000
                    6 Cleanup men in production         12,000

                                             Total      18,000

                    Cost at $3/hr plus 100% burden    $108,000/yr



                     EQUIPMENT OPERATION AND MAINTENANCE

          The cost of equipment operation and maintenance is estimated as:

                                                     $ Per Year

                    Maintenance at 4% of investment     2,200
                    Energy for separators                 580
                    Janitor supplies               not accounted for

                         TOTAL                        $ 2,780

The energy for the separators is estimated at the name plate horsepower

applied eight hours per day at an energy cost of 1 cent/Kwh.
                         CONTRACT DISPOSAL AND FEES

          The contractor fees are as follows:

                                                       $ Per Year

               Contractor No. 1, cleaning office         2,740
                                 at 30%
               Contractor No. 2, cleaning factory        1,900
                                 at 30%
               Contractor No. 3, cy detachable           9,000
               Contractor No. 3, 20 cy detachable        4,400
               Contractor No. 4, waste oil               3,240
               Solvents in drums                          free

                         TOTAL                         $21,280
                                    120

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The dollar amounts were obtained from flat monthly invoice rates, from
a ten-month invoice total for waste oil, and from a  $30 per load fee for
the 20 cy detachable.
                                 TOTAL COST

          The total of the foregoing cost elements is as follows:

                                          $ Per Year    Percent of total
                    Labor                   108,000          78.2
                    Amortization              6,100           4.4
                    Operating and mainte-
                         nance                2,780           2.0
                    Contractor fees          21,280          15.4

                                  Total   $138,160          100.0

                    Per ton of waste   $139.00


                                   TRENDS

          Beginning with the early months of 1971^changes have occurred

in solid waste management at this plant.  The 30 cy open container and the

paper baler were replaced with a 36 cy compactor in which a packed density

of about 333 Ib/cy is achieved.  The compactor is rented from the contractor,

and a fixed charge per haul is made.  In addition the company is invoiced for

the $5/ton incineration fee.  Based on the recorded weights at the incinerator

for the compactor loads.the contractor estimates six tons per load for the  average

of the compactor loads and the 20 cy open detachable loads.  On the basis of

the number of hauls (of both) from the actual invoices starting February 18,

1971,and the estimated fluctuating number of employees in each month as previously

outlined, the equivalent tye for the invoiced months proves remarkably constant

as follows:  February-March (6 weeks), .74 type; April .  .78; May..72; June)

.72; July .72, average of 5 invoices, .74.

          A cafeteria, run by a concessionaire, has been installed in a separate

building.  The wastes are placed in a 2.3 cy front-end loader container oustide

the building and this is picked up twice a week by the contractor who handles

the compactor wastes.
                                 €.
          No other trends are forseen.
                                A
                                      121

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                                  PLANT 7

          Plant 7, classified in SIC Code 3634, manufactures all the small

electrical appliances including some equipment for outdoor use.  In addition

about 25 percent of its dollar output comprises vacuum cleaners (Code 3635) .

          The plant is inside a municipal boundary about 1000 feet from

the nearest  builtup residential area.  The surroundings are 75 percent

light industrial and 25 percent residential.

          It operates five days per week, most departments on one shift but

presses, die casting, and certain fabrication operations on two shifts and

plastic molding on three.  There are eight holidays and a two-week shutdown

period in July, thus a 50-week, 243-working-day-year.

          The average number of factory workers in 1970 was 2,400 and of

total employees 3,000.  The office and administrative employees handle

other establishments for the company in addition to this one at which they

are located.  Employment in the spring of 1971 was about 2,150 and 2,750

respectively.  This represents a slight current slack-off in sales, the

seasonal fluctuation of employment being minimal.

          The waste management responsibility is with the Superintendent of

Maintenance who reports to the Vice-President of Manufacturing.  Operations

are handled by a maintenance manager, a janitor manager, and a manager for

raw materials and scrap.  Scrap sales are handled by the director of

purchasing.

          The scrap and waste generating operations in this plant are:

          Die casting                        Electrostatic spraying
          Stamping                           Plastic molding
          Milling (as machining)             Air cleaning and dust
          Welding and brazing                     collection
          Polishing and buffing              Shipping and receiving
          Electroplating                     Offices, cafeteria

The primary collection containers are drums, pallets, and a dumping

container similar to a Roura hopper (1.5 cy).
                                    122

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          In-plant conveyance to the disposal area is by fork  lift  truck.

There is a semi-formal sequencing, and the frequency at some pickup  points

is specified.

          The waste leaves the plant in three modes:

          An open detachable container  called  "lowboy"
                (15 cy)  for sludges
          A closed sludge tank detachable (15 cy) for liquids
          A compactor detachable (35 cy) for material
               nominally ''burnable''

Pending disposition the materials are stored in these containers.

          The disposition agent is a contractor.  About six compactor  loads

a week (210 cy/wk) are hauled to a merchant incinerator about  three

miles away.  The other disposal facility is a merchant sanitary  landfill about

27 miles away to which the open detachable lowboy is hauled twice a week

and the closed detachable about once every two weeks.

          The streams from the various scrap and waste generating operations  are

handled as follows.

          In the die casting (aluminum) and zinc, about 95 percent  of  the

scrap is remelted and recycled.  The remainder in common with  other scrap ,

is sold to the metal supplier or to commercial salvage.  Scrap from die

casting contaminated with oils, dirt, etc. is collected in a Roura  and

deposited in the open detachable container for sludges.

          The scrap from stamping is handled in the same way except that

there is no recycling.  The materials are steel, stainless steel, aluminum,

and brass and any contaminated material goes to the open detachable
        r
container.

          Shipping and receiving uncrates and unpackages incoming material

and generates cardboard, wood and strapping waste.  Collection is on pallets

and Rouras and the waste goes to the compactor.
                                      123

-------
           The polishing operations  generate  fine dust  of  Al,  Zn,  steel,  Cr,




 plastic.   A pneumatic collection system for  each machine  carries  the dusts




 to wet cyclones which generate wet  sludges of  these particular materials.




 They are  emptied into Rouras and go to the open detachable container.




           Most of the material from plastic  molding is remelted.   The




 contaminated, off color, or reject  pieces go to the compactor via Rouras.




           The electrostatic painting operation generates  peelings (sheets  of




 dry paint film stripped periodically off spray booth walls), which go to




 the compactor via Roura.  Most booths have water curtains. The overspray




 is skimmed from the sumps, shoveled into drums,and taken  to the closed




 container.  The waste paint and solvents generated in  the paint




 preparation and mixing room also go in drums to the closed container.  Paint




 hangers are stripped in a hot salt  and caustic solution by a  dipping and




 soaking operation on a conveyor linej the stripping sludge is taken in drums to




 the closed container.




           Milling (as a machining operation) generates aluminum,  steel,




 stainless steel and brass chips which are collected by hand and centrifuged




 to remove cutting oils.  The centrifuged chips enter the  scrap stream.  The




 oils are  recycled to the machines.




           Cafeteria waste is placed in drums and goes  to  the  compactor.
 Waste  from offices and rest rooms 1m collected/by the janitors\in




•3kMNW» and goes to the compactor.




           Some reject parts from the assembly lines are salvaged.  The plastic




 and aluminum parts are remelted.  Reject aluminum frying pans are remelted




 and the Calrod heating elements fished out of the melt.  Other reject parts,




 bent and damaged pans, pots etc.. go into the scrap stream and  some composite




 reject parts will appear in the waste.

-------
                            QUANTITY COMPUTATION

          The estimated quantities of waste generated, typical of the

period  January-March 1971, are as  follows:

                                                       Per Year
                                             Loads      ^tonsJ     cy

          Compactor                           304       2,280    10,700
          Closed liquid detachable             25         250       375
          Open detachable                     100         450     1,500

                                   Total      429       2,980    12,575

          tye            1.08
          type           1.39

          The compactor weights recorded by the contract scavenger as the

basis for his payment to the incinerator average  15,000 Ibs per compactor^

with a high of 17,000 Ibs.  The compacted density thus averages 429 Ibs/cy.

The liquids are estimated at an assumed specific gravity of 0.8.  The bulk

density of the sludge and other dense material in the open detachable was

visually estimated at 600 Ibs/cy.  The weekly frequencies previously

mentioned applied to these weights  gave the tonnages listed above.

          In the calendar year 1970.there was sold as scrap, steel, brass,

aluminum, stainless steel and copper—a total of 3,794 ty.  This is 1.28 tye

and 1.59 type for the average employees in that period.  These figures,

combined in a tye basis indicated that 54.3 percent of the scrap and waste

was utilized; but this does not include the remelt from the die casting and

the plastic molding.
                                 EQUIPMENT

          The equipment and estimated 1970 replacement investment involved
                 3/XJL
in waste handling =& as follows:

                    25 Hoppers                    $  3,700
                    1 Compactor                     15,000
                    12 Wet cyclones (rotoclones)   120,000
                         and pneumatic systems
                    3 Lift trucks                   26,000


                                      Total       $164,700

                                      125

-------
This amounts to about $55 investment per annual ton of waste.   In contrast^

it was estimated that the equipment for handling scrap, oil chip centrifuges,

scrap bins, and lift truck has a replacement investment of $31,000 or about

$8/annual ton of scrap.

          The amortization of the waste handling equipment at 25 years

and 10 percent would be about $18,000 per year.  The major equipment items,

the wet cyclones, were already 20 years old.



                                   LABOR

          Estimated labor hours and costs for waste handling are as

follows:

                                                  Hours per week

               Fork lift, moving hoppers               50
               Fork lift, moving Rotoclone sludge      10
               Yardmen, dumping                        80
               Compactor operation                     80

                                          Subtotal    220

               Cleaning Rotoclones                    160
               Steam cleaning buffing machines        180
               17 Janitors, estimated 1/3 time
                    applied to waste moving           227

                                             Total    787

               Cost at 3.25 $/hr at 100%
                    burden rate                  $256,000/yr



                            EQUIPMENT OPERATION

          The cost of  equipment operation is estimated according to:

                                                  $ Per Year

               Energy  for compactor, 600
                    operations/week                    50
               Maintenance at 4% of investment      6,600
               Energy  and supplies for fork lifts      350
               Janitor supplies                   not est.
               Energy  for rotoclones                26,900

                                      Total       $33,900
                                      126

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The energy for the Rotoclones is computed for the 1675 connected HP operated

one shift at 90 percent efficiency and 1 cent/KWH.



                                 CONTRACTOR

          The contractor charge for 1970 was $35,400 at a unit price of $2.75/yard,
                                TOTAL COSTS



          The total of the foregoing cost elements is as follows:



                                             $ Per Year     Percent of Total

               Labor                           256,000           74.6
               Equipment amortization           18,000            5.2
               Contractor                       35,400           10.3
               Equipment operation              33,900            9.9

                                     Total    $343,300          100.0

By the time the waste passes off the plant property, $115 per ton have been spent

on it.  A similar figure for the saleable scrap in this plant is a little over

$7/ton, not of course including the material value in the scrap itself.
                                   TRENDS

          The management believes that current practices are now stabilized and
            «
does not forsee any changes for the immediate future.  However, this establishment

formerly had its own incinerator facility.  Increasingly stringent air pollution

regulation led to the abandonment of the incinerator.  The charging doors were

welded shut to prevent unauthorized burning.
                                       127

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                                  PLANT 8

          This plant produces household vacuum cleaners  and other products

related to floor care and is entirely contained in SIC 3635.

          The plant is inside a municipal boundary and actually located within

a high-class residential section, the plant  being so camouflaged and landscaped

that it blends artistically into the residential pattern around it.  The plant

has been located on this site and with this philosophy for many years.  Even

tall structures on the plant grounds are camouflaged with tall trees.  The

noise level outside the plant fence is that of a quiet residential neighborhood.

          The plant operates five days per week with ten holidays and a three—

week shutdown.  Thus, the year has 49 working weeks and 236 working days.  The

plastic molding operation runs three shifts, certain machines in the press and

machining departments two shifts, and the other departments one shift.  Employees

on the second and third shifts are only 10 percent of the total employees.

          Production in this plant is not seasonaljbut employment was unusual in

1970 in that some of the employees were transferred to a new plant at another

location.  The average labor force for 1970, as computed by the company, was

503 production, 437 non-production, total 940.    This plant has an unusually

high number of nonproduction employees because it is the headquarters office

and sales office for the whole division of the corporation involving other

plants.

          The entire responsibility for waste management, planning, engineeringy

and operation is with the plant engineering,grovp.  Sales of scrap and

management of the disposal contract are handled by the purchasing department.

          The scrap^and wastes-generating operations in this plant are:

          Casting, foundry                        Electroplating
          Die casting                             Anodizing
          Stamping and shearing                   Painting, electrostatic and
          Milling (as a machining operation)           electrophoretic
          Welding and brazing                     Plastic molding
                                        129.

-------
          Broaching                               Air cleaning


          Tube expanding                          Liquid  cleaning


          Polishing and buffing                   Shipping and receiving


                                                  Offices, cafeteria  &  snack areas






          The primary collection containers are waste baskets, 55-gallon drums,


steel bins of 1.3 and 3 cy capacity .and  standard tote biaee  2 cy.
                                   •f                      \

          In-plant conveyance to the disposition areas is by  fork lift  truck.


The pickup sequence and schedule is unspecified.


          Solid waste leaves the plant from two locations^.one at a dock in  the


main building next to the shipping and receiving docks and the other  outside


in the plant yard across a driveway and about  100 feet from the dock.


          At this second location are placed two of the disposition devices,


a 10 cy dump truck having extended sideboards  and a 4,000-gallon tank  trailer.


At the other location is spotted a detachable  container,  alternately  30 cy


and 40 cy.


          The disposition agent for the detachable container  is a contractor.


The container receives corrugated, boxes, waste paper and newspaper and some


miscellaneous sweepings, etc, which are segregated for that container.


The company itself operates the dump truck and the tank trailer.


          All the waste from the plant goes to the town dump, six miles


distant.  The disposal and the financial arrangements at  the  town dump  are
                                       130

-------
rather complicated.  The town dump has an incinerator at the site.  There




is no dump fee for loads acceptable in the incinerator.  For loads not




acceptable in the incinerator which include wood, plastic, drums, and




miscellaneous materials considered noncombustible, there is a dump fee of




80 cents per cwt (hundredweight) on the load weight in excess of 200 Ibs.  Some of




the material not acceptable in the incinerator is placed on the dump   (along




with the incinerator residue)  and is covered occasionally.  Other material




not acceptable in the dump, such as combustible liquid in drums, etc.,is




shipped via rail to a disposal area in another state.  All the material in




the detachable container is considered incineratable and goes to the




incinerator.  Some of the dump truck loads also go to the incinerator.




          Pending removal the materials are stored in the detachable container,




in the closed tank, in the open dump truck,and in open and closed drums at




the dump truck site awaiting loading.  The dump truck makes about thrice-daily




trips, so the time in storage is small.




          The streams from the various scrap and waste generating operations  are




as follows.




          From the die casting operation the scrap aluminum is remelted or returned




to the vendor.




          Steel scrap from the stamping and shearing is collected in the  2 cy




tote bins and taken to the scrap dock for sale.
                                      131

-------
          Lubricating and cutting oils from metal fabrication are soluble


oils.  They are filtered and recirculated.  The solids from the  filtration


are placed in 55-gallon drums, about 10 drums per year.


          The small amounts of waste from milling, welding and brazing,


broaching and tube expanding are collected in the 2 cy or 3 cy bins  and  go


to the dump truck.


          The buffing operation is served by four water  scrubbers^from which
the sludge is cleaned night Iv ten
-------
          Incoming material is not unpackaged in the receiving department..

but this is done at the worksite.  The cardboard packaging material and

also waste newspapers are collected in the 1.3 cy bins and taken to the

detachable container.  The prepunched cardboard used for shipping containers

generates a waste from the cutouts in the cardboard.  This is collected in

drums and taken to the detachable container.

          Offices, cafeteria and snack bars are serviced with wastebaskets and

drums .

          The available data on dump truck operation require some

manipulations to arrive at total quantities.  In 1970, the total dump fee was

$5,659 and the average dump cost was 73 cents/cwt dumped.  At 80 cents/cwt

in excess of 2 cwt. this computes to an average load of 2,280 plus-minus

200 pounds for the paid loads.  To check this, weight tickets were made
                                                                            \
available for five fee-paid loads in May and six in September 1971, the
average of the eleven being 2,687 Ibs, standard deviation ^ 585.  The total

cwt in paid loads during the year is computed at 7,750 corresponding to 340

loads fee-paid during the year.  The average number of loads per day, both

paid and unpaid was given as three.  This is checked by the special records

kept for one week in September 1971 which provided 14 loads, six paid and

eight unpaid, or 2.8 per day for that particular week.  At three loads per

day the annual total is 811 loads, 340 paid and 471 unpaid.  The paid as the

percent of total thus computed for the year is 42 percent, the corresponding

figure for the September 1971 week is 43 percent.  The volume capacity of the

dump truck is 10.3 cy and the operator states that he carries it at 100

percent fill.  The average bulk density computed for the fee-paid loads

then is 220 Ibs/cwt.  It was not possible to weigh the unpaid loads since

the weight ticket comprises an invoice for payment.  One might guess that

the incineratable loads would have a lower bulk density than this.  However,
                                     '133

-------
there is no real way of knowing and it  seems  safest to  take  the  bulk  density

of the incineratable loads as the same  as that of the fee-paid loads.
                            QUANTITY COMPUTATION

          The contractor's records show approximately two  loads per  day  of

the paper and corrugated at an estimated 5,000  Ibs/day in  the  two  detachable

containers.  This is 71 Ib/cy, a low figure for typical plant  trash,

attributable to the relatively high proportion  of unstacked corrugated and

boxes.

          The tank truck is computed at an estimated density of 10 Ib/gal

hauled once every two to three weeks.

          The computations result in the following values:

                                                       Per Year
                                              Loads        cy        tons

          Detachable container                  474     16,000        590
          Tank truck                            20         396        400
          Dump truck                            811      8,350        925

                                   Total      1,305     24,746      1,915
          tye                 2.04
          type                3.81
          Detachable container
               as % of other waste - 44.5

          In 1970 there was sold as steel and brass scrap  1,554 tons, and

returned to the vendor as aluminum scrap 150  tons, a total of  1,704  tons.

These figures indicated that 47.2 percent of  the scrap and waste was utilized,

not counting the plastic scrap which is recycled within the plant.

          The paper and corrugated in this plant is waste  and  not  scrap.

However, it is collected and segregated in such a way that the loads contain

little other than paper and corrugated.  Thus,the tonnage  fairly closely

represents the tonnage that could be achieved if the paper and corrugated

were strictly segregated out as such and sold as scrap.   (Run  of the mill

grade waste paper brings about $8/ton in this location.)   Accordingly a
                                         134

-------
computation is presented to show the paper and corrugated as percent of the

other waste comparable with plants handling paper and corrugated as scrap.



                                 EQUIPMENT

          The equipment and estimated 1970 investment involved in waste

handling is as follows:

               Fibre and steel drums                   Free
               30 Steel bins and tote boxes            9,000
               2 Fork lift trucks                     24,000
               3 Mechanical collectors                30,000
               1 5-ton dump truck                      9,000
               1 4000-gallon trailer tank              4,000
               2 Rake classifiers                     12,000
               4 Scrubbers, in buffing               100,000
               1 15-HP air system in paint             8,000

                                             Total   196,000

This amounts to about $102 investment per annual ton of waste.

          The amortization of the waste handling equipment at 25 years and

10 percent would be about $21,600 per year.

          More than half the equipment investment is in the four scrubbers

on the buffing lines.


                                   LABOR

          Estimated labor hours and costs for waste handling are as follows!

                                                       Hours Per Year
               16 Janitors, porters, utility men            16,000
               Dump truck driver                             1,500
               Fork lift operators                           3,600

                                                  Total     21,100

               Total cost including burden                $124,600/yr

          The janitors and utility men are computed at $2.81/hr + 100%

burden, and 50 % of their time applied to solid waste handling.  The dump

-------
truck driver is computed at 6 hours per day applied.and fork lift operators

is 15 hours per day at a rate of $3.40/hr plus burden.  This plant contracts

a night custodial crew of 22 men, accounted for under contract costs.


                            EQUIPMENT OPERATION

          The cost of equipment operation and maintenance is estimated

according to:

                                                       $ Per Year

               Maintenance at 4% of investment           7,900
               Energy and supplies for fork lifts          200
               Energy and supplies for dump truck          600
               Janitor supplies                          not est.
               Energy for mechanical collectors,
                 classifiers, scrubbers, air system      1,800

                                               Total   $10,500

          The dump truck energy and supplies was figured at 6 cents/mile

plus 10 percent for oil, etc.  The energy for equipment is figured at

the approximate horsepower of each unit, operating eight hours per day at

a price of 1 cent/KWH.



                             CONTRACTOR AND FEES

          The contractor and other fees are estimated according  to:

                                                       $ Per Year

               Waste paper and cardboard                 10,185
               Dump fee, excluded loads                   5,659
               Night custodial crew                      19,600

                                             Total       35,444

          The night custodial crew is computed at 30 percent applied to solid

waste handling and a monthly fee of $5,400.  The contractor cost for the

hauling is about $20 per load.
                                      136

-------
                                 TOTAL COST


          The total of the foregoing cost elements is as follows:

                                             $ Per Year   Percent  of Total

               Labor                           124,600          64.9
               Amortization                     21,600           11.2
               Equipment operation &
                  maintenance                   10,500            5.5
               Contractor & fee                 35,400           18.4

                                   Total      $192,100          100.0

               Per ton of waste - $100.3$
                                    TRENDS
          The management does not fo*rsee any trends which would necessitate
changes in waste handling.
                                        137

-------
                                  PLANT 9

          Plant 9, classified in Code 3636 manufactures primarily sewing

machines, 95 percent of the dollar value being in that category, five

percent in die casting for vacuum cleaners, cameras, strip heaters, etc.

          The plant surroundings are 50 percent light industrial, 20 percent

commercial, 25 percent residential, 5 percent parks.  The plant itself

is inside a municipal boundary and within 200 yards from the nearest builtup

residential area.

          The plant operates five days per week, mostly one shift, but

plating, hardening, pressroom and screw department two shifts, and die

casting three shifts.  The plant has nine holidays, a two-week shutdown

in July and a one week shutdown in December, thus a 237 day, 49 week year.
                                       OAJi-
          The production and employment 4« not seasonal.  The factory

employment from two payroll registers in the spring of 1971 averaged 2,568,

and total employment averaged 3,068, plus-minus three percent.  The

1970 employment was not appreciably different from this.

          Solid waste management planning and engineering responsibility

is with the Supervisor of Plant Engineering.  Actual solid waste operations

are under the Manager of Maintenance and his foremen^ who report to the

Manager of Engineering. The scrap-and waste-generating operations in this

plant are:
               Foundry                            Electrostatic painting
               Die casting                        Air cleaning
               Stamping and shearing              Liquid cleaning
               Milling (as a machining operation) Shipping and receiving
               Polishing and buffing              Offices, cafeteria.and
               Rumbling                               snack areas
               Electroplating

          The primary collection containers are trash cans and wheeled Pack

Master containers, one cy.

          In-plant conveyance is by the wheeled Pack Master containers, hand

powered, and a roll-over fork lift truck, the latter handled by one roll-over
                                     139

-------
driver occupying 80 percent of his time.  Most of the waste is handled by hand

power by the 15-man night janitor staff, with one man during the day for miscellaneous

conveyance.  The porters also sort and stack corrugated cardboard.

          The modes and disposition agents by which waste leaves the plant

are as follows:

          A 20 cy packer truck operated by the plant
          A detachable packer operated by a contractor, for skids,
               crates and waste wood.
          A five-ton dump truck for drums and sand operated by the plant

          There are numerous locations at which disposal pickups are made.

The packer truck picks up from four staging areas,-at the main building, at

the foundry, at the recreation building, and at the cafeteria.  The detachable

packer operated by the contractor is sited at another location near one of

the main buildings.  The pickup point for the stake-bed truck with corrugated

cardboard is at still another location.  Minor pickup locations are at the

paint stripper, at the paint preparation room, at a settling basin, called

''sand pit' *, and at the foundry, for sand.

          Both the packer truck by the plant operator and the detachable packer

by a contractor are taken to the city sanitary landfill four miles distant.  The

sand and the paint and paint stripper wastes in drums are taken to a plant

disposal area just outside the plant fence and adjacent to a navigable waterway,

where the drums are buried and the sand used in part for cover.  This plant

disposal area is described in more detail on the accompanying Land Disposal

Site investigation Report form.

          The streams from the various scrap and waste generating operations

are handled as follows.

          From the aluminum die casting operation .all the left-over metal is

remelted, only a very minor quantity finds its way into the general plant trash.

-------
DFPARTMENT OF
 EALTH, EDUCATION. AND WELFARE
       HEALTH SERVICE
                                                                                  \f(l
                                                                                  •i,u No.  u8-S-t)i
                                         COMMUNITY SOLID WASTE PRACTICES
                                LAND DISPOSAL SITE INVESTIGATION REPORT
. STATE ] 2- COUNTY
L 2 3
4. NAME OF SITE 1 i
11 12 13
. NAME OF PERSON COMPLETING FORM




436
3. SITE LOCATION (Politic*! Jurisdiction)
S. ADDRESS OF SITE
8. TITLE
. 6. DATE
14

15
B. ORGANIZATION
T I]
J 7 8 a 10
OF SURVEY
VY^ MONTH^ YEAR
/

16 17
iZ 7 J_
18 19 20
AND ADDRESS
0. POLITICAL JURISDICTIONS SERVED BY LAND DISPOSAL SITE
NAME OF
POLITICAL JURISDICTION

21 22

29 30
L
37 38
i

23

31

30


24

32

40

45 46 47 48
ESTIMATED
PERCENTAGE OF
JURISDICTION
SERVED BY SITE




<


*.









25 26


33 34

41


42

49 50
"v

-. ":



AVERAGE DISTANCE
OF SITE FROM
CENTER OF SOURCE
AREA (Miles)
..!.», , i. , ,











27

36

43


28

36

44

51 S2




/ j.j



FOR ADDITIONAL ENTRIES. CHECK HERE CD (53) AND MAKE ENTRIES IN ITEM t45
11. SITE OPERATED BY
| | PUBLIC AGENCY
IJQPRIVATE AGENCY
12. SITE OWNED BY
[ | PUBLIC AGENCY
NTjPRIVATE AGENCY
1  IS OPERATION

  REGULATED BY A

  HEALTH AUTHORITY?
                              o
                         IF YES. INDICATE LEVEL
                         OF PRINCIPAL AUTHORITY
                              (Check one only)
                                                                     [3] COMMUNITY

                                                                     ||COUNTY
                                                                                     [f~] STATE

                                                                                     [" j OTHER .
                                                                                                    (Snecity)
4 GENERAL CHARACTER OF SITE (Check one only)
Q~] QUARRY OR BORROW PIT |~~] HILLSIDE
~1 GULLY-CANYON [ 1 MARSH. TIDELAND
i OR FLOOD PLAIN
^/TLEVEL AREAS
Jr**
1 j OTHFR
(Specify) Do
not 58
use


i ZONING/ LAND USE SURROUNOINC FACILITY (Chec* predominant
ZONING V>
O NONE 0^ INDUSTRIAL
Q~l RESIDENTIAL | | AGRICULTURAL
r~l COMMERCIAL [ 1 OTHER
15. YEAR SITE PLACED IN OPERATION 19
16. ANTICIPATED LIFE REMAINING (Years)
17. TOTAL AREA OF SITE (Acrea)
'»• AREA TO BE USED FOR LAND
DISPOSAL (Acrsa)
rpe only)
LAND USE

64


0!

65

0
58
J
62
/
66
/
6
eo
Q
63
o
67
Q
68 69 70 71

L_J RESIDENTIAL n AGRICULTURAL
0. COMMERCIAL n OTHER
T>OlNDUSTRIAL (Specify)


72 73
2O 'S USE O F

   COMPLETED

   SITE PLANNED?
                    YES     IF YES. CHECK   Q RECREATIONAL  ,--, LIGHT

                            PREDOMINANT
                                                                                f  ,               r, USE NOT
                                              AREA OR PARK   L J CONSTRUCTION  '-- ' A&R'CULTURE  l_ J DETERMINED
                                              ,-,
                                              L J
                               : ONLY      [_] PARKING LOT    [ J
                                                 HEAVY
                                                 CONSTRUCTION
                                                                                [  ]OTHER
21.
23.
WILL PUBLIC
COMPLETED
FREQUENCY
OF COVER
AGENCY CONTROL
SITE USE?
[_] NONE
y) n DAILY f^^

r::i YES
XNO
2Z.
MATERIAL USED f-]NONE []OTHER
FOR COVER «k>tF»PTU
(Check one oily) ^X
|~~] DAILY fExcept /«cej
"2^*, CH OTHER


(Specify)
24. IS SPREADING AND COMPACTION
OF REFUSE HANDLED IN APPROX-
IMATELY TWO-FOOT LAYERS OR LE
(Specify)
LJlYEs
\XNO
ss? Jr*$



7 S 76


77 78
•5. NUMBER OF DAYS DISPOSAL SITE COULD NOT BE USED BECAUSE OF WEATHER CONNECTED CONDITIONS (Em
                                                                                                iter average j
                                                                                                 per year) j
 «. GENERAL CHARACTER OF OPERATION (Jud&nent evaluation -check appropriate categories)
 =PEARANCE
Nf
    SIGHTLY

      (SIGHTLY
IS BLOWING PAPER
CONTROLLED?
                                 IS BLOWING PAPER
                                 CONSIDERED TO BE
                                 A NUISANCE?
                                  [I] YES
                  XN°
ROUTINK BURNING
     I
     ^ONE
  [~ j UNCONTROLLED
  r I PLANNED AND
  '—' LIMITED
                                                                              ARE THERE SUR-
                                                                              FACE DRAINAGE
                                                                              PROBLEMS?
                                                               L'jYES
                                                                                  NO
                                                                                         ...r
ARE THERE
LEACHING
PROBLEMS?

 r IYES

    NO

-------
                             LAND DISPOSAL SITE I NVESTIGATION REPORT (Page 2)
2". CONTROL PROGRAMS
i YES j NO
i --*
Do \
use I
I 1



    RODENT CONTROL
' \\   PROGRAM
>V:
    FLY CONTROL
      PROGRAM
    BIRD CONTROL
      PBOGRAM
    OUST CONTROL
      PROGRAM
    ODOR CONTROL
     PROGRAM
                         NEEDED

                         PROVIDED
NEEDED

PROVIDED
                         NEEDED
                         PROVIDED
NEEDED

PROVIDED
                         NEEDED
                         PROVIDED
                                       v/f
                                       X
                                   r:
                                     >x
                                     n  X
          n
          n
                                                     1   WATER
                                          [FIREBREAK  [  [OTHER
                                                 30. NUMBER OF TIMES FIRE CONTROL EQUIPMENT
                                                    WAS REQUIRED AT SITE IN THE PAST YEAR
    "Til
'1—!
    j
                                                                                               -fg-  343*
                                                    IS SALVAGING PERMITTED'      L. ]YES     ^^
                                                                    NO
                          .
                           IS SALVAGING PRACTICED'
                                                                                   YES
                                                                                          -^
                                                                                          K>!
                                                                                             NO
                                                 FROM PUBLIC
                                                 COLLECTION
                                                 VEHICLES
                                                  numbe
                                                                             41   42  43
                                                 33. ESTIMATED NUMBER OF LOADS DEPOSITED DAILY (Average)

                                                     < PUBLIC
                                                     -EC TION
                                                     CLES

                                                     'r  T       A   (Enter   I   I         number) T
                                                     her;	f/I number) I   I    	     '  I
                                                          38   39  JO           -~-   '""^
HROM OTHER VEHICLES

     (Specify)
                           CHECK ANY ITEMS LISTED BELOW WHICH ARE
                           EXCLUDED FROM THE DISPOSAL SITE
                                                                                                44  4~5  Te

34. ARE QUANTITATIVE RECORDS
   KE:JT IN ANY FORM'
                            . - .      . -- ,
                               YtS      NO not
                            ' — '      I— '
35. QU AN TITIES OF SOLID WASTES RECEIVED ANNUALLY
TONS WEIGHED
TONS ESTIMATED
CUBIC YARDS
                                                                                         T.«^r
                                                                                         TIRES
                        48   49   50  51  52  53  54
                               57  59   59  60
                     62  63	64	65	66   67  68  69
36. GENERAL  CLASSIFICATION OF SOLID WASTES
   ACCEPTED AT DISPOSAL SI T e (Check those accepted)
                            """"               l^JTSEWAGE        ^^T
                         TB .'UTRESCIBLES      Kj SOLIDS        AjT

                        I—1ALL               t/JUNKED        ^/HAZARDOUS
                        I— 1 NON-COMBUSTIBLES  ^AUTOMOBILES   JAlMATERIALS


                        ^^COMBUSTIBLES      tVVpPt I AuCE?;    LJOTHER <"sPec'


                        |\jp GARBAGE
                                                 TO
   IHOUSEHOLD

    -.OMMERCIAL
               *t
                   NOUS-
                  TRIAL
    INSTITUTIONAL
                                                »ASTES        [—]OTHER (Spec;/y;

                                                :ONSTRUCTION  3I
                                                \C?r-ifitC-            —	

  j—j
  LJ
                              'NCINERATOR
                              RESIDUE ONLY
                                                                                                             LT
36. EQUIPMENT AVAILABLE
   (Average utilized daily)
DRAGLINE OR SHOVEL-TYPE EXCAVATORS
SCRAPERS (Self-propelled)
TRACTORS (Track or Rubber Tire)
         (Bulldozer or High Lilt Loader)
TRUCKS
OTHER,
            (Specify)
                                  Co
                                  no*
                                  use
OTHER
            (Specify)
         Do
         not
         use "44
                                      43
                 NUMBER
                         o
                          ' TOTAL NUMBER OF EMPLOYEES ON SITE (Average daily)
                                          35
                                          37
                         0. HOURS OF
                           OPERATION
                           (On • 24-hour clock)
                                                                            LIZ
                                              3«
                                                    NUMBER OF DAYS OPERATED PER WEEK
                                          39  46
                                          41   42
                        42. ANNUAL OPERATING COST
                           (Including supervision and
                           equipment maintenance)
                                                                                LETIX:C
                                                                                  56  57   58  59   60   e t  62
                                          44  45
                                                  43. IS THIS A SANITARY LANDFILL'
                                                                      Jlfl
                                                                      *
                                                                                                   YES
                                          47  48
44. IF SOURCES OTHER THAN REPORTER DESIGNATED IN ITEM 7 WERE UTILIZED IN COMPLETING THIS FORM. INDICATE BELOW
   THE SOURCES USED AND ITEM NUMBERS
NAME OF PERSON




TITLE




ORGAN) Z ATION



•
ITEM NUMBER(S)




                                                      J4Z

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          Stamping, shearing and milling are the major sources of metal scrap.




Only minor quantities of process waste from these operations find  its way




into the general plant trash.  Waste oil from presses and similar machines




is collected in a 3,000-gallon tank and sold as scrap to an oil reclaimer.




          An investment casting operation uses about 280 ton/s per year of  the




investment material .all of which eventually appears in the packer truck waste.




An associated heat treating operation generates about 200 pounds per year of




salts from cleaning out the salt pot.  These are taken to the company disposal




area in drums.




          This plant carries out a large number of polishing, buffing and rumbling




operations.  Rumbling is a deburring type operation carried out by immersing




small parts in a rotating cylinder filled with pebbles.  The pebbles are water




washed, the slurry of the residual solids being sent to a settling basin which




settles out the solids.  The settling basin also receives solid streams from




floor washing in this part of the plant and from some other  sources.  The




settled sludge is cleaned from the basin with a crane and bucket about once




a month.  The sandy material is piled at the side of the basin for air drying




and then hauled to the company disposal area in a 5-ton truck for use as fill




there.  About four truck loads per month are obtained.




          This plant makes extensive use of small individual dust collectors




at individual machine sites where grinding, buffing and similar dust-generating




operations are carried out.  The containers on each are of about five gallon




capacity.  There are some 120 collectors in the plant, emptied into the Pack




Master containers as filled, from daily to weekly.




          Grinding and tapping machines are equipped with collection tanks




for collecting the chips out of the cutting oil stream.  One man, called a




"chip and solution many is occupied full time in servicing these collectors.




About once every two weeks the collected sludges, which have been shoveled
                                    143

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into a drum, are placed on the pile of drying sand from the sedimentation


basin for hauling to the company disposal area.


          The electroplating operation is very small.  On the rare cleaning


out of the tanks the sludges, if any, are discharged to the sewer.


          All painting is electrostatic.  The paint preparation room generates


about four 55-gallon drums of waste from paint batches per month.  These are


sent to the staging area for disposal in the company disposal area.  Waste

                                  QjHi,
paint and solvents from the lines *• very small in quantity, not


more than 25 gallons in a year.  If it is contained in cans of one gallon or


less it is discarded in the plant trash cans.  Containers greater than one


gallon size go to the staging area for disposal in the company disposal area.


The procedure for paint strippings from the spray booth is that they are placed


in drums and taken to the company disposal area.  There are two Oakite paint


strippers for cleaning the paint hangers.  The process comprises a long-time


soak in the alkaline heated solution.  The sludge from the paint strippers


is cleaned about twice a year, yielding about twenty-five 55-gallon drums each


time, which are taken to the company disposal area.


          The plant has a large investment in air cleaning devices comprising


some nine large cyclones, 5 to 25 horsepower which serve grinding and polishing,


sanding, heat treating and metal finishing, buffing and polishing, and the


foundry.  The cyclones are cleaned about once a week and yield an average of about


one cubic yard at each cleaning.  The material is placed on the drying sandpile


at the sedimentation basin by the roll-over fork lift.


          The liquid cleaning operation is that already described in the


sedimentation basin, mostly for the rumbling operation.
                                       144

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          Shipping and receiving are in a single area.  The receipts are unpacked




in this area and the janitors sort and stack corrugated for conveyance via



the Pack Master containers to the cardboard staging area.  It is stacked on a




stake-bed trailer by the roll-over fork lift.




          Waste from offices and snack areas is collected in the Pack Master




containers by the janitors.  The cafeteria is in a separate building.  Cafeteria




personnel transfer the garbage to a closed container outside the building where




it is picked up daily by the packer truck.









                           QUANTITY COMPUTATIONS




          None of the quantity computations in this study can be claimed to




have high accuracy, but in this plant there are some particularly discordant




data relative to the quantities and bulk densities in the packer truck.  The




plant had run weight checks on the packer truck for a three-week period but




only one of the weight tickets, bearing a March 1970 date was still extant.




That showed a net weight in the 20 cy packer of 15,200 pounds or a bulk density




of 760 Ib/cy. This is a very high bulk density for general plant trash in a




packer.  Furthermore at one period during a breakdown of the packer truck




a commercial disposal company was called in to handle the disposal.  The plant




would typically get 30-32 Pack Master containers, 1 cy each, into the 20 cy




packer truck, but the commercial disposal company got 80 containers in the




same size truck, a compaction ratio of 4.0 which is about the expected value




in normal practice.  Finally, the company has since installed a stationary




compactor of 30 cy capacity and found in its first shakedown runs that 10,000




Ibs was about all that could be packed into it, a bulk density of some 330




Ib/cy, unusually on the low side.  We are therefore faced with highly varying




data on the packed density of the main waste.
                                       145

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          A possible explanation of the discrepancy is as follows.  The cubic



yardage of the packer truck waste is quite secure.  At one trip per day and



one extra trip on one day per week in the 49 week year the total cubic yardage



is 5,880.  At a packed density normally to be expected of 500 Ib/cy the tonnage
                                                                   •if


is 1,470 tons.  However, the packer truck handled the 280 tons per year



of investment casting material and an estimated 340 tons per year of wastes from



weekly cleanout of the seven cyclones, at estimated one cy each and estimated



density of the sand, grit, and polishing waste of one ton per cubic yard.  The



total volume of the investment sand at 1.35 tons/cy and of the cyclone solids



would be 461 cy.  Thus the volume left in the packer truck for the regular plant



waste not including these two items would be 5,419 cy instead of 5,880.  This



5,419 cy would, at the typical 500 Ib/cy packed density, contribute 1,350




tons.  The total tonnage including the investment casting and cyclone waste >



would be 1973 in the 5,880 cy or a bulk density averaged over the year of 670



Ib/cy.  Thus the average bulk density would be in excess of that normally



expected, and it might well be that the single load on which we have the spot



data may have contained substantially more cyclone and investment casting waste



than the daily average.  For example.the load might have been taken on the very



day that the cyclones were cleaned.



          If one considered that the two sand and powder materials did not occupy



any volume, that is .filled the void spaces that otherwise would exist in the



packed material, then the bulk density becomes 715 Ib/cy.



          The tabulation beyond compromises between these two positions and takes



the round number of 2,000 tons.



          Of the wood waste in the trailer hauled by contractor^there



was 70 loads in 1970.  The contractor estimates the bulk density at 350 Ib/cy.



          The bulk density of relatively dry sand is about 2,700 Ib/cy.  This



would make the payload of a 6 cy body eight tons.  The computations assume that



the load is restricted to five tons.





                                    146

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          The paint wastes are estimated, at a specific gravity of  1.0, from

the drum count.

          The foundry in this plant keeps excellent detailed quantity records.

From the 1970 records on beginning and ending inventories, purchases and intraplant

transfers of sand.it is computed that 630 tons of sand appeared as waste.  This

is about 0.3 Ibs of sand per Ib of metal cast.  A great deal of this sand is

recycled even the green sand spilled on the floor.  The deliberate discard

is largely the resin-coated shell sand which cannot be used again.  The foundry

also transferred 290 tons to  the sandblast department, a figure which may

be compared with the 343 tons cleanout from the cyclones mentioned above, most

of which is sand from sandblasting and sanding operation.

          These computations result in the following quantities:
                              QUANTITY SUMMARY
                                                                 Per Year
                                                       Loads        cy       tons
               Packer truck                             294       5,880     2,000
                    includes investment casting sand                          (280)
                    cyclones cleanout                                         (340)
               Wood                                      70       2,240        390
               Sedimentation basin                       45          167        225
               Foundry sand                             126          470        630
               Paint rooms                               19          26         22

                                               Total    554       8,783     3,267
               tye                      1.07
               type                     1.28

               Corrugated scrap                          49       3,430        686
               Corrugated scrap, as
                    percent of waste - 21.0

          In 1970.there was sold as scrap metal 1,730 tons and,as waste oil

at an estimated 7 lb/gal«63 tons.  The scrap cardboard computed at 0.2 tons/cy

amounted  to 686 tons.  The total scrap then was 2,479 tons, 43.2 percent of

the scrap and waste being salvaged, not including the remelt in aluminum die  casting

and the foundry sand.

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                                 EQUIPMENT

          The estimated 1970 investment for equipment  is  as  follows:
               1  Packer truck
               80 Pack Master containers
               1  Power sweeper
               1  Roll-over fork lift
               200 Trash cans
               1  5-ton dump truck
               Cyclones
                    1  - grinding and polishing
                    3  - sanding
                    2 - metal finishing,  heat
                              treating
                    2 - buffing,  polishing

                    1 Pangborn
               10 acres disposal  site
               2 Paint hanger strippers
               120 dust collectors
          This is $102.50per annual ton of waste.






20
7.5
15
--
15
5
7.5
25









HP
HP
HP

HP
HP
HP
HP



25,000
16,000
7,000
15,000
600
11,000
25,000
15,000
20,000
8,000
60,000
10,000
10,000
30,000
10,000
12,000
60,000
                                                  Total    $334,600
          The amortization of this waste handling equipment at 25 years and
10 percent would be about 36,800 $/year.
                                   LABOR

          The estimated labor requirement for waste handling is as follows:

                                                       Hours Per Year
               Packer truck drivers
               Roll-over driver at 80 %
               Janitors - 28 @ 60%
               Dump truck driver
               Paint stripping and hanger handling
               Crane operator at basin
               Backhoe operator at disposal area
               Total janitors and paint at
                    $3.00/hr + 75% burden
               Total vehicle operators at $7.09/hr
                    including burden
 2,000
 1,600
33,600
 1,000
 1,500
   100
   100
                                                  Total    39,900
           $ Per Year


             184,000

              34,000

            $218,000
                                       148

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                    EQUIPMENT OPERATION AND MAINTENANCE

          The cost of equipment operation and maintenance is estimated as:

                                                            $ Per Year

               Maintenance at 4% of investment               13,400
               Packer truck, fuel, oil, license, insurance      700
               Dump truck, fuel, oil, license, insurance        400
               Fork lift, fuel, oil, license, insurance         300
               Power for cyclones                             3,350
               Janitor supplies                   not included

                                                  Total     $18,150

The power for the cyclones is computed by taking the total horsepower of all
dust collectors and cyclones, operated eight hours a day at 70 percent
efficiency and an energy cost of one cent/KWH.
                          CONTRACTOR DISPOSAL AND FEES

          The contractor fee for hauling the wood is $85/load. The city sanitary

landfill fee for dumping the packer truck wee $10/load.  The contractor and fees

cost then is as follows:

                                                       $ Per Year

               Woodwaste                                    5,950
               SLF (sanitary landfill)                      2,940
               Corrugated, hauled free for material         	

                                                  Total    $8,890
                                149

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                                   TOTAL COST

          The total cost of the foregoing cost elements is as follows:

                                                  $ Per Year    Percent of Total

                    Labor                          218,000             77.3
                    Amortization                    36,800             13.1
                    Maintenance and operation       18,150              6.4
                    Contractor and fees              8,890              3.2

                                          Total   $281,840            100.0

                    Per ton of waste - $86.3"



                                   TRENDS

          The plant is considering replacing the packer truck with a stationary

compactor and replacing the 1 cy containers with 2 cy containers (and has done

so since the interview) .  An analysis is available of the packer truck refuse

removal costs, made for considering a refuse removal contractor's bid in 1967.

The analysis contains the breakdown on packer truck costs including dumping fee
                                                         ''
and operators wages actual for 1964, 1965, and 1966 and 1970,,. estimated for 1967,

1968 and 1969.  In 1970 some unusual repair expenses were incurred, about

four times the previous annual average and the operators' wages increased by

50 percent.  The total costs per load for the seven years were in $/load — 50,

68, 49, 49, 46, 54, 78.  The truck depreciation had been taken over a five-year

period.  The total is still lower than the contractori!967 bid and a contractor's

1970 bid would undoubtedly have been inflated over that.  However, a new truck

would have to be purchased shortly.

          The management is not considering the sale, rather than the give-away,

of the corrugated cardboard because the market for it in this area has proven

so poor.

          The are no near-term trends for the ultimate disposal facilities.  The

city sanitary landfill is not threatened .and the company's own disposal area has

many years of remaining life.

                                      150

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                           APPENDIX  2

           DEPARTMENT OF HEALTH. EDUCATION, AND WELFARE
                        PUBLIC HEALTH SERVICE
                               EN VI RON MENTAL HEALTH SLRV,C££
                                     ENVIRONMENTAL CONTROL ADMINISTRATION
                                          CINCINNATI LABORATORIES
                                           CINCINNATI, OHIO 452)3
                        November  16,  1970
TO WHOM IT MAY CONCERN:

The U.S. Department of Health, Education,  and Welfare has contracted
with Louis Koenig-Research of San Antonio,  Texas,  to conduct a
survey of solid waste management in  the  household  appliance industry.

"Solid Waste" refers to all  types of solid industrial waste and
includes waste from processing (production),  shipping and receiving,
office, cafeteria, and other plant activities such as maintenance.
In this study of waste "management",  consideration will be given to
waste generation, characteristics, quantity,  storage, handling,
processing, treatment, disposal, reuse,  and future changes in these
factors.

Proper clearance from the Office of  Management and Budget (formerly
the Bureau of the Budget) has been obtained,  and Louis Koenig-Research
will be conducting a series  of interviews  with important representatives
of the industry.  We view the information  and data to be gathered to
be of a proprietary and confidential  nature,  and it is our intent to
maintain the confidentiality of all  respondents.

The Department of Health, Education,  and Welfare solicits your
cooperation in our study.  Ttfe are hopeful  that the information gained
will benefit you in determining more efficient means of solid waste
management and in locating reclaimable resources.   Everything that  you
can do to assist Dr. Koenig  in this  study  will be  greatly appreciated.
                                Sincerely  yours,
                               Arjcwt**,  ( •
                                Henry T. Hudson
                                Project Officer
                                Engineer, I&ADS,  Basic  Data Branch
                                Division of Technical Operations
                                Bureau of Solid Waste Management
 yo892
                            Page
                                 151

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