National Emissions Standards For Hazardous Air Pollutants Printing and Publishing Industry Background Information For Proposed Standards

United States Environmental Protection Agency Office of Air Quality Planning and Standards Research Triangle Park NC 27711 EPA-453/R-95-002a February 1995 Air MAR 3 ° ERA National Emission Standards for Hazardous Air Pollutants: Printing and Publishing Industry Background Information for Proposed Standards ENVIRONMENTAL PROTECTION AGENCY DALLAS, TEXAS LIBRARY ------- EPA-453/R-95-002a National Emission Standards for Hazardous Air Pollutants: Printing and Publishing Industry Background Information for Proposed Standards Emission Standards Division U.S. ENVIRONMENTAL PROTECTION AGENCY Office of Air and Radiation Office of Air Quality Planning and Standards Research Triangle Park, North Carolina 27711 February 1995 ------- This report has been reviewed by the Emission Standards Division of the Office of Air Quality Harming and Standards. EPA. and approved for publication. Mention of trade names or commercial products i$ not intended to constitute endorsement or recommendation for use. Copies of this report are available through the Library Services Offices (MO-35). U. S. Environmental Protection Agency. Research Triangle PartX N.C. 27711. or from National Technical Information Services. 5285 Port Royal Road. Springfield. Virginia 22161. ------- TABLE OF CONTENTS 1.0 INTRODUCTION 1-1 1.1 OVERVIEW 1-1 1.2 PROJECT HISTORY 1-1 1.2.1 Background 1-1 1.2.2 Data Gathering 1-3 1.2.3 Emissions and Control Data 1-4 1.3 REFERENCES 1-4 2.0 THE PRINTING AND PUBLISHING INDUSTRY 2-1 2.1 INTRODUCTION 2-1 2.2 GRAVURE PRINTING 2-2 2.2.1 Publication Rotogravure 2-3 2.2.1.1 Process Description 2-3 2.2.1.2 Profile of the Publication Rotogravure Segment 2-4 2.2.1.3 HAP Use and Emissions 2-4 2.2.1.4 Baseline Emissions 2-6 2.2.2 Packaging and Product Gravure 2-6 2.2.2.1 Process Description 2-10 2.2.2.2 Profile of the Package/Product Rotogravure Segment 2-11 2.2.2.3 Hap Use and Emissions 2-11 2.2.2.4 Baseline Emissions 2-20 2.2.3 Intaglio Plate Gravure 2-20 2.3 FLEXOGRAPHY 2-22 2.3.1. Wide Web (and Sheetfed) Flexographic Printing 2-22 2.3.1.1 Process Description 2-23 2.3.1.2 Profile of Wide Web Flexographic Segment 2-23 2.3.1.3 HAP Use and Emissions 2-24 2.3.1.4 Baseline Emissions from Wide Web Flexographic Segment 2-40 2.3.2 Narrow Web Flexographic Printing 2-40 2.4 LITHOGRAPHY 2-41 2.4.1 Sheet-fed Lithography 2-42 2.4.2 Non-Heatset Web Lithographic Printing 2-42 iii ------- 2.4.3 Heatset Web Lithographic Printing 2-43 2.5.LETTERPRESS 2-44 2.5.1 Non-heatset Letterpress 2-44 2.5.2 Heatset Letterpress 2-45 2.6 SCREEN PRINTING 2-45 2.7 OTHER PRINTING PROCESSES 2-46 2.7 REFERENCES 2-46 3.0 CONTROL TECHNOLOGY AND PERFORMANCE OF CONTROLS 3-1 3.1 INTRODUCTION 3-1 3.2 CAPTURE SYSTEMS 3-1 3.2.1 Publication Rotogravure 3-2 3.2.2 Product and Package Gravure 3-2 3.2.3 Wide-web Flexographic Printing 3-3 3.3 CONTROL DEVICES 3-3 3.3.1 Carbon Adsorption 3-3 3.3.2 Thermal Incineration 3-4 3.3.3 Catalytic Incineration 3-4 3.4 PERFORMANCE OF CONTROLS 3-5 3.4.1 Publication Gravure 3-5 3.4.2 Product and Packaging Gravure 3—7 3.4.3 Wide-web Flexographic Printing 3-10 3.5 LOW HAP AND HAP-FREE INKS (AND OTHER MATERIALS) 3-15 3.5.1 Publication Rotogravure 3-16 3.5.2 Product and Packaging Rotogravure 3-16 3.5.3 Wide-web Flexographic Printing 3-17 3.6 REFERENCES 3-19 4.0 MODEL PLANTS, CONTROL OPTIONS, AND ENHANCED MONITORING 4-1 4.1 INTRODUCTION 4-1 4.2 MODEL PLANTS 4-1 4.2.1 Publication Rotogravure Model Plants 4-1 4.2.2 Product and Packaging Gravure Model Plants 4-3 4.2.3 Wide-web and Sheet Fed Flexography Model Plants 4-4 4.3 CONTROL OPTIONS 4-31 4.3.1 Control Options for Publication Rotogravure 4-31 iv ------- 4.3.2 Control Options for Product and Packaging Rotogravure 4-33 4.3.3 Control Options for Wide-web and Sheet Fed Flexography 4—37 4.4 ENHANCED MONITORING 4-38 4.4.1 Enhanced Monitoring for Publication Gravure 4-38 4.4.2 Enhanced Monitoring for Product and Packaging Rotogravure 4-40 4.4.3 Enhanced Monitoring for Wide-web and Sheet Fed Flexography 4-41 5.0 ENVIRONMENTAL AND ENERGY IMPACTS OF CONTROL OPTIONS 5-1 5.1 ENERGY IMPACT 5-1 5.1.1 Publication Rotogravure 5-1 5.1.2 Product and Packaging Rotogravure 5-2 5.1.3 Wide-web and Sheet Fed Flexographv 5-3 5.2 AIR IMPACTS 5-5 5.2.1 Publication Rotogravure 5-5 5.2.2 Product and Packaging Gravure 5-5 5.2.3 Wide-web and Sheet Fed Flexography 5-6 5.3 WATER IMPACTS 5-8 5.3.1 Publication Rotogravure 5-8 5.3.2 Product and Packaging Rotogravure and Wide-web and Sheet Fed Flexography 5-8 5.4. SOLID WASTE IMPACT 5-8 5.4.1 Publication Rotogravure 5-8 5.4.2 Product and Packaging Rotogravure and Wide-web and Sheet Fed Flexography 5-8 6.0 MODEL PLANT CONTROL OPTION COST 6-1 6.1 INTRODUCTION 6-1 6.2 PUBLICATION ROTOGRAVURE 6-1 6.3 PRODUCT AND PACKAGING ROTOGRAVURE 6-16 6.4 WIDE-WEB AND SHEET FED FLEXOGRAPHY 6-26 6.5 REFERENCES 6-35 ------- LIST OF TABLES Table 2-1. Publication Gravure Plants 2-5 Table 2-2. Packaging/Product Gravure Responses 2-12 Table 2-3. Rotogravure Facilities Printing on Paper and Cardboard 2-14 Table 2-4. Rotogravure Facilities Printing Exclusively on Foil and Film 2-15 Table 2-5. Rotogravure Facilities Printing Vinyl Products. 2-16 Table 2-6. Rotogravure Facilities Printing on Paper or Cardboard and Foil or Film 2-17 Table 2-7. Rotogravure Facilities Printing Miscellaneous Products 2-18 Table 2-8. Baseline Emissions from Product and Packaging Rotogravure Responses 2-21 Table 2-9. Baseline Emissions from Major Sources in the Product and Packaging Rotogravure Industries 2-21 Table 2-10. Wide-Web Flexographic Printing Responses. . . 2-25 Table 2-11. Baseline Emissions from Flexographic Printing. 2-41 Table 3-1. Overall Control Efficiencies Reported for Publication Gravure Plants 3-7 Table 3-2. Overall Efficiencies Reported for Product and Packaging Gravure Facilities with Control Systems. . . 3-10 Table 3-3. Control Device Efficiencies Reported for Packaging and Product Gravure" Facilities with Control Systems 3-11 Table 3-4. Overall Efficiencies by Industry Segment for Packaging and Product Gravure Facilities with Control Systems 3-11 Table 3-5. Control Devices in Use by Flexographic Printers 3-13 Table 3-6. Overall Efficiencies Reported for Flexographic Facilities with Control Systems 3-15 vi ------- Table 4-1. Publication Rotogravure Model Plants 4-2 Table 4-2. HAP Use by Rotogravure Facilities Printing on Paper and Cardboard 4-5 Table 4-3. HAP Use by Rotogravure Facilities Printing Exclusively on Foil and Film 4-8 Table 4-4. HAP Use by Rotogravure Facilities Printing Vinyl Products 4-9 Table 4-5. Model Plant Specifications for Product/Packaging Rotogravure 4-10 Table 4-6. HAP Use on Flexographic Presses 4-12 Table 4-7. Model Plant Specifications for Flexography. . . 4-30 Table 4-8. Control Options for Publication Rotogravure Plants 4-34 Table 4-9. Control Options for Packaging and Product Rotogravure Plants 4-37 Table 4-10. Control Options for Flexographic Printing Plants 4-40 Table 5-1. Energy Impact of Control Options for Publication Rotogravure Plants 5-2 Table 5-2. Energy Impact of Control Options for Product and Packaging Gravure Plants 5-3 Table 5-3. Energy Impact of Control Options for Wide-web and Sheet Fed Flexography. . 5-5 Table 5-4. Air Impact of Control Options for Publication Rotogravure Plants 5-6 Table 5-5. Air Impact of Control Options for Product and Packaging Rotogravure Plants 5-7 Table 6-1. Publication Rotogravure Model Plant Specifications Used for Control Option Costing 6-2 Table 6-2. Publication Rotogravure Control Device Specifications used for Control Option Costing 6-4 Table 6-3. Capital Costs of Concentrator/Solvent Recovery Systems for Control Option A at Model Publication Rotogravure Plants 6-5 vii ------- Table 6-4. Capital Costs of Concentrator/Solvent Recovery Systems for Control Option B at Model Publication Rotogravure Plants 6-6 Table 6-5. Capital Costs of Concentrator/Solvent Recovery Systems for Control Option C at Model Publication Rotogravure Plants 6-7 Table 6-6. Capital Costs of Required Solvent Recovery System Upgrades for Control Option A at Model Publication Rotogravure Plants 6-8 Table 6-7. Capital Costs of Required Solvent Recovery Upgrades for Control Options B and C at Model Publication Rotogravure Plants 6-9 Table 6-8. Capital Costs of Permanent Total Enclosure for Control Option C at Model Publication Rotogravure Plants 6-10 Table 6-9. Total Annual Costs for Control Option A at Model Publication Rotogravure Plants 6-11 Table 6-10. Total Annual Costs for Control Option B at Model Publication Rotogravure Plants 6-12 Table 6-11. Total Annual Costs for Control Option C at Model Publication Rotogravure Plants 6-13 Table 6-12. Notes to Control Cost Calculations for Model Publication Rotogravure Plants 6-14 Table 6-13. Cost Effectiveness of Concentrator Systems for Incremental Control of Publication Rotogravure Model Plants 6-15 Table 6-14. Model Plant Specifications for Product and Packaging Rotogravure 6-17 Table 6-15. Incinerator Specifications for Product and Packaging Rotogravure Control Options 6-18 Table 6-16. Capital Costs for Thermal Incinerators at Model Product and Packaging Rotogravure Plants - Control Option A 6-20 Table 6-17. Capital Costs for Thermal Incinerators at Model Product and Packaging Rotogravure Plants - Control Option B 6-21 Table 6-18. Total Enclosure Construction Costs for Product and Packaging Rotogravure - Control Option B 6-22 viii ------- Table 6-19. Total Annual Costs for Thermal Incinerators at Model Product and Packaging Rotogravure Plants - Control Option A 6-23 Table 6-20. Total Annual Costs for Thermal Incinerators at Model Product and Packaging Rotogravure Plants - Control Option B 6-24 Table 6-21. Cost Effectiveness of Control Options A and B for Incremental Control at Model Product and Packaging Rotogravure Plants 6-25 Table 6-22. Model Plant Specifications for Flexography. . 6-27 Table 6-23. Incinerator Specifications for Flexography Control Options 6-28 Table 6-24. Capital Costs for Thermal Incinerators at Model Flexographic plants - Control Option A 6-29 Table 6-25. Capital Costs for Thermal Incinerators at Model Flexographic plants - Control Option B 6-30 Table 6-26. Total Enclosure Construction Costs for Flexographic Plants - Control Option B 6-32 Table 6-27. Total Annual Costs for Thermal Incinerators at Model Flexographic Plants - Control Option A 6-33 Table 6-28. Total Annual Costs for Thermal Incinerators at Model Flexographic Plants - Control Option B 6-34 Table 6-29. Cost Effectiveness of Control Options A and B for Control of Model Flexographic Printing Plants. . . 6-35 IX ------- 1.0 INTRODUCTION 1.1 OVERVIEW Section 112 of the Clean Air Act (Act) requires that the U. S. Environmental Protection Agency (EPA) establish emission standards for all categories of sources of hazardous air pollutants (HAP). These national emission standards for hazardous air pollutants (NESHAP) must represent the maximum achievable control technology (MACT) for all major sources. The Act defines a major source as: ...any stationary source or group of stationary sources located within a contiguous area and under common control that emits or has the potential to emit, in the aggregate, 10 tons per year or more of any hazardous air pollutant or 25 tons per year or more of any combination of hazardous air pollutants. In July 1992, the Documentation for Developing the Initial Source Category List1 was published. "Printing/Publishing (Surface Coating)" was included as a source category. The Printing and Publishing Industry NESHAP project will establish standards for major sources in this source category. The purpose of this document is to summarize the background information gathered during the development of the printing and publishing industry NESHAP. 1.2 PROJECT HISTORY 1.2.1 Background The printing industry can be divided by technology, substrate or type of product. Further divisions and industry segments can be identified in each of the major industry divisions. Many manufacturing processes include printing operations as one step in the production process. It is ------- estimated that more than 60,000 establishments in the U. S. operate printing presses2. This estimate excludes plateless printing establishments. The printing industry can be divided by technology into six different segments: gravure, flexographic, lithographic, letterpress, screen, and plateless (xerographic, electrostatic, magnetic, thermal, ink-jet, etc). The technology (i. e. the type of press equipment) dictates the types of inks and coatings which can be used. This defines to a large extent the type of HAP involved, the emissions and the control techniques which are applicable. The printing industry can also be divided by the type of substrate that is printed. Among the flexible substrates, paper, foil and films are printed. Paper can be further classified in many ways, including coated vs. uncoated. Films include polyethylene and a number of other polymers. Rigid substrates include cardboard and vinyl. A given substrate may be printed using different technologies depending on factors such as the end use, quality requirements, quantity, cost and environmental considerations. Textiles are specifically excluded from the printing source category. The printing industry can be additionally divided by the type of product. In general, the end use falls into the broad categories of publication, packaging or product. Publication printing includes newspapers, magazines, books and advertising. Packaging includes paper, plastic and foil bags and wrappers, and cardboard cartons. Products include wall and floor covering, greeting cards and paper towels. Various technologies can be used to print specific items within the broad categories. In 1978, a control technique guidelines (CTG) document was established for the control of VOC from rotogravure and flexographic printing operations3. New source performance standards (NSPS) for VOC emissions from publication rotogravure4 were proposed October 28, 1980 (45 FR 71538) and promulgated November 8, 1982 (47 FR 50644). NSPS for VOC emissions from 1-2 ------- rotogravure printing and coating of flexible vinyl5 were proposed January 18, 1983 (48 FR 2276) and promulgated June 29, 1984 (49 FR 26885). In 1993, a draft CTG document was published for the control of VOC emissions from offset lithographic printing6. None of these efforts were specifically directed towards HAP, however, many HAP of concern in the printing and publishing industry are VOC and the same control devices used to limit VOC emissions are also applicable to control of HAP. HAP are present in some of the inks, coatings, primers and adhesives applied on printing presses, and are also present in some of the materials used for cleaning press parts. Aromatic (e. g. toluene), aliphatic and oxygenated hydrocarbons make up the majority of the HAP used in the printing industry. HAP use associated with various printing technologies and industry segments is discussed in Chapter 2. 1.2.2 Data Gathering In 1993, a questionnaire was developed by EPA and the Gravure Association of America (GAA), to determine HAP use and control in the publication rotogravure segment. Responses to this questionnaire were voluntarily provided to EPA by all publication rotogravure facilities operating in the U. S. Two additional questionnaires were developed by EPA, GAA, and the Flexible Packaging Association (FPA), to determine HAP use and control by product and packaging rotogravure facilities and flexographic printing facilities. These questionnaires were included with information collection requests (ICR) sent out under the authority of section 114 of the Act. Most of the recipients opted to complete the questionnaires in lieu of the ICR. Questionnaires were sent to approximately 90 companies thought to operate product or packaging rotogravure presses, and approximately 370 companies thought to operate wide-web flexographic presses. In addition to information obtained from these questionnaires, several site visits were made to printing facilities. Also, the EPA has met with multiple trade 1-3 ------- organizations and industry representatives over the past several years. 1.2.3 Emissions and Control Data The available emissions and control information for the printing and publishing industry has been summarized in Chapter 3. Most of the information collected is based on calendar year 1992, and is representative of current practices. In some segments of the industry, there has been a shift away from HAP to non-HAP VOC and waterborne materials. Control efficiency data are relevant to current conditions for the purpose of MACT determination. 1.3 REFERENCES 1. U. S. Environmental Protection Agency. Documentation for Developing the Initial Source Category List: Final Report. Publication No. EPA-450/3-91-030. Research Triangle Park, NC July 1992. 2. U. S. Environmental Protection Agency. Use Cluster Analysis of the Printing Industry—Draft Final report. Washington, DC. May 26, 1992. 182 pp. 3. U. S. Environmental Protection Agency. Control of Volatile Organic Compound Emissions from Existing Stationary Sources- Volume VIII: Graphic Arts-Rotogravure and Flexography. Publication No. EPA-450/2-78-033. Research Triangle Park, NC. December, 1978. 52 pp. 4. U. S. Environmental Protection Agency. Publication Rotogravure Printing-Background Information for Proposed Standards. Publication No. EPA-450/3-80-031a. Research Triangle Park, NC. October, 1980. 5. U. S. Environmental Protection Agency. Standards of Performance for New Stationary Sources; Flexible Vinyl Coating and Printing Operations. 48 FR 12. January 18, 1983. p.2276 et. seq. 6. U. S. Environmental Protection Agency. Draft-Control of Volatile Organic Compound Emissions from Offset Lithographic Printing. Research Triangle Park, NC. September, 1993. 234 pp. 1-4 ------- 2.0 THE PRINTING AND PUBLISHING INDUSTRY 2.1 INTRODUCTION The printing industry can be divided by technology, substrate or type of product. Further divisions and industry segments can be identified in each of the major industry divisions. Many manufacturing processes include printing operations as one step in the production process. It is estimated that more than 60,000 establishments in the U. S. operate printing presses1. This estimate excludes plateless printing establishments. The printing industry can be divided by technology into six different segments: gravure, flexographic, lithographic, letterpress, screen, and plateless (xerographic, electrostatic, magnetic, thermal, ink-jet, etc). The technology (i. e. the type of press equipment) dictates the types of inks and coatings which can be used. This defines to a large extent the type of HAP involved, the emissions and the control techniques which are applicable. The printing industry can also be divided by the type of substrate that is printed. Among the flexible substrates, paper, foil and films are printed. Paper can be further classified in many ways, including coated vs. uncoated. Films include polyethylene and a number of other polymers. Rigid substrates include cardboard and vinyl. A given substrate may be printed using different technologies depending on factors such as the end use, quality requirements, quantity, cost and environmental considerations. Textiles are specifically excluded from the printing source category. 2-1 ------- The printing industry can be additionally divided by the type of product. In general, the end use falls into the broad categories of publication, packaging or product. Publication printing includes newspapers, magazines, books and advertising. Packaging includes paper, plastic and foil bags and wrappers, and cardboard cartons. Products include wall and floor covering, greeting cards and paper towels. Various technologies can be used to print specific items within the broad categories. Because inks and other HAP containing materials are customized for particular printing technologies in terms of viscosity (e. g. gravure and flexographic inks are relatively fluid, lithographic, letterpress and screen inks are relatively viscous) and chemical compatibility (e. g. flexographic plates are incompatible with aromatic solvents) HAP emissions will be discussed in terms of printing technology. It should be recognized that in many cases the same product can be produced by more than one technology (e. g. newspapers are produced by lithography, letterpress, and flexography). 2.2 GRAVURE PRINTING Nearly all gravure printing is done by rotogravure. Gravure printing is a printing process in which an image (type and art) is etched or engraved below the surface of a plate or cylinder. On a gravure plate or cylinder, the printing image consists of millions of minute cells.2 Gravure requires very fluid inks which will flow from the cells to the substrate at high press speeds. In addition to inks, other materials including adhesives, primers, coatings and varnishes may be applied with gravure cylinders. These materials dry by evaporation as the substrate passes through hot air dryers. Solvent borne or waterborne ink systems can be used but these ink systems are not interchangeable. Both the printing cylinders and the drying systems are specific to the solvent system in use. The evaporated components of the ink and other 2-2 ------- materials may contain HAP to varying extents. Additional HAP may be present in solvents used to clean presses and press components. Rotogravure can be divided into the publication and product/packaging segments. Because of the expense and complexity of rotogravure cylinder engraving, it is particularly suited to long run printing jobs. 2.2.1 Publication Rotogravure Publication rotogravure printing focuses on magazine, catalog and advertising insert printing. In 1993, there were 27 publication rotogravure plants in the U. S. These plants were operated by six corporations. These plants all use toluene/xylene based ink systems, and operate solvent recovery systems based on carbon adsorption with steam regeneration. Recovered solvent is sold back to the ink manufacturers. Press capture systems vary depending on the age of the press. Press and cylinder technologies, products, inks and control systems are discussed in the Background Information Document for New Source Performance Standards for Publication Rotogravure Printing3. Capture technologies and capture efficiency testing are discussed in The Measurement Solution: Using a Temporary Total Enclosure for Capture Efficiency Testing4. 2.2.1.1 Process Description. On a gravure cylinder, the printing image consists of millions of minute cells which are engraved into the surface of the cylinder5. Different colored inks are applied in succession as the web passes from station to station. A separate cylinder, ink supply and dryer are required for each station. After the ink is applied at each station, the web is dried before being printed by the next station. Typically, four stations are required to print each side of the web. Publication gravure presses in operation in the U. S. have up to 16 stations. Gravure requires very fluid inks which will flow from the cells to the web at high press speeds. The ink dries by evaporation as the substrate passes through hot air dryers. 2-3 ------- Publication gravure presses in the United States use solvent borne ink systems exclusively. Because of the expense and complexity of rotogravure cylinder engraving, it is particularly suited to long run printing jobs. It is generally believed in the industry that publication gravure equipment is capable of higher quality printing than competing processes. 2.2.1.2 Profile of the Publication Rotogravure Segment. There are 27 publication gravure plants in the United States. These plants are owned by six companies, none of which are small businesses. All 27 plants are major sources for hazardous air pollutants. Some of these companies operate additional printing processes using technologies other than rotogravure. In some cases, these other processes are conducted at separate locations. All of the plants voluntarily provided responses to a list of questions developed by the EPA and the Gravure Association of America. The information in this section is based on these responses. Seventeen of the responses are in the public docket; the remaining ten responses contain some confidential business information. A list of plant locations and owners is given in Table 2-1. 2.2.1.3 HAP Use and Emissions. All of the U. S. publication gravure plants use solvent based ink systems. The primary solvent is toluene, a HAP. At some plants xylenes and ethyl benzene, also HAP, are present in the solvent blend and are used, emitted, recovered and handled in the same manner as toluene. The plants purchase ink containing solvent and add additional solvent to obtain the desired viscosity. Ink is applied to the web which then passes through a dryer, where the solvent is evaporated into heated air. The web then travels to the next press station where the process is repeated with a different color. Most of the evaporated solvent is recovered using activated carbon solvent recovery systems. The recovered solvent is reused; excess solvent is 2-4 ------- sold back to the ink manufacturers. Additional solvent (of the same composition as the solvent in the ink) is used for cleaning gravure cylinders and other press components. Table 2-1. Publication Gravure Plants Company Name City State Brown Printing Company R. R. Donnelley Printing Company R. R. Donnelley Printing Company R. R. Donnelley Printing Company R. R. Donnelley Printing Company, R. R. Donnelley & Sons Company R. R. Donnelley & Sons Company R. R. Donnelley & Sons Company R. R. Donnelley & Sons Company R. R. Donnelley & Sons Company R. R. Donnelley & Sons Company R. R. Donnelley & Sons Company Quad / Graph ics Quebecor Printing Atglen Inc. Quebecor Printing Buffalo Inc. Quebecor Printing Dallas Inc. Quebecor Printing Dickson Inc. Quebecor Printing Memphis Inc. Quebecor Printing Memphis Inc. Quebecor Printing Mt. Morris Inc. Quebecor Printing Providence Inc. Quebecor Printing Richmond Inc. Quebecor Printing San Jose Inc. Ringier America Inc. Ringier America, Inc. World Color Press, Inc. World Color Press, Inc. Franklin Casa Grande Lynchburg Newton Des Moines Mattoon Reno Warsaw Spartanburg Lancaster Chicago Gallatin Lomira Atglen Depew Dallas Dickson Baltimore Memphis Mt. Morris Providence Richmond San Jose Corinth Evans Salem Dyersburg KY AZ VA NC IA IL NV IN SC PA IL TN WI PA NY TX TN MD TN IL RI VA CA MS GA IL TN All of the U. s. publication gravure plants account for solvent on the basis of liquid-liquid mass balances. Emissions are calculated taking into account ink purchases, solvent purchases and sales, and changes in inventory over a suitable time frame. All solvent losses are counted as emissions whether they result from pressroom capture losses, control device losses, retention in the finished publications or evaporation from uncontrolled equipment (including proof presses). 2-5 ------- HAP emissions result from incomplete recovery of captured HAP, and from incomplete capture. Activated carbon solvent recovery systems are suitable for control of toluene and similar aromatic solvents. High control efficiencies can be achieved, however some solvent is unavoidably emitted as a result of thennodynamic limitations (the toluene- carbon/toluene-air equilibrium) and flow irregularities (e. g. channelling through the carbon bed). Some HAP is not captured in the dryer exhaust. This includes HAP which evaporates from the ink fountains into the pressroom, HAP which is evaporated from the web in the dryers but is then swept out of the dryer as the web travels towards the succeeding press station, HAP which remains in the web after the last drier which evaporates during additional processing (slitting, folding, stitching, etc.) and HAP which leaves the plant trapped in the magazine, catalog or advertising insert. Additional HAP is emitted from proof presses, which in some plants are uncontrolled, gravure cylinder cleaning, other parts cleaning, storage tank evaporation and breathing losses and ink mixing operations. These sources are relatively minor by comparison, however, they are reflected in the overall efficiencies determined from liquid-liquid mass balances. 2.2.1.4. Baseline Emissions. There are 27 publication gravure plants in the United States. All of the plants voluntarily provided responses to a list of questions developed by the EPA and the Gravure Association of America. The information in this section is based on these responses. Seventeen of the responses are in the public docket; the remaining ten responses contain confidential business information. A total of 38,400,000 pounds (19,200 tons) of HAP was emitted in 1992. The HAP is primarily toluene; some plants report using a mixture containing mixed xylenes and ethyl benzene. 2.2.2 Packaging and Product Gravure The gravure printing operation is, in many cases, a relatively small part of the total package or product 2-6 ------- production process. This section briefly describes the various types of packages and products that include gravure printing in their manufacture, and notes what production steps are required in addition to the gravure printing step. Folding Cartons. Folding carton packages are used for a wide variety of products including wet and dry foods, beverages, bakery items, and candy. They are also used for nonfood products such as detergents, hardware, paper goods, cosmetics, medical products, tobacco products, and sporting goods. The folding carton is made from one of several grades of paperboard. It may be printed, laminated or coated, or may be shipped unprinted to be used with another label or wrapper. Besides printing, operations in the manufacture of folding cartons include creasing, trimming, die-cutting, coating, and gluing. The cartons are shipped flat, to be assembled and filled by the customer. In addition to gravure printing, flexography is used for folding cartons. Letterpress use has declined. Most of the gravure presses used for folding carton printing are web-fed. However, some folding carton presses are sheet-fed, with only one or two print stations.6 Flexible Packaging. Flexible packaging, by one definition, consists of "converted materials intended to package and display products weighing less than 25 pounds."7 The word "converted" in this use is an industry-specific term that refers to the fact that flexible packaging materials start out as rolls of paper or foil, or beads of plastic resin, and are "converted" into a package or roll of packaging material. Flexible package manufacturers are sometimes referred to as "converters". The ratio of gravure printing to flexographic printing among converters is approximately 20:80,* it is, however, an important component of the gravure printing industry. Converters produce a wide range of non- rigid packages made of paper, plastic film, foil laminates, and combinations of these substrates. 2-7 ------- One portion of the flexible packaging industry provides fully printed packaging materials (designated "preformed specialty bags") to contract packagers. Another portion provides combination or laminated materials (designed converted wrap) for printing and/or final packing by captive packaging operations. Applying coatings is a major capability of flexible packaging converters, so the same facilities may be used to manufacture non-packaging materials such as gift wraps and hot stamp foils.9 Labels and Wrappers. Labels and wrappers include roll and sheet labels applied to cans, unprinted cartons, composite cans, bottles and other containers, tags, and self-adhesive label products. Paper is the common substrate, but laminates and foil are also used. The industry makes a distinction between labels and wrappers, which are package components, from a product that becomes the entire package and should be called a flexible package. This is because of the distinction of SIC codes that apply (see above). However, it is suggested that product shipment reports are probably based more on the substrate (i.e., paper for labels and wrappers; plastic film for flexible packages) than on a precise definition of end use.10 One interesting manufacturing technique used in making labels is the use of combination gravure/flexo presses. The manufacturer uses a gravure cylinder for "halftone" material and for coating operations, and uses a flexographic cylinder for typographic material that might have frequent changes." Gift Wraps. About 90 percent of all gift wraps are printed. They are produced by greeting card companies and by label and flexible packaging firms. Because gravure printing is particularly suitable for producing the continuous patterns used on gift wrap, it accounts for 60 to 70 percent of the market.12 Historically a significant portion of the gift wrap was made from laminated foil, as are many flexible packaging materials. Although foil gift wrap is no longer a significant 2-8 ------- product, it is the reason why flexible package manufacturers often print gift wrap.13 Wallcoverings. The wallcovering industry is a traditional user of gravure. The principal types of wallcoverings are prepasted paper, prepasted paper-backed vinyl, fabric-backed vinyl, and specialty items (e.g., metallics, grass cloth, rice paper). Gravure printing is typically used to print only the vinyl wallcoverings.14 The steps in manufacturing wallcoverings include printing the paper and laminating it to the backing sheet. A special effect that may be added in some cases is "registered embossing" to add texture. It is usually done in line with the laminator.15 Vinyl Printing. These products consist of auto upholstery, furniture upholstery, tablecloths, decorative trim, and shower curtains. Gravure dominates this product area because of the complex repeat patterns (e.g., woodgrain), and the requirement, in many cases, for overcoating that is readily applied using a gravure cylinder. Printing is performed on unsupported vinyl, supported vinyl (backed with fabric or paper), and paper substrate that is then coated with vinyl.l6 The manufacturing steps typically consist of printing, coating, embossing, and other finishing. In some cases items that are screen printed or flexographically printed are still coated using a gravure process.17 Decorative Laminates. These products consist of solid, thermoset laminates used in furniture and construction, and other laminates, principally wood grain veneers, widely used in furniture. The dense sheets consist of many layers of polymer-saturated paper. The top sheet is a translucent sheet impregnated in melamine, laid over a printed or solid pigmented pattern sheet. Heat and pressure are both used to produce the final product.18 2-9 ------- Floor Coverings. Gravure presses are used to decorate and apply texture and finish to sheet vinyl floor coverings. Rotary screen printing is sometimes used in combination with gravure. Gravure is also used to print transfer papers used to decorate vinyl tile, and some tile products are printed using "offset/gravure," a hybrid press type using a gravure cylinder offsetting to a rubber image carrier.19 Tissue Products. Some type of printing process is used to apply color patterns to paper towels, bathroom tissue, and napkins. The older paper mills producing tissue products were typically equipped with gravure presses. Today, that production accounts for less than 5 percent of the total production.20 Miscellaneous Specialty Products. Other miscellaneous and specialty products that require a printed patter are also produced using gravure printing. One such product is cigarette tipping paper, the paper with a cork-like or other pattern that is wrapped around cigarette filters. 2.2.2.1 Process Description. The rotogravure printing process is described in section 2.2.1.1. Product and packaging rotogravure differs from publication gravure with respect to the materials used, the applicable control devices, and the decreased importance of the actual printing process in an overall manufacturing process. Packaging and product rotogravure printing uses a wide variety of different ink systems, including the aromatic HAP based ink systems common to publication gravure, solvent based non-HAP ink systems, and waterborne ink systems. Numerous specially mixed colors are applied at various times in this industry segment, in contrast to the publication segment which primarily applies four basic colors. In addition a wider range of materials are applied with gravure cylinders in this segment of the industry. A variety of coatings, adhesives and primers are applied at print stations on rotogravure presses. Because of the variety of materials applied, the approach 2-10 ------- to HAP and VOC control in packaging and product gravure facilities varies. In addition to the activated carbon based solvent recovery systems used by the publication segment, packaging and product gravure facilities also use a variety of thermal and catalytic oxidizers. Many facilities operate without significant HAP use and do not have control devices. Printing is only one stage (often minor) in manufacturing. In many cases, operations such as laminating, cutting, folding and calendering make up a greater proportion of the value of the product or package than the printing operation. 2.2.2.2 Profile of the Package/Product Rotogravure Segment As of 1994, the Gravure Association of America (GAA) estimated that rotogravure printing operations were conducted at 400 locations within the U. S.21 The EPA sent an information collection request (ICR) to approximately 80 parent companies thought to operate rotogravure printing equipment. Responses pertaining to rotogravure operations at more than 100 locations were received. In lieu of completing the ICR, nearly all of the companies chose to respond to a simplified question list developed by EPA with the assistance of GAA and the Flexible Packaging Association (FPA). A list of companies from which usable information was received is given in Table 2-2. These responses are included in the project docket. Specific descriptions of printed products and packaging are given for five substrate categories in Tables 2- 3 through 2-7. 2.2.2.3 Hap Use and Emissions. In product and packaging gravure facilities, HAP is contained in both the printing inks and in other materials (adhesives, coatings) that are applied as part of a continuous manufacturing process. One survey showed that the weight of coatings and lacquers applied in gravure packaging plants was almost as much as the weight of the ink.22 The predominant type of ink is based on nitrocellulose resin, with some polyamide inks. Solvent 2-11 ------- Table 2-2. Packaging/Product Gravure Responses (See Codes Following Table). Company Name Location Code AMGRAPH Packaging, Inc.VersaillesCTM Alcan Foil Products Louisville KY F Alford Packaging Baltimore MD P Allied Stamp Corporation Sand Springs OK P Alusuisse Flexible Packaging, Inc. Shelbyville KY M American Fuji Seal, Inc. Anaheim CA F American Fuji Seal, Inc. Fairfield NJ F American Greetings Corbin KY P Avery Dennison Clinton SC M Avery Dennison Framingham MA P Avery Dennison Schereville IN V Avery Dennison Corporation Pasadena CA W Butler Printing & Laminating, Inc. Butler NJ V CPS Corporation Franklin TN M Cello-Foil Products, Inc. Battle Creek MI M Chiyoda America Inc. Morgantown PA P Cleo, Inc. Memphis TN P Columbus Coated Fabrics Columbus OH V Congoleum Corporation Marcus Hook PA V Congoleum Corporation Mercerville NJ V Constant Services, Inc. Fairfield NJ V DRG Medical Packaging Madison WI M Decor Gravure Corporation Bensenville IL V Decorating Resources Clifton NJ F Decorative Specialties International, Inc.Johnston RI P Decorative Specialties International, Inc.Reading PA M Decorative Specialties International, Inc.West Springfield MA V Dinagraphics Norwood OH W Dittler Brothers Atlanta GA W Dittler Brothers Oakwood GA W Dopaco, Inc. Downingtown PA P Dopaco, Inc. Saint Claries IL P Dopaco, Inc. Stockton CA P Eskimo Pie Corporation Bloomfield NJ M Federal Paper Board Co., Inc. Durham NC P Federal Paper Board Co., Inc. Wilmington NC P Fleming Packaging Corporation Peoria IL M Fres-Co System USA, Inc. Telford PA F GenCorp Inc. Jeannette PA F GenCorp Inc. Salem NH V GenCorp Polymer Products Columbus MS V Graphic Packaging Corporation Franklin OH M Graphic Packaging Corporation Lawrenceburg TN P Graphic Packaging Corporation Paoli PA P Gravure Carton & Label Surgoinsville TN P Gravure Packaging, Inc. Richmond VA P Hallmark Cards Kansas City MO P Hallmark Cards Leavenworth KS P Hargro Flexible Packaging Edinburgh IN M Hargro Packaging Flemington NJ M International Label Company Clarksville TN P International Playing Card & Label CompanyRogersville TN P J. W. Fergusson and Sons, Inc. Richmond VA M JSC/CCA Carol Stream IL P JSC/CCA Lockland OH P JSC/CCA North Wales PA P 2-12 ------- Table 2-2. Packaging/Product Gravure Responses (concluded) JSC/CCA JSC/CCA James River Corporation James River Paper Company James River Paper Company James River Paper Company James River Paper Company James River Paper Corporation Jefferson Smurfit Corporation Jefferson Smurfit Corporation Johio, Inc. Koch Label Company, Inc. Lamotite, Inc. Lux Packaging Ltd. Mannington Mills, Inc. Mundet-Hermetite Inc. Newco Inc. Orchard Decorative Products Orchard Decorative Products Package Service Company Paramount Packaging Corporation Paramount Packaging Corporation Paramount Packaging Corporation Quick Roll Leaf Manufacturing Company Reynods Metals Company Reynolds Metals Company Reynolds Metals Company Riverwood international USA, Inc. Riverwood International USA, Inc. Riverwood international USA, Inc. Roslyn Converters Inc. Scientific Games, Inc. Scientific Games, Inc. Screen Art Screen Art Shamrock Corporation Shamrock Corporation Smurfit Flexible Packaging Smurfit Laminations Somerville Packaging Stone Container Corporation Technographics Printworld The C. W. Zumbiel Company Union Camp Corporation Union Camp Corporation Union Camp Corporation Vernon Plastics Company Vitex Packaging, Inc. Waldorf Corporation Waldorf Corporation Wrico Packaging P^Paper/Cardboard only F«Film/Foil only V=Vinyl product M=Paper/cardboard AND Foil/film W=miscellaneous, NEC Santa Clara CA P Stone Mountain GA P Hazelwood MO M Darlington SC P Fort Smith AR P Lexington KY P Portland OR M Kalamazoo MI P Chicago IL P Jacksonville FL W Dayton OH M Evansville IN M Cleveland OH W Waco TX P Salem NJ V Buena Vista VA P Newton NJ V Blythewood SC M St. Louis MO M Northmoor MO M Chalfont PA F Longview TX F Murfreesboro TN F Middletown NY F Richmond VA F Downingtown PA M Richmond VA M Bakersfield CA P Cincinnati OH P West Monroe LA P Colonial Heights VA P Alpharetta GA W Gilroy CA W Fulton NY M Moorestown NJ F Greensboro NC M Greensboro NC P Schaumburg IL M Elk Grove Village IL M Newport News VA P Louisville KY P North Monroe NC W Cincinnati OH P Asheville NC M Englewood NJ P Spartanburg SC P Haverhill MA V Suffolk VA M Chicago IL P Saint Paul MN P Chicago IL M 2-13 ------- 4J U 3 I 0, 0) 4J i id 2 >i C id ft £ o u •o M a) Si M & 04 £ en c fl en £ u « 04 •o M O ft i-l •>: B 4-> n [? ft •o id M 4J 0 fl 1 fl >! 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E 4J 0 Corpora lexible aminati X* J 0 4J 4J O-rl-rl 111 CO U U) en B •rl Cn en c « Cn o IB fl X ft u Cn IB TJ E ft rl •rl fl CnE O Ifl rH JJ X -H X 0 fa O id A 04 - rH E E •rl -rl fl O Cn M B O • •H U 4-> B « M rl ft Cn Cn UE C S-H -rl enw 4 of ftX X §u u fl « U 04 04 C X 0 o oi o •rl 4-> -rl fi-rl IH 2-17 ------- IQ 4J o 3 o QJ IQ o Q) c (0 ,_! Q) o (0 •H SB C •H 4J C •H CU IQ Q) •H •rH H -H U 10 0) M g (0 M c? 4J O a • r** l M 0) i— 1 •Q (0 EH 4>) U 3 0 M Oi 0) 4J (0 •P CO 0) g £* (0 ft e o o M M" 0) 0) O, O( O >i > -P MM W C Q) Q) C 0 B 4J 0 0) g .p o> w o o w (0 H U .J M •P Q) 0) W .Q 1 1 .Q O (0 (0 ftrH 0) 0) H M M 0) M 5 3 M > 0) > > 0) •H U W W-H M M i tT«H iH Q) M (0 4-> 4J -H -H -H 0) < Q Q Q h) Xi O O O M 0) «M 10 c 10 ^) 10 (0 •P -P -P (0 Cl fl) (0 Q) ,V Ai 0) U O O JS <0 W -H -H , >,<« W •P M M (0 0) 0) M 13 C 4J 4J M Q) OVH 4J 4J aj 4J C g 0 O ft (0 •H (0 iH H (0 C tytH ft-H (0 M-i tw g O Q) O O > i-H (0 U 1 1 -H C^ ^ jG jC ^^ M O O O (0 O £VH M M O TJ (0 Q) O U fl) C ft« W W Q (0 o o cj a •o rH M « . O U U > C C4J H H C -H 10 10 (X 0) 0) • g g W U <0 (0 U C O O-H H X! O O ft «>-H -H 10 0) ------- systems include aromatic, aliphatic and oxygenated hydrocarbon solvent inks, and water-based inks. Due to the wide variety of ink types and colors that are used in this segment of the printing industry, ink is typically received in drum (or smaller container sizes) and tote bins. Only rarely is bulk ink received and stored in tank farms. About 60 percent of the coatings used are petroleum-based waxes and hot melts. About 35 percent of the coatings are extrusion coatings, typically low density polyethylene (LDPE). The remaining 5 percent are solution coatings, typically applied to flexible packaging. The 25 percent of theextrusion coatings that are not LDPE consist of polyvinyl chloride (PVC), polyvinyl acetate (PVA), ethylene vinyl acetate (EVA) copolymers, high density polyethylene, and polypropylene.23 Folding Cartons. About half of the ink used for folding cartons is nitrocellulose based. The remainder is alcohol solvent and water based. On a weight basis, coatings and lacquers are about equal to ink use.24 Flexible Packaging. Solvent-based, nitrocellulose resin ink is the predominant type. Coatings and lacquers are only a third of the ink use, by weight.25 Some flexible packaging printers have switched from the traditional toluene solvent to non-HAP solvents such as iso- and normal-propyl acetate.26 The use of water-based inks in this industry segment is growing. At one company, all HAP except for glycol ethers have been eliminated.27 Labels and Wrappers. Nitrocellulose resin inks account for about half the inks used in this industry segment, with a wide variety of ink types accounting for the rest. Coatings and lacquers amounted to about 1.5 times the weight of ink used.28 Vinyl Products. In response to the ICR, vinyl product manufacturers reported use of methyl ethyl ketone, and methyl 2-19 ------- isobutyl ketone as the major HAP present in materials applied with rotogravure presses. Significant quantities of toluene and xylene were also used. 2.2.2.4 Baseline Emissions HAP emissions data are available for most of the facilities submitting data in response to the ICR. In some cases, responses were received, however, the HAP emissions data were not usable. This resulted from missing or ambiguous answers to questions relating to HAP usage and control efficiency. Specific data on control efficiency for HAP are not available. Data have been analyzed on the assumption that overall HAP control efficiency is equivalent to reported overall efficiency. These data are most often based on tests or vendor guarantees relating to VOC. In many cases, HAP makes up only a minor proportion of the VOC used on-press. Baseline emissions calculated from the responses to the ICR are given in Table 2-8. Analogous information given in Table 2-9 pertains to major sources as determined on the basis of actual HAP emissions. When potential-to-emit is considered there are more major sources. An upper bound on baseline emissions can be estimated by assuming that there are 400 product and packaging gravure facilities and that the facilities providing usable data in response to the ICR are representative of the total population. In this case, baseline emissions from product and packaging gravure would be approximately 32,000,000 Ib/yr. It is more likely that responses were obtained from larger facilities within the industry, and that baseline emissions are much lower. 2.2.3 Intaglio Plate Gravure Intaglio plate gravure or engraving, uses a flat copper plate on a sheetfed press. This process is used for currency, postage stamps, securities and stationery29. It makes up a small proportion of the gravure printing segment. 2-20 ------- Table 2-8. Baseline Emissions from Product and Packaging Rotogravure Responses. Industry Segment Paper /Cardboard Only Foil/Film Only Paper /Cardboard/ Foil/ Film Vinyl Product Miscellaneous Total Number of Usable Responses 40 10 27 10 9 96 HAP Emissions (Ib/yr) 2,004,000 597,900 2,598,000 896,500 1,465,000 7,561,000 Table 2-9. Baseline Emissions from Major Sources in the Product and Packaging Rotogravure Industries. Industry Segment Paper /Cardboard Only Foil/Film Only Paper / Cardboard/ Foi 1 / Fi 1m Vinyl Product Miscellaneous Total Number of Usable Responses 16 4 9 3 4 36 HAP Emissions (Ib/yr) 1,811,000 581,100 1,257,000 822,500 1,418,000 5,890,000 2-21 ------- 2.3 FLEXOGRAPHY Flexographic printing is considered to be the application of words, designs and pictures to a substrate by means of a printing technique in which the pattern to be applied is raised above the printing plate and the image carrier is made of rubber or other elastomeric materials.30 It has been estimated that there are 1,587 plants in the U. S. with flexographic presses.31 The major applications of flexographic printing are flexible and rigid packaging; tags and labels; newspapers, magazines, and directories; and paper towels, tissues etc. Because of the ease of plate making and press set up, flexographic printing is more suited to shortproduction runs than gravure. It is estimated that 85 percent of package printing is done by flexography.32 Flexographic inks must be very fluid to print properly. Flexographic inks include both waterborne and solvent based systems. Solvents used must be compatible with the rubber or polymeric plates; thus, aromatic solvents are not used. Some of the components of solvent based flexographic ink include ethyl, n-propyl and i-propyl alcohols; glycol ethers, aliphatic hydrocarbons, acetates and esters.33 Flexographic printing can be divided between publication and packaging/product printing. An alternate approach, and the one chosen for this project, is to divide between wide web and narrow web equipment with an 18 inch web width being an arbitrary cutoff between the two categories. Additional distinctions can be made on the "basis of web vs. sheetfed press equipment. 2.3.1. Wide Web (and Sheetfed) Flexocrraphic Printing Wide web flexographic presses are used to print flexible and rigid packaging; newspapers, magazines, and directories; and paper towels, tissues etc; and printed vinyl shower curtains and wallpaper. Corrugated cartons are one of the few substrates printed by sheetfed f lexography.34 Substrates include polyolefins, polystyrene, polyesters, glassine, 2-22 ------- tissue, sulfite, kraft and other paper stocks, aluminum foil, paperboard, corrugated, folding cartons, gift wraps, paper cups and containers.35 2.3.1.1 Process Description. Flexographic presses can be divided into three main types depending on the relative relationship of the print stations. Stack presses have individual print stations oriented vertically with the unwind and rewind sections on the same side of the print stations. Stack presses are easily accessible for rapid changeovers between pressruns. Common impression presses have the print stations around the circumference of a single large impression cylinder. The web is constantly supported between print stations, which is an advantage for printing on stretchable materials. In-line presses have the print stations in a horizontal row (the geometry is similar to rotogravure presses). These presses have an advantage when used with additional converting (such as cutting, gluing and laminating) equipment.36 2.3.1.2 Profile of Wide Web Flexoaraphic Segment. Most wide web flexographic printing facilities produce various types of packaging. Flexible packaging producers often operate both flexographic and rotogravure presses at the same facilities; the selection of equipment for a particular job depends on length of run, quality requirements and substrate. The printing component makes up a relatively minor part of the value of some types of packaging. Facilities that produce corrugated cartons and paper bags may not consider themselves to be printers. Large paper companies often operate many small facilities at locations around the country to serve local markets. Newspaper production makes up a small proportion of flexographic printing facilities. There are 35 flexographically printed newspapers in the U. S.37 This number is expected to grow as newspapers replace aging 2-23 ------- letterpress equipment. Several large newspaper chains use flexographic presses at multiple locations. The EPA sent an information collection request (ICR) to approximately 380 parent companies thought to operate flexographic printing equipment. Approximately 100 of these facilities were found to operate only narrow web presses; no information was collected from narrow web printers other than their names, addresses and numbers of employees. Responses pertaining to wide web flexographic printing operations at approximately 500 facilities were received. In lieu of completing the ICR, nearly all companies chose to respond to a simplified question list developed by EPA with the assistance of the Flexible Packaging Association (FPA). A list of the names and locations of facilities submitting information is given in Table 2-10. These responses, with the exception of confidential business information, are included in the project docket. 2.3.1.3 HAP Use and Emissions. HAP emissions result from components of ink (and other materials applied with flexographic plates, including varnishes, primers, and adhesives) and solvents used to clean presses and equipment. In the past, flexographic platemaking systems commonly used HAP; these systems are becoming rare as improved HAP free platemaking technologies have become available. Within the converting industry, printed substrates are formed or purchased then printed and converted to packaging such as bags or boxes. In many cases, the printing operation is a relatively small part of the processing which may include film blowing, laminating, coating, adhesive application, and cutting. Some or all of these processing operations are done at flexographic press stations or in-line with the presses. Converting operations done in conjunction with flexographic printing may result in additional HAP emissions. Most flexographic printing (including all flexographic newspaper and corrugated carton printing) is done with 2-24 ------- Table 2-10. Wide-Web Flexographic Printing Responses. Name Abbott Box Co. Inc. Action Packaging Acorn Corrugated Box Co. Advance Packaging Corporation Advance Packaging Corp. Akron Beacon Journal All-Pak, Inc. Alusuisse Flexible Packaging, Inc. Alusuisse Flexible Packaging, Inc. Alusuisse Flexible Packaging, Inc. American Greetings Corp American Greetings Corp. American National Can/Food Plastics American National Can/Food Plastics American National Can/Food Plastics American National Can/Food Plastics American National Can/Food Plastics American National Can/Food Plastics American National Can/Food Plastics American National Can/Food Plastics American Packaging Corp. American Packaging Corp. American Packaging Corp. American Packaging Corp. Amko Plastics, Inc. Anagram International, Inc. Arcata Graphics\Kingsport Arcon Coating Mills, Inc. Arkansas Poly, Inc. Atlanta Film Converting Co, Inc. Address 58 Teed Drive, Randolph, MA 02368 667 Atkins Avenue, Brooklyn, NY 11208 5133 H. 65th Street, Bedford Park, IL 60638 4450 36th Street, SE, P.O. Box 888311, Grand Rapids, MI 49588-8311 2400 E. High St., P.O. Box 730, Jackson, MI 49203 44 East Exchange St., Akron, OH 44309 5383 Truman Drive, Decatur, GA 30035 1403 Fourth Ave.,New Hyde Park, NY 11040 5303 St. Charles Road, Be11wood, IL 60104 6700 Midland Industrial Drive, Shelbyville, KY 40065 P.O. Box 1570, Corbin, KY 40702-5851 Hwy. 11 E ByPass, Afton, TN 37616 1300 S. River St., Batavia, IL 60510 1500 E. Aurora Ave., Des Moines, IA 50313 271 River St., Menasha, WI 54952 150 26th Ave. SE, Minneapolis, MN 55414 201 W. Madison St., Mount Vernon, OH 43050 1815 Marathon Ave.,Neenah,WI 54956 6590 Central Ave., Newark, NJ 94560 3600 Alabama Ave.,St. Louis Park, MN 55416 2900 Grant Ave., Philadelphia, PA 19114 125 W. Broad St., Story City, IA 50248 200 Continental Dr., Columbus, WI 53925 777 Driving Park Ave., Rochester, NY 14613 12025 Trilon Road, Cincinnati, OH 45246 7700 Anagram Drive, Eden Prairie, MN 55344 P.O. Box 711, Press and Roller Streets, Kingsport, TN 37662 3067 New Street, Oceanside, NY 11572 1248 So. 28th Street, Van Buren, AR 72956 1132 Pryor Rd., P.O. Box 6756, Atlanta, GA 30315 2-25 ------- Table 2-10. Wide-Web Flexographic Printing Responses (continued). Automated Packaging Systems, Inc. Automated Label Systems Co. Avery-Dennison, K & M Division Avery-Dennison Bagcraft Corporation of America Bancroft Bag, Inc Banner Packaging, Inc. Bell Packaging Corp Bingo Paper Inc. Bomarko, Inc Bonar Packaging, Inc. Bryce Corporation BRC, A Division of Bryce Corporation Bryce Corporation Johnson Bryce Corp. Bryce Dixico Tennessee Packaging Koch Container All-Size Corrugated Prods. Buckeye Container Buckeye Packaging Burrows Paper Corporation Burrows Paper Corporation Cadillac Products, Inc. Cadillac Products, Inc. Cadillac Products, Inc. Cello-Wrap Printing Company, Inc. Central States Diversified, Inc. Champion International Corp. Champion International Corp. 13555 McCracken Road, Garfield Heights, OH 44125 8400 Darrow Road, twinsburg, OH 44087 4100 Hwy 45 North, Meridian, MS 39305 4350 Avery Drive, P.O. Box 547, Flowery Branch, GA 30542 3900 West 43rd St., Chicago, IL 60632 425 Bancroft Blvd, West Monroe, LA 71291 3550 Moser Street, Oshkosh, WI 54901 3102 S. Boots St., Marion, IN 46953 801 River Drive So., Great Falls, MT 59405 1955 North Oak Road, P. O. Box K, Plymouth, IN 46563 2410 N. Lyndon, Tyler, TX 75702 450 S. Benton St., Searcy, AR 72143 75 Isabelle Street, Buffalo, NY 14207-0007 4505 Old Lamar and 3861 Delp Street, Memphis, Tennessee 38118 4224 Premier Street, Memphis, TN 38118 1300 South Polk St., Dallas, TX 75224 Hwy 11 Longmeadow Rd, Sweetwater, TN 37874 777 Old Dutch Road 14564 P.O. Box 4544, Lancaster, PA 17604 P.O. Box 16, 326 N. Hillcrest Drive, Woostor, OH 44691 12223 Marlboro Avenue, Alliance, OH 44601 101 Commerce Drive, Mt. Vernon, OH 43050 1722 53rd Street, Fort Madison, IA 52627 840 Woodrow St., S.W., Atlanta, GA 30310-3431 2005 S. Main St., Paris, IL 61944-2950 7000 East 15 Mile Rd, Sterling Heights, MI 48311-8012 110 N. Main, P.O. Box 32, Farmersville, TX 75442 5221 Natural Bridge, St. Louis, MO 63115 155 East Hanover Ave, Morristown, NJ 07960 1500 South 14th Street, Clinton, IA 52732 2-26 ------- Table 2-10. Wide-Web Flexographic Printing Responses (continued). Champion International Corp. Champion International Corp. Champion International Corp. Charleston Packaging Company, Inc. Clark Container, Inc. Cleo, Inc. Compak, Inc. Webcor Packaging Corp. Crystal Tissue Castle Rock Container Company C. P. C. Packaging, Inc. Cryovac Division Cryovac Division Cryovac Division Bemis Company, Inc. Bemis Company, Inc. Bemis Company, Inc. Bemis Company, Inc. Bemis Company, Inc. Bemis Company, Inc. Bemis Company, Inc. Bemis Company, Inc. Bemis Company, Inc. Bemis Company Inc. Bemis Company, Inc. Bemis Company, Inc. Bemis Specialty Films Bemis Curwood Bemis Curwood Bemis Milprint Bemis Milprint Cello-Foil Products, Inc. 7920 Mapleway Drive, Olmsted Falls, OH 44138 1901 Windsor Place, Fort Worth, TX 76110 600 Dairy Pak Road, Athens, GA 30607 4229 Domino Ave, North Charleston, SC 29405-7486 P.O. Box 160, Bates Crossing Industrial Park, Lyles, TN 37098 3963 Vernal Pike, Bloomington, IN 47402 8789 E. Lansing Road, Durand, MI 48429 1220 N. Center Road, Burton, MI 48509 1118 Progress Way, Maysville, KY 41056 P.O. Box 530 - Grove Street, Adams, WI 53910 214 Brace Ave., Eluria, OH 44035 1301 West Magnolia Avenue, Iowa Park, TX 76367 1125 Wilson Avenue, S.W., Cedar Rapids, IA 52406 P.O. Box 338 (803 N. Maple St.), Simpsonville, SC 29681 1401 West 3rd Avenue, Crossett, AR 71635 1975 Latham St., Memphis, TN 38106 2705 University Ave., Minneapolis, MN 55418 3514 South 25th St., Omaha, NE 68105 Sloan St., Peoria, IL 61603 Chapel Place, Pepperell, MA 01463 55 South Atlantic St., Seattle, WA 98124 1401 West 4th Plain Blvd, Vancouver, WA 98660 1000 East 13th St., Wichita, KS 67214 1350 North Fruitridge Ave., Terre Haute, IN 47808 Rt. 12 West, P.O. Box 475, Flemington, NJ 08822 Jaycee Drive, Hazleton, PA 18201 2450 Badger Avenue, Oshkosh, WI 54904 19th and Wall Sts., Murphysboro, IL 62966 718 High St., New London, WI 54961 590 Woodrow St., Denmark, WI 54902 1309 HWY 61 North, Lancaster, WI 53813 155 Brook Street, Battle Creek, MI 49017 2-27 ------- Table 2-10. Wide-Web Flexographic Printing Responses (continued). Custom Poly Bag, Inc. Dart Container Corporation Deco Paper Products, Inc. Design Containers, Inc. Dixico, Inc. Dynamic Packaging, Inc. Eisenhart Wallcoverings Co. Eskimo Pie Corporation Equitable Bag Co., Inc Excelsior Transparent Bag MFC Corp. Fabricon Products Fabricon Products Spec-Fab Fleetwood Container & Display fp Webkote, Inc. Spiralkote, Inc. Flex-Pak, Inc. Flexo Transparent, Inc. Focus Packaging, Inc. Fort Wayne Newspapers Frank C. Meyer Company, Inc. Gateway Packaging Gentry Poly Specialties, Inc. Georgia-Pacific Corp. Georgia-Pacific Corp. Georgia-Pacific Georgia-Pacific Corp Georgia-Pacific Corp Georgia-Pacific 9465 Edison Street, NE, Alliance, OH 44601 60 E. Main Street, Leola, PA 17540 1028 South Eighth Street, Louisville, KY 40203 2913 West Side Blvd., Jacksonville, FL 32209 276 S. Parkway West, Memphis, TN 38109 7875 School Road, Cincinnati, OH 45249 400 Pine Street, P.O. Box 464, Hanover, PA 17331 118 J.F. Kennedy Dr. North, Bloomfield, NJ 07003 7600 Empire Drive, Florence, KY 41042 159 Alexander Street, Yonkers, NY 10701 1721 W. Pleasant, River Rouge, MI 48218 4101 North American Street, Philadelphia, PA 19140 1818 Rowland Street, Riverton, NJ 08077 2721 E. 45th Street, Vernon, CA 90058 1016 S. W. Adams St., Peoria, IL 61602-1694 1200 Central Florida Parkway, Orlando, FL 32809 555 Branch Drive, Alpharetta, GA 30201 28 Wasson St, Buffalo, NY 14210 5207 Richland Ave., Kansas City, KS 66106 600 W. Main St., Fort Wayne, IN 46801 585 S. Union Street, Lawrence, MA 01843 P.O. Box 29, Granite City, IL 62040 P.O. Box 688, Route 2, Gentry, AR 72734 1500 Orchard Hill Drive, LaGrange, GA 30240 327 Margaret Street, Plattsburgh, NY 12901 P.O. Box 3333, Crossett, AR 71635 17 Forester Ave, Warwick, NY 10990 P.O. Box 919, Palatka, FL 32178-0919 RR6 Box 8, Riverside Lane, Brattleboro, VT 2-28 ------- Table 2-10. Wide-Web Flexographic Printing Responses (continued). Georgia-Pacific G-P Albany Plant G-P Asheboro Plant G-P Augusta Plant G-P Bradford Plant G-P Buena Park Plant G-P Canton Plant G-P Chicago Plant G-P Cincinnati Plant G-P Circleville Plant G-P Cleveland Plant G-P Cleveland Plant G-P Doraville Plant G-P Dubuque Plant G-P Franklin Plant G-P Huntsville Plant G-P Kansas City Plant G-P Lake Placid Plant G-P Madera Container Plant G-P Martinsville Plant G-P Memphis Plant G-P Milan Plant G-P Modesto Plant G-P Monticello Plant G-P Mt. Olive Plant G-P Mt. Wolf Plant G-P Olympia Plant G-P Ooltewah Plant G-P Oshkosh Plant 300 H. Laurel Street, Bellingham, WA 98225 405 Maxwell Drive, Albany, GA 31701 200 McDowell Road, Asheboro, NC 27203 Perkins & New Savannah Rd, Augusta, GA 30913 One Owen's Hay, Bradford, PA 16701 6300 Regio Avenue, Buena Park, CA 90620 2820 Hinfield Way, Canton, OH 44705 440 Bast 138th Street, Chicago, IL 60627 220 West North Bend Road, Cincinnati, OH 45216 2850 Owens Road, Circleville, OH 43113 4660 Brook Park Road, Cleveland, OH 44142 4200 Old Tasso Road, Cleveland, TN 37311 4600 NE Expressway, Doraville, GA 30340 2150 Kerper Boulevard, Dubuque, IA 52004 210 Grove Street, Franklin, MA 02038 3420 Stanwood Boulevard, Huntsville, AL 35811 8600 Northeast 38th Street, Kansas City, MO 64161 400 S.R. 70 West, Lake Placid, FL 33852 24600 Avenue 13, Madera, CA 93637 US 200 and Route 970, Martinsville, VA 24112 611 Winchester Road, Memphis, TN 38116 951 County Street, Milan, MI 48160 2400 Lapham Drive, Modesto, CA 95354 823 North Cedar Street, Monticello, IA 52310 Old Rt. 66 and 8th Street, Mt. Olive, IL 62029 25 Walnut Street, Mt. Wolf, PA 17347 1203 Fones Road, Olympia, WA 98501 5201 Ooltewah-Ringwold Road, Ooltewah, TN 37363 413 East Murdock Avenue, Oshkosh, WI 54902 2-29 ------- Table 2-10. Wide-Web Flexographic Printing Responses (continued). G-P Owosso Plant 465 S. Delaney Road, Owosso, MI 48867 G-P Schenectady Plant Building 801 Corporations Park, Schenectady, NY 12302 G-P Sheboygan Plant 1927 Erie Avenue, Sheboygan, WI 53082 G-P So. San Francisco Plant 249 East Grand Avenue, So. San Francisco, CA 94080 G-P Spartanburg Plant 3100 Southport Road, Spartanburg, SC 29304 G-P Valdosta Plant Highway 31 South, Clyattville, GA 31601 G-P Warren County Plant U.S. Highway 1, Hanson, NC 27553 G-P West Monroe Plant 400 Central Street, West Monroe, LA 71292 G-P Waxahachie Plant 5800 Hwy 35 East, Waxahachie, TX 75165 Gilman Converted Products 3201 McRae Highway, Eastman, GA 21023 Glenroy, Inc. W158 N9332 Nor-X-Way Ave., P.O. Box 534, Menomonee Falls, WI 53052-0534 Graphic Packaging Corporation 708 South Avenue, Franklin, OH 45005 Graphic Packaging Corp. Mathews and Cedar Hollow Road, P.O. Box 500, Paoli, PA 19301 Greif Bros. Corp 2750 - 145th Street West, Rosemount, MM 55068-4998 Gulf Coast Plastics Div. Dairy-Mix, Inc.9314 Princess Palm Ave., Tampa, FL 33619 Gulf States Paper Corp. 244 Warner Road, Maplesville, AL 36750 H. S. Crocker Co., Inc. 12100 Smith Drive, Huntley, IL 60142 Hallmark Cards Select Drive, Leavenworth, Kansas Hallmark Cards Eisenhower Road, Leavenworth, Kansas Hargo Flexible Packaging Corp County Line Road, Boyertown, PA 19512 Hargo Flexible Packaging Corp 1501 North Seventh Street, Harrisburg, PA 17102 Hargro Flexible Packaging U.S. 31 North, P.O. Box 188, Edinburgh, IN 46124 Hargro Health Care Packaging 3500 N. Kimball Avenue, Chicago, IL 60618-5508 Home Plastics, Inc. 5250 NE 17th St, DesMoines, IA 50313 Huntsman Packaging Products, Corp 8039 S. 192nd Street, Kent, Washington 98032-2162 Carolina Printing & Converting InterflexRt. 4 Box 4 Highway 268 West, Wilkesboro, NC 28697 International Paper 310 Airport Drive, Presque Isle, ME 04769 International Paper Auburndale International Paper Carson International Paper Chicago International Paper Cincinnati International Paper Dallas 2-30 ------- Table 2-10. Wide-Web Flexographic Printing Responses (continued). International Paper International Paper International Paper International Paper International Paper International Paper International Paper International Paper International Paper International Paper International Paper International Paper International Paper International Paper International Paper International Paper International Paper International Paper International Paper International Paper International Paper-Bag Pack International Paper-Bag Pack International Paper-Bag Pack International Paper-Bag Pack International Paper-Bag Pack International Paper-folding Cartons International Paper—Label Div International Paper-Specialty Div. International Paper-Specialty Div. International Paper-Specialty Div. International Paper-Specialty Div. Interstate Packaging Corp. James River Paper Company James River Paper Co James River Paper Co. James River Paper Co Inc Inc. James River Paper Co., James River Corp. Location 571 James River Paper Co James River Corporation James River Corp James River Corp James River Corp James River Paper Co., Detroit Edinburg El Paso Fond du Lac Geneva Georgetown Minneapolis Mobile Modesto Mt. Carmel Nashville Putnam Russellvile San Jose Shreveport Spring Hill Statesville Stockton Tallman Hooster Camden Jackson Mobile Pittsburg Wilmington Hopkinsville Peoria Menasha Lancaster Kaukauna Knoxville P.O. Box 271, Coldenham Road, Walden, NY 12586 Camas Mill; 4th and Adams; Canvas, HA 98607 P.O. Box 500, 126 A Avenue, Darlington, SC 29532 James River Corporation, 605 Kuebler Rd., Easton, PA 18042 4411 Midland Blvd., Fort Smith, AR 72904 1505 West Main Street, Greensburg, IN 47240 310 McDonnell Blvd., Hazelwood, 63042 451 Harbison Rd., Lexington, KY 40511 Creative Expressions3500 North Arlington Ave., Indianapolis, IN 46218 Canal Plant, 258 River Street, Menasha, WI 54952 River Road and Grantham Lane, Castle, DE 19720 400 Island Avenue, Parchment, MI 49004 Inc. North Portland Plant, 3400 N. Marine Drive, Portland, OR 97217 MO New 2-31 ------- Table 2-10. Wide-Web Flexographic Printing Responses (continued). James River 2424 SE Holgate, Portland, OR 97202 James River - Specialty Tabletop 18554 S. Susana Road, Rancho Dominguez, CA James River Corp. 2101 Williams Street, San Leandro, CA 94577 James River Paper Co. 210 Kansas City Ave., Shreveport, LA 71107 James River Corp - Wausau Plant 200 West Bridge Street, P.O. Box 1047, Wausau, WI 54402-1047 Smurfit Flexible Packaging 1228 E Tower Road, Schaumburg, IL 60173-4386 Jefferson Smurfit Corp 170 Lisle Road, Lexington, KY 40511 Jefferson Smurfit/Container Corp. of America601 Monster Road, SW, Renton, WA 98055 Smurfit Flexible Packaging 7074 W. Parkland Ct, Milwaukee, WI 53188 Jefferson Smurfit Corp 301 S Butterfield Road, Muncie, IN 47303 Jefferson Smurfit Corp 12005 N. Burgard Road, Portland, OR 97203 JSC/CCA 99 Harris Street, Fulton, NY 13069 JSC/CCA 8440 Tewantin, Houston, TX 77061 Jefferson Smurfit Corp./Container Corp. of AmericaShawnee & Ridge Road, Muskogee, OK 74401 Jefferson Smurfit Corp Sixth and Zschokke, Highland, IL 62249 Jefferson Smurfit Corp 122 Quentin Ave., New Brunswick, NJ 08901 Jefferson Smurfit Corp./Container Corp. of America577 Goddard Ave., Chesterfield, MO 63005 Jefferson Smurfit/Container Corporation of America265 W Trigg Avenue, Memphis, TN 38106 Jefferson Smurfit Corporation 3505 Tree Court Industrial Blvd., St. Louis, MO 63122 Jefferson Smurfit Corporation 201 S. Hillview Drive - Milpitas, CA 95035 Jefferson Smurfit Corp. 4600 Newlon Rd., Ft. Smith, AR 72914 Jefferson Smurfit Corp. 6701 South Freeway, Fort Worth, TX 76134 Jefferson Smurfit Corp. 3 N. Sherman Street, Anderson, IN 46016 Jefferson Smurfit 111 Folmar Parkway, Montgomery, AL 36105 Jefferson Smurfit Corp 75 Cascade Blvd, Milford, CT 06460 JSC/CCA 100 McDonald Boulevard, Aston, PA 19014 Jefferson Smurfit 41 Campion Road, New Hartford, NY 13413 Jefferson Smurfit Corporation 12200 Westport Rd., Louisville, KY 40245 Jefferson Smurfic Corp 8209 CR 131, Wildwood, FL 34785 Jefferson Smurfit Corporation 365 Audubon Road, Wakefield, MA 01880 2-32 ------- Table 2-10. Wide-Web Flexographic Printing Responses (continued). Jefferson Smurfit Corp Jefferson Smurfit Corp 4512 Anderson Road, Knoxville, TN 37918 2200 Industrial Dr., P.O. Box 2277, Jonesboro, AR72402 Jefferson Smurfit/Container Corp. of America2601 S. Malt Ave., Los Angeles, CA 90040 Container Corporation of America 6541 Eastern Avenue, Baltimore, MD 21224 Jefferson Smurfit/Container Corporation of AmericalSS N. Smith Street, Jefferson Smurfit Corp Jefferson Smurfit Corp. JSC/CCA Container Corporation of America JSC/CCA Jefferson Smurfit Corporation Jefferson Smurfit Jefferson Smurfit Corportion Jefferson Smurfit Corp Jefferson Smurfit Corp Jefferson Smurfit Corporation Jefferson Smurfit Corporation Jefferson Smurfit Corp Jefferson Smurfit Corp Jefferson Smurfit Corp./CCA Packaging Unlimited, Inc. Jefferson Smurfit Corporation John H. Harland Company Kookaburra USA LTD Kleartone, Inc. Lin Pac, Inc. Lin Pac Longhorn Packaging, Inc. Macon Telegraph Mafcote Industries Corona, CA 91720 301 E 144th Street, Dolton, IL 60419 2743 South Pierce Street, Dallas, TX 60419 2525 S. Sunland Avenue, Fresno, CA 93725 9960 Alliance Road, Cincinnati, OH 45242 975 North Freedom, Ravenna, OH 1201 East Lincolnway, LaPorte, IN 46350 N Pt. Blvd., Winston Salem, NC 1720 Ninth Avenue, Humboldt, TN 38343 1601 Tri View Avenue, Sioux City, IA 51103 Pearl and Central, Lancaster, NY 14086 775 South Linwood Road, P.O. Box 1268, Galesburg, IL 61402-1268 JSC Preprint, 9960 Alliance Road, Cincinnati, OH 45242 1125 Haley Road, Murfreesboro, TN 37133-0638 460 N Belcrest, Springfield, MO 65808 662 Washburn Switch Rd., Shelby, NC 28150 P.O. Box 5102, Pta de Tierra Station, San Juan, Puerto Rico 00906 2101 Rossville Ave, Chattanooga, TN 37408 293 Miller Rd, Decatur, GA 30035 1 Commerce Drive S, Harriman, NY 10926 695 Summer Avenue, Westbury, NY 11590 4200 Cambridge Road, Fort Worth, TX 76155 5725 Commerce, Morristown, TN 37814 110 Pierce Ave., San Antonio, TX 78208 120 Broadway, Macon. GA 31213 4525 N. Euclid Ave., St. Louis, MO 63115 2-33 ------- Table 2-10. Wide-Web Flexographic Printing Responses (continued). Mafcote/SWACO Mail-Well Envelope Maine Poly, Inc. Malnove, Inc. Marglo Packaging Corp. 101 Ascher Street., Quitman, MS 38355 4500 Tiedeman Road, Cleveland, OH 44144 P.O. Box 8, Route 202, Greene, ME 4115 University Blvd. Court West, Jacksonville, FL 32217 1522 Old Country Road, Plainview, NY 11803 Massillon Container 49 Ohio Street, Navarre, OH 44662 McClatchy Newspapers, Inc., dba The Modesto Beel325 "H" Street, Modesto, CA 95354 McClatchy Newspapers, Inc. dba The Fresno Beel626 E Street, Fresno, CA 93786 Mead Packaging 1105 Herndon Street, NW, Atlanta, GA 30318 Menasha Corporation Menasha Packaging - Neenah Plant, 1645 Bergstrom Rd., Neenah, WI 54957 Miami Herald Publishing Co. One Herald Plaza, Miami, FL 33032 Mid-West Poly Pak, Inc. P.O. Box 35, 89 Marion Street, Doylestown, OH 44230 Milwaukee Container 2800 W. Custer Avenue, Milwaukee, WI 53209 M.T.P. Industries, Inc. (Mason Transparent Pkg)1180 Commerce Avenue, Bronx, NY 10462 Neenah Printing - Wide Web Flexo Plant 1257 Gillingham Road, Neenah, WI 54957-0425 4848 South Hoyne Avenue, Chicago, IL 60609 701 "A" Street NW / Box 583, Auburn, WA 98002 2275 Commerce Drive, Fremont, OH 43420 2901 45W Bypass, Humboldt, TN 38343 1201 North Main Street, Viroqua, WI 54665 38 Depot Street, Nichols, WI 54152 Operator-1051 Bloomfield Rd., Bardstown, KY 40004 Midwest Film Corp Mohawk Northern Plastics, Inc. Moore, Business Forms and Systems NCR Corp. NCR - B.F.D. Nichols Paper Products Co., Inc. Owens-Illinois, Inc. Package Printing Co., Inc. Package Products Flexible Corporation Packaging Corp of America Packaging Corp of America Packaging Corp of America Packaging Corp of America Packaging Corp of America Packaging Corp of America Packaging Corp of America Packaging Corp of America Packaging Corp of America Packaging Corp of America Packaging Corp of America Packaging Corp of America 33 Myron Street, West Springfield, MA 01089 2203 Hawkins St., Charlotte NC 28203 Akron, OH Arlington, TX Ashland, OH Atlanta, GA Buffalo, NY Burlington, WI Colby, WI Denver, CO Garland, TX Gas City, IN Goldsboro, NC Grafton, WV 2-34 ------- Table 2-10. Wide-Web Flexographic Printing Responses (continued). Packaging Packaging Packaging Packaging Packaging Packaging Packaging Packaging Packaging Packaging Packaging Packaging Packaging Packaging Packaging Packaging Packaging Packaging Packaging Packaging Packaging Packaging Packaging Packaging Packaging Packaging Packaging Packaging Packaging Packaging Packaging Packaging Corp of America Corp of America Corp of America Corp of America Corp of America Corp of America Corp of America Corp of America Corp of America Corp of America Corp of America Corp of America Corp of America Corp of America Corp of America Corp of America Corp of America Corp of America Corp of America Corp of America Corp of America Corp of America Corp of America Corp of America Corp of America Corp of America Corp of America Corp of America Corp of America Corp of America Corp of America Industries, Inc. Packaging Materials Incorporated Packaging Products Corp. Packaging Products Corporation Packaging Products Corp. Packaging Specialties, Inc. Pacquet Oneida, Inc. Paramount Packaging Corp. Paramount Packaging Corp. Paramount Packaging Corp. Paramount Packaging Corp. Percy Kent Bag Co., Inc. Phoenix Packaging Phoenix Products Co., Inc. Grandville, MI Hanover, PA Harrisonburg, VA High Point, NC Honea Path, SC Jackson, TN Jacksonville, Knoxville, TN Lancaster, PA Los Angeles, CA MarshalItown, IA Miami, FL Middletown, OH Milwaukee, WI Minneapolis, MN Morganton, NC Newark, OH Newberry, SC Northhampton, MA Omaha, NE Opelika, AL Phoenix, AZ Pittsburgh, PA Piano, TX Plymouth, MI Richmond, VA Salisbury, NC Syracuse, NY Trexlertown, PA Vincennes, IN Winter Haven, PL 2450 Alvarado Street, San Leandro, CA 94577 62805 Bennett Avenue, Cambridge, OH 43725 1807 Parrish Drive, Rome, GA 30161 999 Lee Street, Elk Grove Village, IL 60007 6800 W. 61st St., Mission, KS 66202 P.O. Box 360, 1663 Armstrong Ave., Fayetteville, AR 72702-0360 10 Clifton Blvd., Clifton, NJ 07015 800 Jordan Vally Rosad, Longview, TX 76508 202 Oak Ave. Chalfont, PA 18914 720 Eagle Blvd. Shelbyville, TN 37160 106 Samsonite Blvd, Murfreesboro, TN 37130 5910 Winner Road, Kansas City, MO 64125 10949 91st Ave, N, Maple Grove, MN 55369 6161 N. 64th Street, Milwaukee, WI 53218 2-35 ------- Table 2-10. Wide-Web Flexographic Printing Responses (continued). Pioneer Balloon Company 2400 Pioneer Drive, El Dorado, KS 67042 Viskase Corp. 24th and O'Neal Streets, P.O. Box 250, Centerville, IA 52544 Plastic Packaging Corp 750 South 65th Street, Kansas City, KS 64111 Plastic Packaging, Inc. 1246 Main Ave., S.E., P.O. Box 2029, Hickory, NC 28603 Plicon Corp. 6001 River Road, Suite 300, Columbus, GA 31904 Poly Plastic Packaging, Inc. 510 Industrial Avenue, P.O. Box 219, Boynton Beach, FL 33425 Poly Plastic Packaging, Inc. 36-36 36th Street, Long Island City, NY 11101 Polyflex Film & Converting, Inc. 1301 Hwy 51 N, Summit, MS 39666 Press Telegram 604 Pine Avenue, Long Beach, California 90844 Procter and Gamble Co. 512 Liberty Expressway, Albany, GA 31703 Procter and Gamble Co. Mehoopany, PA 18629 Procter and Gamble Co. 501 Eastman Ave., Green Bay, WI 54302 Procter and Gamble Co. 800 North Rice Ave., Oxnard, CA 93010 Providence Journal Company 210 Kinsley Avenue, Providence, RI 02903 Rand -Whitney/Northeast Container 45 Industrial Way, Dover, NH 03820 Rand -Whitney/Southeast Container Corp. 455 Narragansett Park Dr.,Pawtucket, RI 02861 Rand -Whitney Container Corp. Agrand St., Worcester, MA 01607 Rex-Rosenlew International, Inc. 1308 Blair Street, Thomasville, NC 27360 The Robinette Company 250 Blackley Road, Bristol, TN 37625 Rock-Tenn Company 329 Industrial Park Road, Harrison, AR 72601 Rock-Tenn Company 525 West 19th Street, Chattanooga, TN 37408 Rock-Tenn Company 4691 Lewis Road, Stone Mountain, GA 30086 Rock-Tenn Company 302 Hartman Drive, P.O. Box 997, Lebanon, TN 37087 Rock-Tenn Company Forest Hills School Road, Marshville, NC 28103 Rock-Tenn Company 105 Tote - M Avenue, Eutaw, AL 35462 Rock-Tenn 198 Commerce, Conway, AR 72032 Rock-Tenn Company 6702 Hwy. 66W, Greenville, TX 75402 Rock-Tenn Company 302 Hartman Drive, P.O. Box 997, Lebanon, TN 37087 R. R. Donnelley 6 Sons Company Lancaster West Plant, 1375 Harrisburg Pike, Lancaster, PA 17601 Sealright Packaging Company 814 South First Street, Fulton, NY 13069 Sealright Packaging Co. 2925 Fairfax Road, Kansas City, KS 66115 2-36 ------- Table 2-10. Wide-Web Flexographic Printing Responses (continued). Sealright Packaging Co. Venture Packaging Jaite Packaging Packaging Industries, Inc. Selig Sealing Products, Inc. Solar Press Solo Cup Company Solo Cup Company Southern Colortype Co., Inc. Specialty Container Corporation Standard Packaging & Printing Corp. The Standard Register Company Sunrise Packaging, Inc. Superpac, Inc. Susan Crane, Inc. Teepak, Inc. Tennessee Press, Inc. Toph Toph Uniflex, Inc. Union Camp Corp. - Container Division Union Camp Corp Union Camp Corp Union Camp Corp. Union Camp Corporation Union Camp Corp. Union Camp Corp Union Camp Corp Union Camp Corp 4209 E. Noakes Street, Los Angeles, CA 90023 1600 Hestinghouse Blvd., Charlotte, NC 28273 1972 Akron-Peninsula Road, Akron, OH 44313 2450 Alvarado Street, San Leandro, CA 94577 342 E. Wabash, Forrest, IL 61741 1500 Shore Road, Naperville, IL 60563-1799 1951 Highway 304, Belen, New Mexico 87002 1501 E. 96th Street, Chicago, IL 60628 2927 Sidco Drive, Nashville, TN 37204 1608 Plantation Rd., Dallas, TX 75235 NC Hwy 73W, Mt. Gilead, NC 27306 Industrial Avenue, Rocky Mount, VA 24151 2025 W. South Branch Blvd., Oak Creek, WI 53154 1220 Industrial Boulevard, Southampton, PA 18966 8107 Chancellor Row, Dallas TX 75247 915 N. Michigan Avenue, Danville, IL 61832 1400 Sixth Avenue, Knoxville, TN 37917 1120 Heritage Drive, Osage, IA 50461-0119 1001 Rialto Rd., Covington, TX 38019 474 Grand Blvd., Westbury, NY 11590 1975 Lakeside Parkway SW 314, Tucker, GA 30084 W. Lathrop Ave., Savannah, GA 31402 345 Cedar Springs Rd., P.O. Box 5497, Spartanburg, SC 29302 Hazleton Plant, Maplewood Drive, Hazleton, PA 18201 501 Williams Street, Toman, WI 54660 901 Commerce Circle, Shelbyville, KY 40065 10801 lona Ave., Hanford, CA 93230 3100 Jim Christal Rd., Denton, TX 76207 2200 D. Avenue East, Freeman Field, Seymour, IN 47274 2-37 ------- Table 2-10. Wide-Web Flexographic Printing Responses (continued). Union Camp Corp 3055 Sweeten Creek Rd., Asheville, NC 28813 Union Camp Corp. Cloverdale Rd., P.O. Box 278, Sibley, IA 51249 Union Camp, Inc. 1829 Hwy. 35S, Monticello, AR 71655 Union Camp Corp Rt. 2, Box 433K, Tifton, GA 31794 Union Camp Corp., Richmond Retail Pkg. 2801 Cofer Road, Richmond, VA Union Camp Corp Viskase Corp. Vitex Packaging, Inc. Waldan Paper Services, Inc. Ward/Kraft, Inc. Western Publishing Co., Inc. Beach Products Wabash Pioneer Container Corp. Westvaco Envelope Division Westvaco Envelope Division Westvaco Envelope Division Westvaco Envelope Division Westvaco Envelope Division Westvaco Envelope Division Westvaco Envelope Division Westvaco Envelope Division Westvaco - Flexible Packaging Westvaco Container Division Westvaco Container Division Westvaco Container Division Westvaco Container Division Westvaco Westvaco Container Division Westvaco Container Division Westvaco Container Division Westvaco Container Division 23224 1304 Arthur K. Bolton Parkway, Griffin, GA 30223 24th & O'Neal Streets, P.O. Box 250, Centerville, IA 52544 1137 Progress Road, Suffolk, VA 23434 167 W. 28th Avenue, Oshkosh, WI 54901 2401 Cooper Street, P.O. Box 938, Fort Scott, Kansas 66701 1220 Hound Avenue, Racine, WI 53404 2001 Fulford, Kalamazoo, MI 49001 N143 W6049 Pioneer Road, Cedarburg, WI 53012 Springfield Plant, 315 Industry Avenue, Springfield, MA 01104-3246 Williamsburg Plant, Route 866, P.O. Box C, Williamsburg, PA 16693 Atlanta Plant, 5625 New Peachtree Road, Chamblee, GA 30341 North Chicago Plant, 1001 South Sheridan, North Chicago, IL 60064 Indianapolis Plant, 6302 Churchman Bypass, Indianapolis, IN 46203 Dallas Plant, 10700 Harry Mines Blvd., Dallas, TX 75220 Los Angeles Plant,2828 East 12th Street, Los Angeles, CA 90023 San Francisco Plant, 5650 Hollis Street, Emeryville, CA 94608 311 Industry Avenue, Springfield, MA 01101 3400 East Biddle Street, Baltimore, MD 21213 85 Dorothy Street, Buffalo, NY 14206 4400 West 45th Street, Chicago, IL 60632 2110 West 110th Street, Cleveland, OH 44102 Blue Springs Road, Cleveland, TN 37311 4847 Cargo Drive, Columbus, GA 31907 RR 2, Hwy 35, Eaton, OH 45320 601 North Modena Street, Gastonia, NC 28053 Empire Avenue, Meriden, CT 06453 2-38 ------- Table 2-10, Wide-Web Flexographic Printing Responses (concluded). Westvaco Container Division Westvaco container Division Westvaco, Liquid Packaging Division Weyerhaeuser Paper Company Weyerhaeuser Paper Company Weyerhaeuser Paper Company Weyerhaeuser Paper Company Weyerhaeuser Company/IMPAK Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Willamette Industries, Inc. Zim's Bagging Co., Inc. 2300 Jefferson Davis Hwy, Richmond, VA 23234 Flexpak Plant 2910, Cofer Road, Richmond, VA 23224 2828 Cofer Road, Richmond, VA 23224 100 Hawkes Street, Westbrook, ME 04092 950 Shaver Road NE, Cedar Rapids, IA 52402 6706 N. 23rd Street, Tampa, FL 33610 261 Broadway, P.O. Box 509, Franklin, KY 42134 5099 North Royal Atlanta Drive, Tucker, GA 30084 Beaverton, OR;P. O. Box G Buena Park, CA Dallas, TX Kansas City, MO Tacoma, WA Aurora, IL Beaverton, OR; P. O. Box 666 Bellvue, Wa Bellmawr, NJ Bowling Green, KY Cerritos, CA Compton, CA Dallas, TX Delaware, OH Elk Grove, IL Fort Smith, AR Golden, CO Griffin, GA Indianapolis, IN Kansas City, KS Lincoln, IL Louisville, KY Lumberton, NC Matthews, NC Memphis, TN Moses Lake, WA Newton, NC Sacramento, CA San Leandro, CA Sanger, CA Sealy, TX St. Paul, MN West Memphis, AR Tigard, OR 4200 Big Sandy Rd., Prichard, WV 25555 2-39 ------- waterborne inks. Waterborne inks are available for some applications which contain no HAP. Some waterborne inks contain relatively low proportions of HAP, principally ethylene glycol and glycol ethers. Most solvent based flexographic inks contain little or no HAP. Capture and control devices used with solvent based inks are usually designed, permitted and operated for VOC control. 2.3.1.4 Baseline Emissions from Wide Web Flexoqraphic Segment. HAP emissions data are available for most of the facilities submitting data in response to the ICR. In some cases, responses were received, however the HAP emissions data were not usable. This resulted from missing or ambiguous answers to questions relating to HAP usage and control efficiency. Nospecific control efficiency relative to HAP was requested. Data have been analyzed on the assumption that overall HAP control efficiency is equivalent to reported overall efficiency. These data are most often based on tests or vendor guarantees relating to VOC. In many cases, HAP makes up only a minor proportion of the VOC used on press. HAP emissions were calculated from wide-web flexographic press operations at 475 facilities. Most facilities reported data for calendar year 1992; in some cases data for more recent twelve month periods were reported. A total of 10 facilities were determined to be major sources on the basis of emissions of 25 tons of HAP per year, or 10 tons of any individual HAP per year. If major source status is determined by potential-to-emit, there will be a greater number of major sources. Baseline emissions are given in Table 2-11. 2.3.2 Narrow Web Flexooraphic Printing Narrow web flexographic presses are used principally for printing and adhesive application on tags and labels. The presses can be used to print on paper, foil, film or other substrates. Ink systems for narrow web flexographic printing can be similar to those for wide web; in addition, ultraviolet cure inks are used with some narrow web presses. 2-40 ------- Table 2-11. Baseline Emissions from Flexographic Printing. Number of Facilities Material Applied (Ib/yr) HAP Used (Ib/yr) HAP Emitted All Responses 485 176,000,000 2,350,000 1,680,000 Major Sources 10 10,200,000 827,000 706,000 Narrow web presses have the potential to emit relatively small quantities of HAP. These presses are sometimes operated with no capture or control systems. 2.4 LITHOGRAPHY Lithography is a planographic method of printing (in contrast to gravure, in which the image is etched into the plate or flexography, in which the image is raised above the surface of the plate). The plate surface is divided between water repellent (ink receptive) and water receptive (ink repellent). In offset lithographic printing, ink is transferred from the plate to a rubber blanket cylinder. The blanket cylinder is used to print the substrate38. An extensive discussion of the processes, equipment, inks, and other substances with the potential to result in HAP emissions is given in the Control Techniques Guideline for Offset Lithographic Printing39. There are over 54,000 lithographic printing plants in the US, which supply about 50 percent of the market for printing. About 91 percent of printing facilities have lithographic presses40. The lithographic printing industry is divided on the basis of press equipment between sheet-fed, non-heatset web and heatset web printing. The CTG41 makes a further distinction between newspaper non-heatset web and non- newspaper non-heatset web printing. 2-41 ------- 2.4.1 Sheet-fed Lithography About 92 percent of the facilities with lithographic presses have sheetfed lithographic presses. Sheetfed presses are used to print on metal, paper, cardboard, foil and film. Commercial printing (e. g. advertising, brochures, annual reports, business forms, etc.) is usually done by sheetfed lithography42. Organic emissions can arise from inks, fountain solutions and cleaning chemicals, although potential HAP emissions come primarily from fountain solutions. Sheet-fed lithographic inks contain phenolic, maleic-modified or rosin-ester resins dissolved in vegetable drying oils (e. g. linseed and soya) and diluted with hydrocarbon solvents43. Most inks used in sheetfed printing contain less than 25 percent VOC44, and no HAP. Fountain solutions are used to dampen the printing plates to make the non-image areas repellent to ink. Traditionally, these solutions were primarily isopropanol and water with some added resins and buffering salts. These solutions contain no HAP. In an attempt to reduce VOC emissions, alcohol substitutes which often contain glycols and glycol ethers, which are HAP, are now in use. Generally, no attempt has been made to capture glycol ethers emitted from sheetfed lithographic printing. Refrigeration of the fountain solutions is a practical means to control emissions of VOC from this source, but lower VOC, HAP containing alternatives have been adopted in some cases as an alternative to refrigeration of higher VOC, no HAP solutions. Solvents used for press clean-up are usually kerosene type high boiling point hydrocarbons, sometimes mixed with detergents45. These materials can contain up to 100 percent VOC but are generally free of HAP. 2.4.2 Non-Heatset Web Lithographic Printing Non-heatset web lithography is used to print newspapers, journals, directories and forms. It is estimated that there 2-42 ------- are 4950 plants with non-heatset web lithographic presses46. The ink used is similar to that used in sheetfed lithography and generally contains less than 35 percent VOC47. Fountain solutions and clean-up solvents are similar to those used in sheet-fed lithography. The main source of HAP from this process is low VOC fountain solutions which contain glycols and glycol ethers. Typically no controls for HAP are used. Refrigeration of the fountain solutions is a practical means to control emissions of VOC from this source, but lower VOC HAP-containing alternatives have been adopted in some cases as an alternative to refrigeration of higher VOC, no HAP solutions. 2.4.3 Heatset Web Lithographic Printing Heatset web lithography is used to print magazines, periodicals and catalogs. It is estimated that there are 1376 plants with heatset web lithographic presses48. The inks are about 40 percent VOC and contain high boiling petroleum distillates, resins and pigments. In general, there are no HAP in the ink. Fountain solutions and clean-up solvents are similar to those used in sheet-fed lithography. The main source of HAP from this process is low VOC fountain solutions which contain glycols and glycol ethers. Capture systems for heatset lithographic presses are used to collect drier exhaust gases, which contain about 20 percent of the VOC in the ink. Control system options include thermal incinerators, catalytic incinerators, condenser filters with activated carbon and condenser filters without activated carbon. VOC control efficiencies are estimated at 98 percent for incinerators, 95 percent for condenser filters with activated carbon and 90 percent for condenser filters without activated carbon49. It should be noted that there are no performance test data relating to HAP control efficiencies. Refrigeration of the fountain solution is a practical means to control emissions of VOC from this source, but lower VOC HAP-containing alternatives have been adopted in some 2-43 ------- cases as an alternative to refrigeration of higher VOC, no HAP solutions. Clean-up solvents which contain no HAP, or only very low levels of HAP are available. 2.5 LETTERPRESS Letterpress printing uses a relief printing plate as does flexography and viscous inks similar to lithographic inks. Various types of letterpress plates are available. These plates differ from flexographic plates in that they have a metal backing. Both sheetfed and web presses are in use. Web letterpress equipment using heatset and non-heatset inks is in use. Newspapers were traditionally printed by web non-heatset letterpress, however these are gradually being replaced by flexographic and lithographic presses. Letterpress is used to print newspapers, magazines, books, stationery and advertising. It is estimated that there are about 21,000 plants with letterpress equipment of which about 19,000 have sheetfed letterpress equipment50. 2.5.1 Non-heatset Letterpress Non-heatset web letterpress ink is similar to non-heatset lithographic ink differing mainly in that it contains less low viscosity mineral oils and more vegetable oils and high viscosity mineral oils51. No fountain solutions are required. Cleaning solvents are similar to those used in lithography. This process can be almost entirely HAP free. Non-heatset letterpress equipment typically has no emissions control systems. Non-heatset sheetfed letterpress ink varies depending upon factors including the substrate printed, the type of plate and press, and the press speed. In most applications, this process can be almost entirely HAP free and is typically conducted with no control system. No fountain solutions are required. Cleaning solvents are similar to those used in lithography. "Moisture set" inks used in some packaging applications contain triethylene glycol, which is a HAP. "Water washable" letterpress inks are sometimes used for 2-44 ------- printing kraft paper and corrugated boxes. These inks contain glycol based solvents which may contain HAP. 2.5.2 Heatset Letterpress Heatset letterpress is used for publication printing on coated papers. Heatset letterpress ink is similar to heatset lithographic ink. These inks contain resins dissolved in aliphatic hydrocarbons. These inks are dried in hot air ovens; drier exhausts can be ducted to VOC control systems. The inks can be entirely HAP free. No fountain solutions are required. Cleaning solvents are similar to those used in lithography. 2.6 SCREEN PRINTING Screen printing processes involve forcing ink through a stencil in which the image areas are porous. The screens are generally made of silk, nylon or metal mesh. Screen printing is used for signs, displays, electronics, wall paper, greeting cards, ceramics, decals, banners and textiles. It has been estimated that there are more than 40,000 screen printing plants in the U. S., nearly half of which print textiles52. Ink systems used in screen printing include ultraviolet cure, waterborne, solvent borne and plastisol with plastisol (polyvinyl chloride) being mainly used in textile printing. Solvent based ink systems contain aliphatic, aromatic and oxygenated organic solvents. Both sheetfed and web presses are used. Depending on the substrate printed, the substrate can be dried after each station or, for absorbent substrates, after all colors are printed. Solvent and waterborne inks are dried in hot air or infrared drying ovens. Dryer gases are partially recycled and partially vented (either to the atmosphere or to a control system). Both thermal and catalytic oxidizers are in use on screen printing dryer exhausts for solvent borne ink systems. Overall control efficiencies of 70 to 80 percent are achievable53. 2-45 ------- 2.7 OTHER PRINTING PROCESSES Plateless printing technologies are relatively new processes used primarily for short runs on paper substrates. These processes include electronic (e.g., laser printers), electrostatic (e.g., xerographic copiers), magnetic, thermal (e.g., facsimile machines) and ink jet printing. In 1991, plateless printing processes accounted for 3 percent of the total value of printing54. Electrostatic toners and ink jet printer inks may contain HAP, however the quantities emitted at any location are small. 2.7 REFERENCES 1. U. S. Environmental Protection Agency. Use Cluster Analysis of the Printing Industry, Draft Final Report. Washington, DC. May 26, 1992. p. 8. 2. Documentation for Developing the Initial Source Category List. U. S. Environmental Protection Agency, Research Triangle Park, NC. EPA-450/3-91-030. December, 1991. 3. Publication Rotogravure Printing - Background Information for Proposed Standards. U. S. EPA. Research Triangle Park, NC. EPA-450/3-80-031a. October, 1980. pp2-l to 4-40. 4. Edgerton, Stephen, Joanne Kempen and Thomas W. Lapp. The Measurement Solution: Using a Temporary Total Enclosure Method for Capture Efficiency Testing. EPA-450/4-91-020. August 1991. 5. Reference 3, p. 3-7. 6. Profile Survey of the U. S. Gravure Industry; A Market Study of Industries Using Gravure and a Profile of Equipment, Cylinders, Ink and Substrates. Gravure Association of America. 1989. p. PRESS-18. 7. Reference 6, p. SUM-10. 8. Memorandum from Green, D., RTI, to D. Salman, EPA/ESD. April 6, 1993. Summary of meeting with EPA, RTI, and representatives of the Flexible Packaging Association, Research Triangle Park, NC. 9. Reference 6, p. MAR-56. 10. Reference 6, p. MAR-67. 2-46 ------- 11. Reference 6, p. MAR-72. 12. Reference 6, p. SUM-12. 13. Reference 6, p. MAR-79. 14. Reference 6, p. MAR-86. 15. Reference 6, p. MAR-87. 16. Reference 6, p. SUM-14. 17. Reference 6, p. MAR-97. 18. Reference 6, p. SUM-16. 19. Reference 6, p. SUM-18. 20. Reference 6, p. SUM-21. 21. Memorandum from Green, D., RTI, to D. Salman, EPA/ESD. September 12, 1994. Summary of Meeting with Representatives of the Gravure Association of America. 22. Reference 6, p. INK-5. 23. Reference 6, p. INK-11. 24. Reference 6, p. INK-6. 25. Reference 6, p. INK-8. 26. Memorandum from Green, D., RTI, to Salman, D., EPA/CPB. July 30, 1993. Summary of meeting with Representatives of the Flexible Packaging Association. 27. Reference 26. 28. Reference 6, p. INK-9. 29. Reference 6, p. MAR-126. 30. Reference 2. 31. Reference 1, p. 15. 32. Mulvihill, Donna C. Flexography Primer, Graphic Arts Technical Foundation, Pittsburgh, PA. 1985. p. 57. 33. Printing Ink Handbook, Fifth edition. National Association of Printing Ink Manufacturers, Inc. Harrison, NY. 1988. p. 38. 2-47 ------- 34. Reference 32, p. 60. 35. Reference 32, p. 60-64. 36. Reference 32, p. 49-50. 37. Cunningham, Elizabeth. Flexo in Flux. American Ink Maker. June 1992. pp. 52. 38. U. S. Environmental Protection Agency. , Control of Volatile Organic Compound Emissions from Offset Lithographic Printing -Draft. Research Triangle Park, NC. September, 1983. p. 2- 1. 39. Reference 38, 235 pp. 40. Reference 1, p. 63. 41. Reference 38, p. 2-4 42. Reference 33, p. 34. 43. Kirk-Othmer Encyclopedia of Chemical Technology, Third Edition. "Inks". New York, NY. 1982. p. 374. 44. Reference 38, p. 2-8. 45. Reference 38, p.2-4. 46. Reference 1, p. 63. 47. Reference 38, p. 3-37. 48. Reference 1, p. B-28. 49. Reference 38, p.4-1 to 4-14. 50. Reference 1, p. 101. 51. Cunningham, H. W. Nonheatset Web Printing, in Bunicore, A. and W. T. Davis. Air Pollution Engineering Manual. New York, NY. 1992. 52. Kinter, Marcia. Screen Printing, in Bunicore, A. and W. T. Davis. Air Pollution Engineering Manual. New York. NY. 1992. 2-48 ------- 53. Reference 52. 54. Reference 1, p. 40. 2-49 ------- 3.0 CONTROL TECHNOLOGY AND PERFORMANCE OF CONTROLS 3.1 INTRODUCTION There are two approaches to limitation of HAP in the printing and publishing industry. The first approach is to improve capture and control systems or to add control devices where none are in use. Capture and control can be addressed separately, although in many cases, improved capture is achieved through an increase in the amount of air handled. This can necessitate upgrades to existing control devices. The second approach, focusing on pollution prevention, is to substitute low HAP or HAP-free materials for materials (inks, coatings, varnishes, adhesives, primers, etc.) presently in use. 3.2 CAPTURE SYSTEMS Capture systems are designed to collect solvent laden air and direct it to a control device. In heatset printing processes, solvent is removed from the printed substrate by evaporation in a dryer. The exhaust from the dryer can be ducted to a control device. Additional systems are often used to collect solvents which evaporate from other parts of the printing press, as well as those which escape from the dryer. In addition, pressroom ventilation air can be exhausted to a control device. Differences in capture efficiency contribute much more to the variation in overall efficiencies than the choice of control device. Reported capture efficiencies ranged from estimates of less than 50 percent to the 100 percent capture which is assumed for systems meeting the requirements of permanent total enclosures. Test procedures have been established for determining capture efficiency1 and for confirming the presence 3-1 ------- of permanent total enclosures.2 Capture systems can be improved through collection of additional solvent laden air from the press area and through construction of additional hooding and press enclosures. In theory, capture can be improved to (nearly) 100 percent for any press or pressroom by retrofitting walls and increasing ventilation to meet the requirements of permanent total enclosures. In practice, it may be prohibitively expensive to retrofit some existing facilities. 3.2.1 Publication Rotogravure. Within the publication rotogravure industry, all presses have dryer exhaust gases routed to the solvent recovery system. Based on responses to the voluntary question list developed by the EPA and the GAA, additional capture systems in place were described as dryer hood systems, partial upper deck enclosures, full upper deck enclosures, enclosed presses, permanent total enclosures, room enclosures, rooms operated under negative pressure and floor sweeps. It is not known whether the capture systems described as enclosed presses and room enclosures meet the EPA definition of permanent total enclosure3. Typically, solvent laden air captured from several presses is combined and treated with a common solvent recovery system. The individual presses may have different capture devices, and different capture efficiencies. 3.2.2 Product and Package Gravure. In the product and package gravure industry, many facilities use low VOC (and low-HAP) inks and coatings. Dryer exhausts from these facilities may be captured and vented to the atmosphere without the use of a control device. Where solvent based inks are in use, more elaborate capture and control systems may be required. Capture systems in use at product and packaging gravure facilities include combinations of dryer exhausts, floor sweeps, collection ducting, hoods, press enclosures, total enclosures, room enclosures, negative pressure pressrooms, partial enclosures and ink pan covers. With the exception of total enclosures, none of these technologies has a precise 3-2 ------- definition with regard to capture efficiency. In many cases terms are used interchangeably. Where control devices are in use, solvent laden air from several presses may be combined and ducted to a common control device. 3.2.3 Wide-web Flexoaraphic Printing. Capture systems in use at flexographic printing facilities include combinations of dryer exhausts, floor sweeps, hoods, and total enclosures. Capture efficiencies of between 50 and 100 percent were reported, although many respondents did not report capture efficiencies.Many facilities, including most sheetfed corrugated box facilities have no capture systems and rely on pressroom exhaust to the atmosphere to dilute the small amount of HAP present in the ink. 3.3 CONTROL DEVICES The control devices in use in rotogravure and flexographic printing processes include carbon adsorption, thermal incineration and catalytic incineration. The selection of a control device is influenced by the type of inks (and other materials) applied on the press, the volume of solvent laden air to be treated and the operating schedule of facility. Design procedures and limitations for these control devices are given in ! the EPA Control Technologies Handbook4. 3.3.1 Carbon Adsorption. Activated carbon is a material with a high surface area which adsorbs many organics from air streams. Typically, solvent laden air is passed through two or more fixed beds of granular activated carbon. Organic HAP in the air is adsorbed on active sites on the carbon, until, at some point the capacity of the carbon is exhausted, and the organics pass through unadsorbed. Adsorbers are operated in parallel so that when the capacity of one unit is exhausted, it can be removed from service and a second adsorber can be put into service. The exhausted carbon in the first adsorber is then regenerated5. In contrast to incineration techniques, carbon adsorption does not destroy the HAP in the treated air. Carbon adsorbers in 3-3 ------- the printing industry are regenerated by passing steam through the carbon beds. The HAP is removed from the carbon, and transferred to the steam. The steam-HAP mixture is then condensed, and the solvent separates from the water. The solvent can then be decanted for sale or reuse. Carbon adsorption systems can achieve control device efficiencies of 95 to 99 percent for some organic HAP6. These systems are most suitable for solvent systems which are immiscible with water, such as toluene and xylene. They are not recommended for ketones such as methyl ethyl ketone and methyl isobutyl ketone. 3.3.2 Thermal Incineration Thermal incinerators are control devices in which the solvent laden air is preheated and the organic HAP are ignited and combusted to carbon dioxide and water. Dilute gas streams require auxiliary fuel (generally natural gas) to sustain combustion. Various incinerator designs are used by different manufactures. The combustion chamber designs must provide high turbulence to mix the fuel and solvent laden air. The other requirements are a high enough temperature and a long enough residence time to insure essentially complete combustion. Thermal incinerators can be operated to achieve a wide range of control device efficiencies7. Efficiencies of 98 percent* to greater than 99 percent are possible9. Because the incinerator must be in operation at times when HAP emissions are very low (e. g. when presses are on standby between jobs) supplemental fuel requirements will vary. Incinerators are supplied with controls to start-up and bring the combustion chamber to the proper temperature. These controls can provide an interlock to prevent operation of the press until the incinerator temperature is adequate to insure destruction of HAP. 3.3.3 Catalytic Incineration Catalytic incinerators are control devices in which the solvent laden air is preheated and the organic HAP are ignited and combusted to carbon dioxide and water. In the presence of a 3-4 ------- catalyst, this reaction will take place at lower temperatures than those required for thermal incineration. Temperatures between 350 and 500 degrees Celsius are common. The catalysts are metal oxides or precious metals where are supported on ceramic or metallic substrates. Catalytic incinerators can achieve control device efficiencies of 95 to 99 percent10. From an operational standpoint, the lower reaction temperature means that the requirement for supplemental fuel is reduced or eliminated during normal operation. The lower operating temperatures will also decease the formation of oxides of nitrogen. The use of a catalyst is inconsistent with certain ink formulations. Chlorinated solvents and some silicone ink additives can poison or deactivate catalysts. Design of catalytic incinerators varies from manufacturer to manufacturer. The major differences involve the geometry of the combustion chamber, the type of catalyst and support material, and the type of contact between the gas and the catalyst. 3.4 PERFORMANCE OF CONTROLS 3.4.1 Publication Gravure The 27 plants currently operating in the U. S. all use toluene based ink systems, and operate solvent recovery systems which include fixed bed activated carbon adsorption units which are regenerated with steam. Recovered solvent is added to the as-purchased ink to adjust the viscosity as necessary. Excess recovered solvent is sold back to the ink manufacturers. Press capture systems vary depending on the age of the press, however the majority of the solvent is captured through the dryer exhausts. A total of 31 separate solvent recovery systems are in service at the 27 publication gravure plants. In addition, some plants have substituted non-HAP solvents for a portion of the toluene based solvent in publication gravure ink. Catalytic and thermal oxidation systems are technically feasible for control of publication gravure emissions. These technologies 3-5 ------- offer little or no potential improvement in control and have economic disadvantages as they destroy rather than recover the solvent. The control devices in use at all publication gravure facilities are similar in design and operation. Capture efficiencies of between 85 and 100 percent were reported, however this information was not available for the majority of the presses. Control device efficiencies of 95 to 99.9 percent were reported, however, these data were not reported for all control systems. The median control efficiency reported was 98 percent. One solvent recovery system manufacturer estimates control device efficiencies for publication gravure systems at 97 to 99 percent. This estimate excludes solvent retained in the web equal to between 1 and 5 percent of that applied11. This indicates a maximum expected overall efficiency of 98 percent (i.e. 99 percent control of the 99 percent of the HAP which is not retained). Excluding that portion of the HAP which is retained in the web and emitted after it leaves the press, control device efficiencies can theoretically be improved with thicker carbon beds. Improvement in capture efficiency is expected to be more cost effective in many cases, as capture efficiencies of close to 100 percent have been achieved using total enclosures. Overall efficiencies, based on liquid-liquid mass balances were reported for all control systems. Overall efficiency represents the product of capture efficiency and control device efficiency. These involve determinations of total VOC present in purchased ink and other VOC containing materials, inventories of solvent recovery and use through tank level measurements, and flow meters on ink distribution and recovered solvent purchases. These balances are conducted frequently by all facilities, and are typically reported as monthly averages. Long term averages are highly accurate as noise from measurement errors is averaged out. The nature of the testing, i. e. material balance, eliminates much of the error associated 3-6 ------- with sampling and analysis of stack emissions. Analyses of VOC and HAP content of inks and other materials are, however, subject to chemical analysis errors. On an annual basis, overall efficiencies were reported in the range of 83 to 109 percent. It should be noted that the system reporting 109 percent overall efficiency is able to achieve a solvent recovery of over 100% by drawing air from a pressroom controlled by a separate control system, containing presses with a lower capture efficiency. Thus, this control system actually recovers fugitive emissions from a separate source, in addition to the emissions from the presses that it controls. All facilities reported overall efficiencies achieved in 1992, and provided the range of overall efficiencies achieved determined on a monthly basis for 1992. Since some facilities operate more than one control system, data from 33 control systems were reported by the 27 facilities. The range of overall control data reported for these control systems in the voluntary responses provided to EPA is given in Table 3-1. Table 3-1. Overall Control Efficiencies Reported for Publication Gravure Plants. Basis of Ranking Overall Control Best System Median System Worst System Best Month % 115 94 85 Annual Average % 109 91.8 83 Worst Month % 96 88 78 3.4.2 Product and Packaging Gravure Product and packaging gravure facilities use a variety of ink systems. Inks in use include toluene based inks which are similar or identical to those used in publication gravure (See 3-7 ------- section 3.4.1), high VOC solvent based inks with very low or no HAP content, waterborne ink with low VOC and low HAP content and waterborne ink with low VOC and no HAP content. The type of ink used is influenced by factors including the nature of the substrate printed, the type of product or package printed, the age of the press and existing air pollution regulations and permit requirements related to VOC emissions. Product and packaging rotogravure ink can contain HAP such as toluene, hexane, methyl ethyl ketone, methyl isobutyl ketone, methanol and glycol ethers as well as non-HAP VOC such as ethyl acetate propyl acetate and butyl acetate. The control technologies employed are influenced by the type of ink used. Existing control technologies for product and packaging rotogravure are directed to control of VOC. In most cases, the HAP and non-HAP portion of the VOC present in the ink are equally difficult to control. Based on data submitted in response to the ICR, control devices in use at product and packaging gravure facilities include carbon adsorption, catalytic incineration, fume incineration, fume/vapor incineration, (unspecified) incineration, fumes burned in boiler, periodic recuperative thermal oxidation, recuperative incineration, regenerative thermal oxidation and regenerative thermal incineration. These terms refer to devices which can be divided into three groups: carbon adsorption, thermal incineration and catalytic incineration. Emissions data submitted in response to the ICR are based on emissions tests, equipment vendors guarantees and various types of engineering estimates. In all cases, emissions test data refer to VOC emissions. It is assumed that recovery or destruction of VOC is equivalent to that for HAP. Capture efficiencies of between 30 and 100 percent were reported, although many respondents did not report capture efficiencies. Control device efficiencies of between 89 and 100 percent were reported by respondents reporting non-zero control device 3-8 ------- efficiencies. Control device efficiencies were not reported by all facilities which operate control devices. Data on overall efficiency were reported for 87 control systems. Some facilities responding to the ICR did not operate control systems. The 87 systems for which usable data were available claimed overall efficiencies of between 45 and 100 percent. The basis for the estimates vary. Where solvent recovery systems are in place the overall efficiencies are typically determined by liquid-liquid mass balances (as described in Section 3.4.2). If total enclosures are in place capture efficiency is assumed to be 100 percent; control device efficiency is calculated. For catalytic and thermal incineration control devices test data is available for overall efficiency in some cases and for control device efficiency in others. Where test data is available for destruction across the control device, capture efficiencies are often estimated using engineering judgment. Overall efficiencies incorporate these judgments. In many cases, either the control device efficiency or the capture efficiency was based on vender guarantees and the overall efficiency was estimated. In general, when operated as designed, control devices will out-perform vender guarantees on an average basis. It should be noted that the accuracy of the reported overall efficiencies varies. In addition to the (presumably biased low) data based on vendor guarantees, estimates made by operating personnel of capture efficiency may not be realistic. There is, however, less likelihood of a consistent bias (high or low) in these estimates. Overall efficiency data were reported for 87 control systems. Other facilities had no control devices in place. These data are of variable reliability, as described above. In addition it should be recalled that reported efficiency data pertain to VOC control and that the applicability of these data to the HAP portion of the VOC has not been determined. The range of overall efficiencies for carbon adsorption, catalytic 3-9 ------- incineration and all other types of incineration are given in Table 3-2. Table 3-2. Overall Efficiencies Reported for Product and Packaging Gravure Facilities with Control Systems. Control Device Carbon Adsorption Catalytic Incineration Thermal Incineration Number of Systems 22 24 41 Minimum Efficiency 45 65 47.5 Average Efficiency 79.8 85.4 83.6 Maximum Efficiency 100 99.2 99.2 The range of control device efficiencies for the systems where these data are reported is given in Table 3-3. Overall efficiencies reported for three specific industry segments are given in Table 3-4. These data are also given for the major sources (as determined by actual HAP emissions) in the industry segments. 3.4.3 Wide-web Flexoaraphic Printing Flexographic printing facilities use a variety of ink systems. Solvent based inks are primarily formulated with non- HAP solvents which may contain small proportions of ethylene glycol, glycol ethers and methanol which are HAP. Solvent based inks are available for some applications which are completely HAP free. Capture and control systems used with these systems are designed and operated for control of VOC. In the absence of compound specific performance data it is assumed that individual HAP are controlled to the same extent as VOC. The type of ink used is influenced by factors including the nature of the substrate printed, the type of product or package 3-10 ------- Table 3-3. Control Device Efficiencies Reported for Packaging and Product Gravure Facilities with Control Systems. Control Device Carbon Adsorption Catalytic Incineration Thermal Incineration Minimum Efficiency (%) 89 88.8 88.8 Maximum Eff iciency(%) 100 99.7 99.3 Table 3-4. Overall Efficiencies by Industry Segment for Packaging and Product Gravure Facilities with Control Systems (Data for Major sources in Parentheses). Industry Segment Paper/Cardboard Only Foil/Film Only Vinyl Product Overall Efficiency (%) 45-98.6 (65-95.3) 65-95 (65-95) 80-97.7 (80-93) 3-11 ------- printed, the age of the press and existing air pollution regulations and permit requirements related to VOC emissions. Packaging ink is subject to additional requirements depending on the intended contents of the package. Many wide web flexographic printing facilities use waterborne inks with either no HAP or low HAP content. The majority of these facilities have no control devices, and may have converted from solvent based to waterborne materials to avoid the need to install control devices to comply with VOC regulations. Existing control devices for flexography are directed to control of VOC. In most cases, the HAP and non-HAP portion of the VOC present in the ink are equally difficult to control. Where control devices are in use, solvent laden air from several presses may be combined and ducted to a common control device. In addition, HAP from flexographic printing may be ducted to control devices designed and operated for control of HAP from other processes (such as rotogravure) operated at the same plant. Based on data submitted in response to the ICR, control devices in use at flexographic facilities include carbon adsorption, catalytic incinerators, and thermal incinerators (including, but not limited to regenerative and recuperative). Usable ICR data are reported by industry segment and control device in Table 3-5. Emissions data submitted in response to the ICR is based on emissions tests, equipment vendors guarantees and various types of engineering estimates. In all cases, emissions test data refer to VOC emissions. It is assumed that recovery or destruction of VOC is equivalent to that for HAP. Control device efficiencies of between 90 and 99 percent were reported by respondents reporting non-zero control device efficiencies. A total of 53 facilities operated control devices. Those facilities which do not operate control devices were assumed to emit 100% of the HAP used. Not all of the facilities which 3-12 ------- CO >-l 0) JJ c U •H Q. re o x 0) Q) (0 C •H (0 (U o •H (U Q 4J C O U ID 0) u •l-l i •-I o •p § u •-I w ^* o H 4J M C 01 0) > > O •H O O 0) W P5 rator 0) c •H u c H iH id 01 H 1 •H in ^ 0) c 01 0) a 0) •H 4J & 3 U 0) Vl o 22 •H ID J_) ^ £o! rH C •P U id c o M § o ^ c V 01 (0 oc CN o o o o o ao x ffr •g •JB O* 3 § O C 0* ^ ,y U a. 0 ,Q •r< X 0 •-I fa ^ 00 « o „ VD CN in ,_! •4 o •^ \| fa ^ O o o o l-l o •o o o Vl id u Vi a 0. ro vo H CN H in rH CO \| e M e g TJ X as o o o o o at a 4J ^ i-i Cb ^». 1 0. 0 • o o o o o o ^ l-l c 0 I o. ^> 0 o o 0 o a 4J e CO 0 o o o o CO n 0 V\| 0 43 u s •o D O 0 n 00 o o o 0 0 00 a I Ou CD 1 0\ 00 ^* CN CN CN in CN VD ro f-l id i i Q H 3-13 ------- reported overall efficiencies provided separate data on capture and control efficiencies. The basis for the estimates vary. Solvent recovery systems are in place at two facilities; overall efficiency data for these control systems are typically determined by liquid-liquid mass balances (as described in Section 3.4.1). For catalytic and thermal incineration control devices test data is available for overall efficiency in some cases and for control device efficiency in others. Where test data is available for destruction across the control device, capture efficiencies are often estimated using engineering judgment. Overall efficiencies incorporate these judgments. In many cases, either the control device efficiency or the capture efficiency was based on vender guarantees and the overall efficiency was estimated. It should be noted that the accuracy of the reported overall efficiencies varies. In addition to the (presumably biased low) data based on vendor guarantees, estimates made by operating personnel of capture efficiency may not be realistic. There is, however, less likelihood of a consistent bias (high or low) in these estimates. Based on approximately 500 usable responses to the ICR, 125 facilities reported using no HAP whatsoever for flexographic printing. Overall efficiency data was reported for 53 control systems. It should be noted that none of the facilities operating control devices had HAP emissions in excess of 25 tons per year of HAP of 10 tons per year of any specific HAP. Reported efficiency data pertain to VOC control and the applicability of these data to the HAP portion of the VOC has not been determined. The range of overall efficiencies for carbon adsorption, catalytic incineration and all other types of incineration are given in Table 3-6. Most of the variation in overall efficiencies is due to variation in capture efficiencies. All of the reported control device efficiencies were greater than 91 percent, although not 3-14 ------- Table 3-6. Overall Efficiencies Reported for Flexographic Facilities with Control Systems. Control Device Carbon Adsorption Catalytic Incineration Thermal Incineration Number of Systems 2 42 9 Minimum Efficiency 91 48 48 Average Efficiency 93 77 76 Maximum Efficiency 95 98 95 all facilities reporting overall efficiencies provided data on control device efficiencies. Control device capabilities applicable to flexographic printing are comparable to those for packaging and product rotogravure (see Section 3.4.2). Capture systems for in-line presses are comparable to those for gravure presses. Capture systems for dryer exhausts from common impression and stack presses may be less efficient than those for in-line presses. The technology and capabilities of total enclosures and press room ventilation described in Section 3.2 are applicable to flexographic printing. 3.5 LOW HAP AND HAP-FREE INKS (AND OTHER MATERIALS) Most facilities have adopted air pollution control strategies directed towards elimination or control of VOC. Many low HAP inks contain high proportions of VOC. VOC control devices also control organic HAP. Some existing regulations have resulted in lower VOC emissions as sources converted from solvent based to waterborne inks. In some cases, conversion to waterborne inks, which could result in significant reduction in VOC use, will be inhibited if HAP standards are formulated in terms of percentage reduction. 3-15 ------- The types of control devices used by facilities using solvent based inks, are not likely to adequately function as HAP control devices when waterborne inks are used, because the dryer exhaust streams will contain relatively large amounts of water and relatively low heat content. In cases where low HAP (as opposed to no HAP) inks are necessary for particular products or packaging, the feasibilty of conversion to waterborne inks may form the basis for segmentation of the industry for HAP regulation. Conversion from solvent based inks to waterborne inks may in some cases increase the amount of HAP in the press exhaust. 3.5.1 Publication Rotogravure At present all publication gravure facilities use solvent systems based on HAP. The solvent in use is principally toluene; other aromatic HAP (xylenes and ethylbenzene) are sometimes present in the solvent blend. Eleven of the 33 control systems use solvents which are 100 percent HAP. Some facilities have been able to print with acceptable speed and quality using a solvent which contains a lower proportion of HAP. While the solvent in use is still 100 percent VOC, the substitution of non- HAP solvent represents a HAP pollution prevention opportunity of demonstrated feasibility. As of yet, water-borne publication gravure inks have not been developed which offer the production speed and print quality of solvent based inks12. The development of acceptable waterborne inks may represent a future pollution prevention opportunity. 3.5.2 Product and Packaging Rotogravure Pollution prevention, in terms of HAP elimination has been achieved by many facilities in the packaging and product rotogravure industry. Inks with zero HAP content are available and in use at some facilities in all industry segments. In addition, many facilities, particularly those printing on paper and cardboard packaging, use waterborne inks which contain only a very low percentage of HAP. These inks typically contain a small 3-16 ------- proportion of glycol ethers which function to reduce surface tension and improve flow characteristics. The adoption of these inks by additional existing sources is a likely consequence of increased regulation of HAP emissions. It should also be noted that some solvent based inks are completely HAP free. Packaging and product rotogravure facilities produce a wide variety of products. Flexible packaging producers, in particular, print on many different substrates within the same facility. Low HAP inks may not be available to meet all of the performance requirements of these facilities. In addition, many facilities use hundreds of different inks to print various custom colors required by their packaging customers. Low HAP inks may not be available for all substrates in all of the colors required by some facilities. Existing facilities with well performing control systems may have little incentive to make additional investments to adapt to inks with no HAP. Some sources currently use carbon adsorption steam regeneration solvent recovery systems. These systems have important pollution prevention benefits, in that they recover solvent for reuse as opposed to thermal or catalytic destruction. At present, solvent recovery systems work best with HAP solvents, particularly toluene. Conversion to no HAP or low HAP acetate based solvent systems would complicate or eliminate the utility of these systems and increase VOC use. In cases where existing solvent recovery systems are performing well, they may represent an overall pollution prevention benefit. One possibility would be to regulate product and packaging rotogravure facilities with solvent recovery systems under the same standards which are applied to publication rotogravure facilities. 3.5.3 Wide~web Flexographic Printing Pollution prevention, in terms of HAP elimination has been achieved by many facilities in the flexographic printing industry. Inks with zero HAP content are available and in use at some facilities in all industry segments. In addition, many facilities use inks which contain only a very low percentage of 3-17 ------- HAP. These inks typically contain a small proportion of glycol ethers which function to reduce surface tension and improve flow characteristics. The adoption of these inks by additional existing sources is a likely consequence of increased regulation of HAP emissions. Flexographic printing facilities produce a wide variety of products. Flexible packaging producers, in particular, print on many different substrates within the same facility. Low HAP inks may not be available to meet all of the performance requirements of these facilities. In addition, many facilities use hundreds of different inks to print various custom colors required by their packaging customers. Low HAP inks may not be available for all substrates in all of the colors required by some facilities. Replacement of existing inks with inks containing less HAP (for those applications for which satisfactory replacements are available) is likely to occur. Two specific examples where pollution prevention strategies are promising are corrugated box and newspaper production. In both cases facilities using zero HAP inks can produce nearly identical products to those using low HAP inks. Increased awareness of the options available will cause some flexographic printers to eliminate HAP. Based on approximately 500 usable responses to the ICR, 125 facilities reported using no HAP whatsoever for flexographic printing. These facilities included 49 corrugated box manufacturers, 22 paper product manufacturers, 2 product manufacturers that made at least some plastic products, one book manufacturer, and 51 flexible packaging manufacturers. Of the flexible packaging manufacturers, 15 printed on paper substrates, 19 printed on foil or film substrates. The remaining 17 flexible packaging manufacturers either indicated that they printed on both paper and film or did not provide specific information about substrate. It should be noted that 9 of these facilities operated catalytic incinerators for VOC control. Some unknown fraction of the facilities which reported no HAP use on press may 3-18 ------- have been unaware of the HAP content. It is clear, however, that HAP free formulations are available for printing on both porous and non-porous substrates. Many other facilities applied materials on their flexographic presses which contained very low proportions of HAP on an average annual basis. The types of control devices used by facilities applying solvent based materials are not likely to adequately function as HAP control devices when waterborne inks are used, because the dryer exhaust streams will contain relatively large amounts of water and relatively low heat content. In cases where low HAP (as opposed to no HAP) inks are necessary for particular products or packaging, the feasibility of conversion to waterborne inks may be a basis for segmentation of the industry for HAP regulation. Conversion from solvent based inks to waterborne inks may in some cases increase the amount of HAP in the dryer exhaust. 3.6 REFERENCES 1. Edgerton, Stephen, Joanne Kempen and Thomas W. Lapp. The Measurement Solution: Using a temporary Total Enclosure Method for Capture Efficiency Testing. EPA-450/4-91-020. August 1991. p.39-42. 2. Reference 1, p. B-l through B-4. 3. Standards of Performance for Magnetic Tape Coating Facilities. 40 CFR 60, Subpart SS, July 1990. pp.438-444. 4. U. S. Environmental Protection Agency. Handbook: Control Technologies for Hazardous Air Pollutants. Publication No. EPA/625/6-91/014. Cincinnati, OH. June 1991. 168 pp. 5. U. S. Environmental Protection Agency. Internal Instruction Manual for ESD Regulation Development: Combustion Controls for Organic Emissions from Process Vents, Second Printing. Research Triangle Park, North Carolina. August 31, 1994. p. 3-39 through 3-43. 6. Reference 4, p.3-4. 7. Reference 6, p. 3-16 through 3-21. 8. Reference 6, p. 3-16. 3-19 ------- 9. Handbook: Control Technologies for Hazardous Air Pollutants. (Ref. 2) p.4-2. 10. Reference 4, p. 4-10. 11. Worrall, M. J. VOC Capture for High Speed Publication Rotogravure Printing. Paper 93-TA-33.02, presented at AWMA Meeting. June 1993. 12. Reference 11. 3-20 ------- 4.0 MODEL PLANTS, CONTROL OPTIONS, AND ENHANCED MONITORING 4.1 INTRODUCTION This chapter describes model plants, control options and enhanced monitoring options for specific segments of the printing and publishing industry. Model plants were developed to evaluate the effects of various control options on the source category. Control options were selected based on the application of presently available control devices and varying levels of capture consistent with different levels of overall control. Enhanced monitoring options are specified to insure the consistent performance of control devices. 4.2 MODEL PLANTS Model plants have been specified for three segments of the printing industry. Model plants have been selected to represent the range of capacity and overall control efficiency existing in these industry segments as determined by responses to the information collection requests. 4.2.1 Publication Rotogravure Model Plants Model plants have been selected to represent a total industry population of 33 separate control systems at 27 publication rotogravure plants. Specifications for these plants are given in Table 4-1. Information on HAP usage and overall control efficiencies are available for the entire population. Four model plants are based on size (based on ink usage) and control efficiencies reported in voluntary responses to EPA question lists. The large plants (Model Plants 1 and 2) were specified based on the 80th percentile of ink usage. The small plants (Model Plants 3 and 4) were specified based on the 20th percentile of ink usage. 4-1 ------- 01 JJ I (U s (0 c o 10 O 0) •H X) 10 in ^ ro CM rH •P C ft. rH 1 * CO 1ft U) CO ••» * 00 «• r-* 00 rH 00 n -S •{j 01 0 0 ID n Q) M 04 O in rH O CM rH O CM rH O CM O CM 4* <•>• ^J & C s Vl D n 0 u &. o CM rH O CM rH O CM rH O in rH 0 in rH £• X E g m B 0 a. o 0 o o" o 0 * ^H o o o o" o ID* o o o cT o 40 o o o o o in CM CM o o o o o in CM CM «B^ £ il^ rH 0 id B 3 04 g ro Q^ o CM rH CO CM in in CO CM in in in ro " o> iH in ro oC rH «^ C "e S 0 id n 3 Pi g „ * O r** • o H CO t- C5 rH • CO ^•^ i ^f u c 0 u <4 H 0 3 Ql u o o\ o r o» o o Is- o * ^ ^M, dP ^ u c 0 •H U •H in H rH o 4J C 0 u 0 CO o CO fln uu CM in 0 CO CM t in ^ * i^ H 0 IH C S iH tH fd i^ 0 S O 0 O 0 CM 0 r^ o o o CM ro 10 in 0 o CO CM cr> o VO O 0 o o o 00 en rH 0 o o o CM ^* ^ CM ^^ >; •O rH ^^ •d 0 rH rH 2 0 u Pi rS 0 o o o CO o n o o o CO \o f- 0 o CM o ro o o o o O r- CM o O 0 o CO o rH ^4 ^•j s^ A rH ^ •o 0 J •g 0) 0- 0 o o o rH CM O O 0 lO ON o o o VO 0 o in 1^ ro ro o O in i-. ro ro ^ •^. ^3 rH "•* •o 0 c •rl 5 Vl a. o 0 0 ^. ro in CM O o CM a> CPi o o in CM o 0 o in in r^ rH 0 O 0 o en ^^ ^4 ^ rH w g 0 Vl a I PM 0 Oc 0 O o o 5)1 m o o o CM ro o 0 o CM ro * 0 o o o CO o rH o o o o CO o rH sr o ^^ 0) § rH £ § 8 B B 0 Vt a. • E o o o s a jfi 4J •o •rl 0) ^> g V 1 4J 1 V rH 0 id 4J rH 3 •0 «t k ^Q S 0 JC ^J c 2 c -«H S w a •o 0 a 3 ^ JC ------- Plants with a high level of control (Model Plants i and 3) were selected based on the 80th percentile of overall control efficiencies. Plants with a low level of control (Model Plants 2 and 4) were specified based on the 20th percentile of overall control efficiency. One additional model plant (Model Plant 5) was selected based on the lowest reported monthly overall control efficiency. The size of this plant was specified based on the approximate size of the actual plant reporting this efficiency. Presses under control at each model plant were specified based on the approximate equipment in use at plants with this level of ink usage. Pressroom dimensions were assumed based on equipment size. Actual facilities may have multiple pressrooms under control by common systems, or more widely spaced presses separated by other equipment. All plants in this segment of the industry have similar solvent recovery systems; most of the difference in overall control is due to variations in capture. All or nearly all of the HAP in use at the plants is accounted for by overall liquid-liquid mass balances. Unrecovered HAP may be due to fugitive emissions, stack emissions or residual solvent shipped out in the product (this is assumed to be emitted at some stage in the life cycle of the product). 4.2.2 Product and Packaging Gravure Model Plants Data provided by packaging and product rotogravure facilities in response to the ICR were used to subcategorize this part of the printing industry on the basis of substrate and end use. The list of facilities for which usable information was received and the subcategories into which these facilities were placed is described in Chapter 2. HAP usage varied widely among the facilities. In addition, HAP usage as a proportion of total material applied on rotogravure presses varied widely. At least twelve facilities reported zero HAP usage, including one facility which applied over 7 million pounds per year of inks and coatings. The availability of suitable low HAP or no HAP ink may be dependent upon the substrate and specific end product. In addition, 4-3 ------- existing control devices, which in most cases are designed and operated for VOC control, may not be compatible with low HAP formulations. Substitution of inks with lower HAP content may be an important pollution prevention option at some facilities. Other facilities, which are operating efficient VOC control systems may have little incentive to reduce the HAP content of their inks. Facilities printing on paper and cardboard packaging only, film and foil packaging only and vinyl products have been listed in Tables 4-2 through 4-4. Based on data submitted in response to the ICR, total ink (including coatings, adhesives, varnishes and primers) use, HAP use associated with this ink use, estimated overall control and probable major source status have been listed in these tables. In some cases, data were incomplete or ambiguous. These tables exclude facilities which print on both paper or cardboard and foil or film, and other miscellaneous products. Lists of these facilities are given in Chapter 2. Model plants were selected from the mid-range of the identifiable manor sources within each subcategory. It should be noted that while this is representative of the sources which will be regulated, it is not necessarily representative of the subcategory as a whole. Because of the varying approaches to emissions control used by the major sources in the packaging subcategories (relatively high HAP use with extensive control versus relatively low-HAP use with no control), two model plants have been selected for paper/cardboard and foil/film packaging. Model plant specifications are given in Table 4-5. Ink, HAP and VOC use, overall efficiency and numbers of presses and stations were based on actual responses from representative facilities in each sub-category. 4.2.3 Wide-web and Sheet Fed Flexography Model Plants Data were provided by approximately 500 flexographic printing facilities in response to the ICR. The list of facilities for which usable information was received is included in Chapter 2. Responses were obtained from printers of flexible 4-4 ------- board T C •o c * 2 q a. c o c •r * C V 04 n 01 •P — { iH •rl U h 0) Vl 3 Vl o o 0. a a D O4 CM * rH •8 H O 0 0 a 1 •u TI X rH rH id Vl 01 ft U* Q < At §1 O •^ C H i 3 2 C 1 o U ^^, Vl >1 £ " ^•fc dp ^ o Vl 4J 0 u t. 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I Q 1^ •o 0 u •o c (0 H 1 o, c 0 tr c •rl •P -•« ^1 ^ i^. 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O C rl * a c o •H a n i •a 0 4> E •H n 0 g •a 0 n J3 H 9 0 ailabl *. d o 2 H 4-9 ------- in ff) c o* a u * "8 s o T5 VI « U VI S< a. roducts P4 PH •H •^ 01 .p ^1 ^J a 3 M O O o C5 0 ro O O O O O 0 ro O o o * o o 0 (N o o 0 o 00 •t o o o o o o J^ id 0) ^ x,^ I-l % 0) (0 & c M o o o ^ 0 in 1-1 o o o o o in w CN o o o •k o o oo o 0 o o o o I-l 0 0 o o o & Vl a) 0) ^, x,,^ 5 «. 0) CO D g o o o % in vo o o o o o o ^ rH O O O * O o VO O O o o 0 , 5 ^ 0) to D a, < ^•^ z in o^ rt sT •-I oo 00 dP ^ ^ Q C 0) ft u IM VM ft) 01 Vl 3 U o in o r- in 0) U #> 0) N c ~H 01 0 -H Vl O 4J •H CIM O IM U H O O a\ 0 Q\ f. ID 00 , ^i u c 0) u IS H ^4 •"H dJ (^ I VO ^ ^ ao ------- packaging, products, corrugated cartons and newspapers. Flexible packaging and products involved both porous and non-porous substrates. HAP usage varied widely among the facilities. In addition, HAP usage as a proportion of total material applied on flexographic presses varied widely. Over 100 facilities reported zero HAP usage; many more reported HAP usage well below one percent of the total material applied. The availability of suitable low HAP or no HAP ink is dependent upon the substrate and specific end product. In addition, existing control devices, which in most cases are designed and operated for VOC control, may not be compatible with low HAP formulations. Substitution of inks with lower HAP content may be an important pollution prevention option at some facilities. Other facilities, which are operating efficient VOC control systems may have little incentive to reduce the HAP content of their inks. A list of facilities for which usable data are available is given in Table 4-6. Based on data submitted in response to the ICR, total ink (including coatings, adhesives, varnishes and primers) use, HAP use associated with this ink use, estimated emissions and type of substrate have been listed in this table. In some cases, data were incomplete or ambiguous. Model plants have been selected to represent those sources which are likely to be regulated under the standard. It should be noted that while this is representative of the sources which will be regulated, it is not necessarily representative of the sub-category as a whole. Three model plants are specified in Table 4-7. Plants 1 and 2 and based on actual responses from uncontrolled major sources due to flexographic printing. Model plant 1 is a large plant using waterborne inks with a low HAP concentration and no control device. Model plant 2 is a medium sized plant using solvent based inks containing a significant amount of HAP and no control device. A number of facilities operate flexographic printing operations as well as other more HAP intensive operations such as 4-11 ------- Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table). Name Abbott Box Co. Inc. Acorn Corrugated Box Co. Advance Packaging Corporation Advance Packaging- Jackson Tennessee Packaging Koch Container All-size Corrugated Prods. Compak, Inc. Webcor Packaging Corp. Castle Rock Container Company Fleetwood Container & Display Focus Packaging, Inc. Frank C. Meyer Company, Inc. GP-Albany Plant GP-Asheboro Plant GP-Augusta Plant GP-Bradford Plant GP-Buena Park Plant GP-Canton Plant GP-Chicago Plant GP-Cincinnati GP-circleville Plant GP-Cleveland Plant GP-Cleveland Plant GP-Doraville Plant GP-Dubuque Plant GP-Franklin Plant GP-Huntsville Plant GP-Kansas City Plant INK ETC. APPLIED (Ib/yr) 15,000 161,000 122,100 13,400 19,454 2,154 11,178 10,295 122,060 231,768 78,660 36,000 333,045 361,893 165,206 225,000 212,664 1,235,300 70,627 135,335 114,342 224,653 134,926 131,708 114,791 216,303 180,000 187,152 219,516 HAP USED ON PRESS (Ib/yr) 10 0 1,591 745 72 0 0 193 2,512 10 Not major 0 0 3,619 1,652 4,500 2,127 12,353 706 2,707 1,143 2,247 1,349 13,171 1,148 649 12,600 0 0 HAP Emissions (Ib/yr) 10 0 1,591 745 72 0 0 193 2,512 10 0 0 3,619 1,652 4,500 2,127 12,353 706 2,707 1,143 2,247 1,349 13,171 1,148 649 12,600 0 0 PROD. b b b b b b b b b b b b b b b b b b b b b b b b b b b b b 4-12 ------- Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table). Name GP-Lake Placid Plant GP-Madera Container Plant GP-'Martinsville Plant GP-Memphis Plant GP-Milan Plant Modesto Plant GP-Monticello Plant GP-Mt. Olive Plant GP-Mt. Wolf Plant GP-Olympia Plant GP-Ooltewah Plant GP-Oshkosh Plant GP-Owosso Plant GP-Schenectady Plant GP-Sheboygan Plant GP-So. San Francisco Plant GP-Spartanburg Plant GP-Valdosta Plant GP-Warren County Plant GP-West Monroe Plant GP-Waxahachie Plant GP-Gulf States Paper Corp. International Paper— Presque Isle International Paper-Auburndale International Paper-Carson International Paper-Chicago International Paper-Cincinnati International Paper-Dallas International Paper-Detroit INK ETC. APPLIED (Ib/yr) 721,374 213,754 250,000 69,786 190,693 175,052 26,779 212,188 70,586 133,080 1,000 27,077 94,057 57,763 122,629 932,691 141,211 540,000 120,173 140,969 228,934 424,405 101,725 223,525 375,752 226,287 129,055 166,287 146,360 HAP USED ON PRESS (Ib/yr) 0 641 0 209 572 525 7,498 664 212 1,198 40 542 1,882 1,329 2,453 2,798 0 0 361 5,639 9,157 0 844 1,182 822 770 523 390 1,020 HAP Emissions (Ib/yr) 0 641 0 209 572 525 7,498 664 212 1,198 40 542 1,882 1,329 2,453 2,798 0 0 361 5,639 9,157 0 844 1,182 822 770 523 390 1,020 PROD. b b b b b b b b b b b b b b b b b b b b b b b b b b b b b 4-13 ------- Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table). Name International PaperEdinburg International Paper-El Paso International Paper-Fond du Lac International Paper-Geneva International Paper-Georgetown International Paper-Minneapolis International Paper-Mobile International Paper-Modesto International Paper-Mt. Carmel International Paper-Nashville International Paper-Putnam International Paper-Russellville International Paper-San Jose International Paper-Shreveport International PaperSpring Hill International Paper-Statesville International PaperStockton International Paper-Tallman International Paper-Wooster International Paper-Hopkinsville James River-Portland Jefferson Smurfit Corp-Lexington Jefferson Smurfit-Renton Jefferson Smurfit Corp-Muncie INK ETC. APPLIED (Ib/yr) 240,391 197,102 230,990 98,250 59,711 95,542 230,224 347,046 337,500 245,662 228,407 247,201 328,783 417,513 254,985 158,250 2,626 447,392 200,425 308,312 124,655 6,000 103,004 13,100 HAP USED ON PRESS (Ib/yr) 856 1,900 683 136 2,846 720 3,039 1,341 4,940 8,685 890 1,198 775 0 3,957 5,315 36 2,139 859 2,312 0 113 483 0 HAP Emissions (Ib/yr) 856 1,900 683 136 2,846 720 3,039 1,341 4,940 8,685 890 1,198 775 0 3,957 5,315 36 2,139 859 2,312 0 113 483 0 PROD. b b b b b b b b b b b b b b b b b b b b b b b b 4-14 ------- Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table). Name Jefferson Smurfit Corp-Port 1 and JSC/CCA-Fulton JSC/CCA-Houston Jefferson Smurfit Corp. -Muskogee Jefferson Smurfit Corp-Highland Jefferson Smurfit Corp-New Brunswick Jefferson Smurfit Corp-Chesterf ield Jefferson Smurfit -Memphis Jefferson Smurfit -St. Louis Jefferson Smurfit Milpitas Jefferson Smurfit-Ft. Smith Jefferson Smurfit-Ft. Worth Jefferson Smurfit -Anderson Jefferson Smurf it-Montgomery Jefferson Smurfit -Milford JSC/CCA-Aston Jefferson Smurfit-New hartford Jefferson Smurf it-Louisville Jefferson Smurf it-Wildwood Jefferson Smurfit -Wakefield Jefferson Smurf it-Knoxvi lie Jefferson Smurf it-Jonesboro Jefferson Smurfit-Los Angeles JSC/CCA-Baltimore Jefferson Smurf it-Corona Jefferson Smurf it-Dolton Jefferson Smurf it-Dallas INK ETC. APPLIED (Ib/yr) 111,952 42,672 150,200 94,733 101,000 156,597 68,000 193,043 39,000 210,000 6,500 186,000 102,625 252,000 63,990 312,136 121,488 98,300 183,798 100,300 na na 179,367 140,170 129,419 151,682 40,300 HAP USED ON PRESS (Ib/yr) 0 0 2,148 344 0 815 0 3,455 0 0 49 0 1,840 0 422 1,853 728 1,760 1,060 496 1,320 14 0 894 0 550 22 HAP Emissions (Ib/yr) 0 0 2,148 344 0 815 0 3,455 0 0 49 0 1,840 0 422 1,853 728 1,760 1,060 496 1,320 14 0 894 0 550 22 PROD. b b b b b b b b b b b b b b b b b b b b b b b b b b b 4-15 ------- Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table). Name JSC/CCA-Fresno JSC/CCA-Cincinnati JSC/CCA-Ravenna Jefferson Smurfit -LaPorte Jefferson Smurfit-Winston-Salem Jefferson Smurfit -Humboldt Jefferson Smurf it-Sioux City Jefferson Smurfit -Lancaster Jefferson Smurf it-Galesburg JSC Preprint-Cincinnati Jefferson Smurfit -Murfreeesboro Jefferson Smurf it-Springfield Jefferson Smurfit -Shelby Packaging Unlimited, Inc. Jefferson Smurfit -Chattanooga Lin Pac, Inc. Mafcote Industries Mafcote/SWACO Malnove, Inc. Massillon Container Menasha Corporation Milwaukee Container PCA/Akron PCA/Arlington PCA/Ashland PCA/Atlanta PCA/Buffalo PCA/Burlington PCA/Colby INK ETC. APPLIED (Ib/yr) 135,093 178,484 75,753 174,297 240,000 11,887 160,536 79,000 46,149 251,500 115,466 15,589 83,773 121,382 120,000 52,289 138,189 96,674 27,606 13,000 197,095 139,571 21,860 198,800 234,000 120,000 62,300 305,000 116,000 HAP USED ON PRESS (Ib/yr) 0 3,195 1,356 316 0 270 92 620 0 0 0 0 586 6,386 0 3 9,130 0 0 0 282 2,791 219 1,998 2,340 1,200 623 3,050 1,160 HAP Emissions { Ib/yr) 0 3,195 1,356 316 0 270 92 620 0 0 0 0 586 6,386 0 3 9,130 0 0 0 282 2,791 219 1,998 2,340 1,200 623 3,050 1,160 PROD. b b b b b b b b b b b b b b b b b b b b b b b b b b b b b 4-16 ------- 1 » V Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table). Name PCA/Oenver PCA/Garland PCA/Gas City PCA/Goldsboro PCA/Grafton PCA/Grandville PCA/Hanover PCA/Harrisonburg PCA/High Point PCA/Honea Path PCA/Jackson PCA/Jacksonville PCA/Knoxville PCA/Lancaster PCA/Los Angeles PCA/Marshalltown PCA/Miami PCA/Middletown PCA/Milwaukee PCA/Minneapoolis PCA/Morganton PCA/Newark PCA/Newberry PCA/Northhampton PCA/Otnaha PCA/Opelika PCA/Phoenix PCA/Pittsburgh PCA/Plano PCA/Plymouth PCA/Richmond INK ETC. APPLIED (Ib/yr) 119,900 145,800 97,300 11,400 43,000 110,600 28,000 160,000 19,100 45,950 137,000 126,700 3,520 187,800 294,000 129,800 64,300 75,022 38,300 78,000 60,800 76,300 109,500 133,900 90,000 10,600 98,800 193,800 140,600 60,500 49,400 HAP USED ON PRESS (Ib/yr) 1,199 1,458 973 114 430 1,106 280 1,200 191 460 1,370 1,267 35 1,878 1,470 1,298 643 750 383 780 1,250 763 1,095 1,339 900 106 988 1,938 1,406 605 494 HAP Emissions (Ib/yr) 1,199 1,458 973 114 430 1,106 280 1,200 191 460 1,370 1,267 35 1,878 1,470 1,298 643 750 383 780 1,250 763 1,095 1,339 900 106 988 1,938 1,406 605 494 PROD. b b b b b b b b b b b b b b b b b b b b b b b b b b b b b b b 4-17 ------- Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table). Name PCA/Salisbury PCA/Syracuse PCA/Trexlertown PCA/Vincennes PCA/Wtnter Haven Rand -Whitney/Northeast Container Rand -Whitney/Southeast Container Corp. Rand -Whitney Container Corp. Rock-Tenn-Harrison Rock-Tenn -Chattanooga Rock-Tenn-Stone Mountain Rock-Tenn-Lebanon Rock-Tenn-Marshvi 1 le Rock-Tenn-Eutaw Rock-Tenn-Conway Rock-Tenn Greenville Sealright Packaging Co. Union Camp Corp. -Tucker Wabash Pioneer Container Corp. Westvaco-Baltimore Westvaco-Buffalo Westvaco Chicago Westvaco-Cleveland OH Westvaco-Cleveland TN Westvaco-Columbus Westvaco-Eaton Westvaco-Gastonia Westvaco-Meridian Westvaco-Richmond INK ETC. APPLIED (Ib/yr) 97,000 141,800 158,332 65,500 238,800 18,087 17,426 91,727 25,000 30,000 117,624 104,400 15,000 200,000 28,719 125,000 326,000 126,000 498,303 305,000 219,000 423,000 205,000 290,000 249,000 292,000 125,000 214,400 128,000 HAP USED ON PRESS (Ib/yr) 970 1,418 1,583 655 2,388 158 5 0 0 300 1,340 0 0 500 4 0 0 2,720 2,145 15,410 1,590 290 870 5,300 1,900 4,740 2,630 1,400 560 HAP Emissions (Ib/yr) 970 1,418 1,583 655 2,388 158 5 0 0 300 1,340 0 0 500 4 0 0 2,720 2,145 15,410 1,590 290 870 5,300 1,900 4,740 2,630 1,400 560 PROD. b b b b b b b b b b b b b b b b b b b b b b b b b b b b b 4-18 ------- Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table). Name Westvaco-Flexpak-Richmond Weyerhaeuser -Westbrook Weyerhaeuser-Cedar Rapids Weyerhaeu ser-Tampa Weyerhaeuser -Franklin Weyerhaeuser-Tucker Willamette -Beaverton Willamette -Buena Park Willamette -Dallas Willamette -Kansas City Willamette -Tacoma Willamette -Aurora Willamette -Beaverton 2 Willamette -Ellvue Willamette -Bellmawr Willamette -Bowling Green Willamette -Cerritos Willamette -Compton Willamette -Dallas 2 Willamette -Delaware Willamette -Elk Grove Willamette -Ft. Smith Willamette -Golden Willamette -Griffen Willamette -Indianapolis Willamette -Kansas City Willamette-Lincoln Willamette -Louisville Willamette -Lumberton Willamette -Matthews INK ETC. APPLIED (Ib/yr) 482,000 145,609 151,270 464,367 540,817 1,674,177 435,581 394,942 383,384 140,814 130,604 435,235 237,772 460,521 265,373 226,528 268,859 403,363 299,787 679,079 223,379 231,814 58,801 380,183 63,083 168,945 41,256 11,924 41,488 90,770 HAP USED ON PRESS (Ib/yr) 0 790 1,971 421 3,366 151 0 0 0 0 0 962 311 1,895 355 516 515 685 684 3,334 447 440 90 1,784 159 338 80 16 191 203 HAP Emissions (Ib/yr) 0 790 1,971 421 3,366 151 0 0 0 0 0 962 311 1,895 355 516 515 685 684 3,334 447 440 90 1,784 159 338 80 16 191 203 PROD. b b b b b b b b b b b b b b b b b b b b b b b b b b b b b b 4-19 ------- Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table). Name Willamette -Memphis Willamette -Moses Lake Willamette -Newton Willamette -Sacramento Willamette -San Leandro Willamette -Sanger Willamette -Sealy Willamette -St. Paul Willamette -West Memphis American Greetings Corp Avery-Dennison Cadillac Products, Inc. Paris Cadillac Products, Inc. Cleo, Inc. Crystal Tissue Eisenhart Wallcoverings Co. Pioneer Balloon Company Waldan Paper Services, Inc. American Greetings Corp. Af tan Deco Paper Products, Inc. Design Containers, Inc. GP-LaGrange GP-Plattsburgh GP-Crosett GP-Palatka GP-Bratt leboro GP-Be 1 1 ingham Oilman Converted Products Hallmark Cards INK ETC. APPLIED (lb/yr) 40,958 302,716 65,621 297,249 423,133 227,039 133,688 81,811 157,355 230,000 15,954 250,633 25,516 20,000 125,333 63,076 113,820 550,000 4,187,556 571,308 11,201 36,941 1,757,500 652,182 329,000 134,810 76,650 913,367 69,900 HAP USED ON PRESS (lb/yr) 214 549 475 537 590 496 289 118 177 7,400 0 27,334 3,039 400 170 321 1,484 0 0 4,055 21 843 0 8,424 0 125 0 5,460 14 HAP Emissions (lb/yr) 214 549 475 537 590 496 289 118 177 7,400 0 27,334 3,039 400 170 321 1,484 0 0 4,055 21 843 0 8,424 0 125 0 5,460 14 PROD. b b b b b b b b b d d d d d d d d d e e e e e e e e e e e 4-20 ------- Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table). Name James River Darlington James River-Easton James River-Lexington James River-Indianapolis John H. Harland Company Kookaburra USA LTD Mail-Hell Envelope Moore, Business Forms and Systems NCR Corp. Procter and Gamble-Albany Procter/Gamble-Mehoopany Procter/Gamble-Green Bay Procter /Gamble-Oxnard Solo Cup Company-Belan Solo Cup Company-Chicago The Standard Register Company Susan Crane, Inc. Toph-Osage Toph-Covington Ward/Kraft, Inc. Beach Products Westvaco-Springf ield Westvaco-Wil 1 iamsburg Westvaco-Atlanta Westvaco-North Chicago Westvaco-Indianapolis Westvaco-Dallas Hestvaco-Los Angeles Westvaco-San Francisco Arcata Graphics \Kingsport INK ETC. APPLIED (Ib/yr) 234,017 93,644 88,592 281,088 121,650 55,329 103,150 124 117,290 636,886 949,300 423,400 113,450 38,680 18,870 209,305 136,840 60,000 203,963 37,783 260,000 855,473 929,945 840,289 546,821 890,044 721,007 831,225 460,905 57,117 HAP USED ON PRESS (Ib/yr) 5,277 0 0 0 0 0 426 1,101 0 0 0 0 0 0 0 1 0 0 0 5 1,660 0 7,284 0 7,277 4,608 5,662 2,656 0 0 HAP Emissions (Ib/yr) 5,277 0 0 0 0 0 426 1,101 0 0 0 0 0 0 0 1 0 0 0 5 1,660 0 7,284 0 7,277 4,608 5,662 2,656 0 0 PROD. e e e e e e e e e e e e e e e e e e e e e e e e e e e e e g 4-21 ------- Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table). Name R. R. Donnelley & Sons Company Western Publishing Co., Inc. Interstate Packaging Corp. American Packaging-Storry City American Packaging-Columbus Avery-Dennison, K & M Division Bagcraft Corporation of America Bancroft Bag, Inc Bingo Paper Inc. Champion-Morristown Champion-Clinton Champion-Olmstead Falls Chamption-Ft. Worth Champion-Athens Bemis Company-Crosett Bemis Company-Memphis Bemis Company-Minneapolis Bemis Company-Omaha Bemis Company-Peoria Bemis Company-Pepperell Bemis Company-Seattle Bemis Company-Vancouver Bemis Company-Wichita Graphic Packaging Corp. Hallmark Cards International Paper-Camden International Paper-Mobile INK ETC. APPLIED (Ib/yr) 367,200 57,200 217,277 892,160 1,869,137 28,500 650,000 1,522,877 38,701 294,738 167,415 304,197 192,319 285,554 530,107 323,542 16,000 665,336 318,364 182,063 105,275 437,010 7,138 195,031 72,286 663,359 650,000 HAP USED ON PRESS (Ib/yr) 100 5,475 8,361 7,660 3,293 19,950 15,000 350,870 0 23,832 18,728 19,028 14,790 22,213 0 2,070 0 1,728 3,021 0 2,377 0 0 0 846 0 355 HAP Emissions (Ib/yr) 100 5,475 2,341 7,660 3,293 19,950 15,000 350,870 0 23,832 18,728 19,028 14,790 22,213 0 2,070 0 1,728 3,021 0 2,377 0 0 0 846 0 355 PROD. g g h h h h h h h h h h h h h h h h h h h h h h h h h 4-22 ------- Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table). Name International Paper-Pittsburg International Paper-Wi Imington James River -Ft. Smith James River - Specialty Tabletop James River Corp - Wausau Plant Mead Packaging Percy Kent Bag Co., Inc. The Robinette Company Sealright Packaging Co. Union Camp-Savannah Union Camp-Spartenburg Union Camp-Hazleton Union Camp-Hanford Union Camp-Sibley Westvaco, Liquid Packaging Willamette Industries, Inc. Alusuisse-Shelbyville Equitable Bag Co., Inc Alusuisse-New Hyde Park Bryce Corporation BRC, A Division of Bryce Corporation Bemis -Terre Haute Bemis -Oshkosh INK ETC. APPLIED (Ib/yr) 195,000 396,000 41,959 12,500 425,873 2,267,734 665,500 633,000 82,491 320,362 1,476,648 206,000 155,864 435,923 135,900 1,070,078 206,000 1,805,400 2,030,000 2,045,155 294,587 5,114,960 2,619,780 HAP USED ON PRESS (Ib/yr) 0 57 2,937 0 291 564 0 0 0 4,416 21,420 0 1,045 13,500 8,524 0 1,000 46,152 76,000 0 34 27,267 108,864 HAP Emissions (Ib/yr) 0 57 2,937 0 291 564 0 0 0 4,416 21,420 0 1,045 13,500 8,524 0 282 13,107 15,124 0 14 7,089 14,261 PROD. h h h h h h h h h h h h h h h h m m m m m m m 4-23 ------- Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table). Name Bemis Milprint Denmark Bemis Milprint Lancaster Spec-Fab Spiralkote, Inc. Glenroy, Inc. Smurfit Flexible Packaging Kleartone, inc. Packaging Products Corp. , Rome, GA Division Pacquet Oneida, Inc. Westvaco Envelope Springfield Fabricon Products Alusuisse-Bellwood Union Camp-Asheville Graphic Packaging Corporation American Packaging Philadelphia American Packaging Rochester Bell Packaging Corp Bomarko, Inc Bryce Corporation Burrows Paper Corporation - Ft. Madison Facility Cello-Wrap Printing Company, Inc. Charleston Packaging Company, Inc. Bemis Curwood-Murphysboro Bemis Curwood-New London Dixico, Inc. INK ETC. APPLIED (Ib/yr) 1,268,300 3,644,494 34,088 844,943 124,809 90,167 118,953 338,780 712,400 453,238 287,616 1,540,000 224,842 120,000 89,756 49,557 27,832 499,260 3,060,900 344,426 170,120 415,057 330,112 2,919,293 734,273 HAP USED ON PRESS (Ib/yr) 2,118 1,628 681 19,360 0 7,731 2,271 12,792 1,735 36,470 4,172 8,000 5,193 100,000 243 250 453 0 0 6,180 2,453 350 12,329 38,367 0 HAP Emissions (Ib/yr) 593 133 102 6,970 0 951 227 1,254 226 6,565 1,168 2,160 2,700 9,100 243 250 453 0 0 6,180 2,453 350 12,329 38,367 0 PROD. m m m m m m m m m m m m m m m m m m m m m m m m m 4-24 ------- Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table). Name Fabricon Products fp Hebkote, Inc. Gateway Packaging Greif Bros. Corp H. S. Crocker Co., Inc. Hargo-Harrisburg Hargro-Edinburgh IP-Jackson IP-Peoria IP-Menasha IP-Lancaster IP-Kaukauna IP-Knoxville James River -Camas James River-Hazelwood James River-Menasha James River-San Leandro Longhorn Packaging, Inc. Neenah Printing - Wide Web Flexo Plant Midwest Film Corp NCR - B.F.D. Nichols Paper Products Co., Inc. Phoenix Products Co., Inc. Solar Press Standard Packaging & Printing Corp. Sunrise Packaging, Inc. Superpac, Inc. Teepak, Inc. Union Camp-Monticello INK ETC. APPLIED (Ib/yr) 104,364 111,606 10,000 279,494 91,823 349,576 200,942 591,966 325,387 100,254 24,124 525,606 127,235 68,000 991,726 64,025 866,000 29,894 364,376 276,679 33,342 86,289 61,040 131,324 305,000 632,789 560,300 816,691 368,000 HAP USED ON PRESS (Ib/yr) 1,158 19,800 200 0 0 0 7702 942 33,827 6,490 1,477 3,189 55 0 923 28 0 ? 1,924 20 0 418 16,656 0 0 4,579 7,039 0 12,232 HAP Emissions (Ib/yr) 1,158 19,800 200 0 0 0 7,702 942 33,827 6,490 1,477 3,189 55 0 923 28 0 1,924 20 0 418 16,656 0 0 4,579 7,039 0 12,232 PROD. m m m m m m m m m m m m m m m m m m m m m m m m m m m m m 4-25 ------- Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table). Name Union Camp-Tifton Vitex Packaging, Inc. Akron Beacon Journal Fort Wayne Newspapers Macon Telegraph Modesto Bee The Fresno Bee Miami Herald Publishing Co. Press Telegram Providence Journal Company Bonar Packaging, Inc. Georgia-Pacific-Warwick Paramount Packaging-Longview Paramount Packaging-Chalfont Action Packaging All-Pak, Inc. Atlanta Film Converting Co, Inc. Automated Packaging Systems, Inc. Automated Label Systems Co. Banner Packaging, Inc. Cryovac-Iowa Park Cryovac-Cedar Rapids Cryovac-S impsonvi 1 le Bemis Company-Hazelton Cello-Foil Products, Inc. Excelsior Transparent Bag MFC Corp. Flex-Pak, Inc. INK ETC. APPLIED (Ib/yr) 469,967 502,402 308,031 381,022 195,000 394,237 699,367 981,662 236,000 930,300 334,260 721,500 169,577 440,317 120,370 254,199 398,621 344,101 346,955 1,718,688 70,786 248,500 1,060,000 7,622,511 551,055 1,358,606 400,694 HAP USED ON PRESS (Ib/yr) 0 5,819 3,018 0 1,053 0 0 22,743 82 2,902 13,401 210 109,200 1,154 602 748 0 2,329 1,461 46,311 350 8,100 1,515 59,472 0 5,300 0 HAP Emissions (Ib/yr) 0 5,819 3,018 0 1,053 0 0 22,743 82 2,902 3,886 84 5,460 196 138 187 0 326 136 12,967 182 1,944 348 13,381 0 1,007 0 PROD. m m n n n n n n n n P P P P P P P P P P P P P P P P P 4-26 ------- Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table). Name Hargo-Boyerstown Huntsman Packaging Products, Corp Smurfit Flexible Packaging Marglo Packaging Corp. Package Printing Co., Inc. Package Products Flexible Corporation Packaging Materials Incorporated Packaging Products Corp. Plastic Packaging, Inc. Pi icon Corp. Poly Plastic Packaging, Inc. Union Camp-Toman Union Camp -Griffen Central States Diversified, Inc. Mohawk Northern Plastics, Inc. Maine Poly, Inc. Amko Plastics, Inc. Anagram International, Inc. Arcon Coating Mills, Inc. Arkansas Poly, Inc. Johnson Bryce Corp. Bryce Dixico Buckeye Container Buckeye Packaging Cadillac Products, Inc. Clark Container, Inc. C. P. C. Packaging, Inc. INK ETC. APPLIED (Ib/yr) 605,047 409,000 392,612 13,506 108,896 2,360,000 7686 397,000 1,002,196 216,717 55,229 305,483 383,193 200,288 101,214 312,000 370,630 254,542 261,812 145,796 230,390 505,943 37,775 115,737 158,021 81,660 9,725 HAP USED ON PRESS (Ib/yr) 1,876 10,205 ??? 333 0 0 0 5,904 126 11,740 506 117,815 2,180 1,973 3,684 4,996 21,354 3,436 787 2,134 0 52 0 0 0 5,216 1,945 HAP Emissions (Ib/yr) 413 1,765 130 0 0 1,830 41 3,992 104 16,494 109 322 280 999 21,354 3,436 787 2,134 0 52 0 0 0 5,216 1,945 PROD. P P P P P P P P P P P P P P P P P P P P P P P P P P P 4-27 ------- Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table). Name Bemis -Flemington Custom Poly Bag, Inc. Dart Container Corporation Dynamic Packaging, Inc. Eskimo Pie Corporation Flexo Transparent, Inc. Gentry Poly Specialties, Inc. Gulf Coast Plastics Div. Dairy-Mix, Inc. Hargro Health Care Packaging Home Plastics, Inc. Carolina Printing & Converting A Division of Interf lex James River-Greensburg James River-New Castle James River-Parchment James River-Portland James River-Shreveport Lin Pac Mid-West Poly Pak, Inc. M.T.P. Industries, Inc. (Mason Transparent Pkg) Owens-Illinois, Inc. Packaging Industries, Inc. Packaging Products Corporation Packaging Specialties, Inc. Paramount Packaging-Shelbyville Paramount Packaging -Murfreesboro INK ETC. APPLIED (Ib/yr) 53,139 71,417 26,149 189,489 41,767 107,033 38,192 9,702 24,335 35,000 162,739 4,756,127 874,312 150,000 407,858 2,088,304 317,468 25,015 125855 1,438,000 836,972 188,780 598,431 320,770 566,370 HAP USED ON PRESS (Ib/yr) 56 0 0 1,591 0 11,094 0 0 0 700 10,694 0 31 0 292 0 298 112 0 42,086 12,117 7,693 14,425 1,169 96,821 HAP Emissions (Ib/yr) 56 0 0 1,591 0 11,094 0 0 0 700 10,694 0 31 0 292 0 298 112 0 42,086 12,117 7,693 14,425 1,169 96,821 PROD. P P P P P P P P P P P P P P P P P P P P P P P P P 4-28 ------- Table 4-6. HAP Use on Flexographic Presses (See Motes Following Table). Name Phoenix Packaging Viakase Corp. Plastic Packaging Corp Poly Plastic Packaging, Inc. Polyflex Film & Converting, Inc. Rex-Rosenlew International, Inc. Sealright Packaging Company Packaging Industries, Inc. Selig Sealing Products, Inc. Southern Colortype Co., Inc. Specialty Container Corporation Tennessee Press, Inc. Uniflex, Inc. Union Camp-Shelbyville Union Camp-Denton Union Camp-Freeman Field Union Camp Corp., Richmond Viskase Corp. Zim's Bagging Co., Inc. INK ETC. APPLIED (Ib/yr) 8,170,551 103,718 65,560 26,800 566,106 494,445 429,758 836,972 16,950 65,176 60,819 1,546,762 208617 256,216 269,994 332,087 217,253 103,718 1,400 HAP USED ON PRESS (Ib/yr) 19,784 5,924 0 226 0 1 12,729 12,117 26 332 45,790 0 208,617 0 13,499 558 0 5,924 25 HAP Emissions (Ib/yr) 19,784 5,924 0 226 0 1 12,729 12,117 26 332 45,790 0 50,068 0 13,499 558 0 5,924 25 PROD. P P P P P P P P P P P P P P P P P p P Notes: b=corrugated box, d=paper/plastic products, e=paper products, g=books, hspaper packaging, m=mixed packaging, n=newspaper s , p=plastic packaging 4-29 ------- X3 a (0 o X 0) to O to C o •H •P (0 U •H •H •P rH 3 8 0) -P (0 4J to XI CO O 0 0 o o in ^ H O O 0 o o CO o o o k o o in H to (0 0) ^^ jO rH 0) to O •g H O O o •b o o H ^ H O O 0 •b o in in o o o » in CM <0 Q) rH Q) to P CJ o > o o o CO o o o o o H o o o V H CM to (0 0) xT rH 0) to fi a CO f^ o o <> ^ Q s o •H «M Q) O •H ^ 0) >i Q U C H 0) O-H to U •P-H C (LJ O 4-1 U W n f». o o «> ^1 Q 0) •H U •H B •H O E 0 O rl to to Q) 04 4-30 ------- rotogravure. Model plant 3 represents a flexographic printing operation which is not a major source when considered alone. Some flexographic operations of this nature will come under the NESHAP regulations because of other HAP emitting operations at the facility. It is possible that more flexographic facilities will be regulated because of non-flexographic printing emissions than because of the HAP which results from flexographic operations by themselves. 4.3 CONTROL OPTIONS 4.3.1 Control Options for Publication Rotogravure All publication rotogravure plants in the United States presently use solvent recovery systems incorporating activated carbon adsorption and steam regeneration. Control device efficiencies of 95 percent to greater than 99 percent were reported. The recovered solvent is blended with purchased ink to maintain the proper viscosity for printing. Excess solvent is resold to the ink manufacturers. Most of the variation in overall efficiencies reported by publication gravure facilities is due to variations in capture systems. In all cases, dryer exhausts, containing relatively concentrated solvent laden air, are ducted to the solvent recovery system. Additional solvent losses during the printing process result from evaporation from ink fountains, escape of solvent laden air from driers (e. g. carried out with web between stages) and residual solvent left in substrate after the final press station. Non-production solvent losses occur from uncontrolled proof presses, off-press cylinder cleaning, and the storage, mixing, shipping and receiving of ink and solvent. Control options include varying degrees of improvement in capture and reduction in HAP content of ink. Improved capture involves containment of additional solvent laden air. Capture technologies, beyond collection and ducting of dryer exhausts, presently in use include floor sweeps, partial and full upper deck hooding of the presses, and total enclosures. Total enclosures are used in conjunction with collection and treatment 4-31 ------- of all pressroom ventilation air. Control options involving air handling can be specified in terms of varying degrees of air collection, up to and including construction of (or conversion of existing pressrooms to) permanent total enclosures. Improvements to press capture systems, including "close-in" hooding, will result in less HAP escaping to the pressroom. Reduced flows of HAP to the pressroom will decrease the overall air treatment requirements (with or without a total enclosure) if pressroom ventilation air must be treated to improve overall efficiency. All improved capture and control options, costed in Chapter 6, require the handling and treatment of additional volumes of air. The incremental solvent captured will be present at lower concentrations than the solvent laden air presently ducted to the solvent recovery systems. In the case of total enclosure systems, the HAP concentration in the additional air will approximate that of the pressroom. Pressroom concentrations of toluene, the HAP present in highest concentration in the ink (and the pressroom air), are limited by occupational health considerations to 100 ppmv. It may be economically advantageous to pretreat the additional air resulting from improvements in capture efficiency using solvent concentrator systems. It should be noted that systems of this type are not presently in use in the publication gravure industry segment; they are, however, in use in related applications including control of paint spray booth emissions. Concentrator systems are designed to adsorb solvents from dilute air streams. The sorbent (activated carbon or zeolite) is regenerated with hot air. The regeneration air requirement is only about ten percent of the volume of air treated. Thus the dilute solvent laden air stream is converted to a concentrated regeneration air stream which is exhausted to another control device. In this case, the exhaust from the concentrator system may be ducted to the existing solvent recovery system. Some increase in capacity of the existing solvent recovery systems may be required. 4-32 ------- The substitution of non-HAP solvents for a portion of the HAP solvents in the ink is a control option which may be used to decrease HAP emissions without increasing either the capture efficiency or the control device efficiency. This control option may not be available to all facilities. No information is available on the cost and effects on output quality resulting from substitution of non-HAP solvents for HAP such as toluene. It should be noted that while substitution of non-HAP solvents for HAP could be encouraged as a pollution prevention option, it does not significantly affect VOC emissions. All demonstrated control options include the use of solvent recovery systems as the control device. The systems of demonstrated effectiveness are composed of fixed bed activated carbon adsorption units which are cyclically regenerated with steam. These systems include regeneration gas condensers and solvent/water decanters. The distinction among the control options is the capture system employed. The specification of ventilation, hooding and ducting for incremental improvements to existing systems is site specific. There are an infinite number of gradations between existing capture systems and permanent total enclosures. Table 4-8 lists control options which represent discrete levels of capture. In all cases pollution prevention could be encouraged by allowing credit for elimination of HAP emissions through substitution of non-HAP solvent for HAP. A reduction in HAP emissions through substitution, combined with some degree of improvement in capture can achieve the same reduction in HAP emissions as that of the specified control option. 4.3.2 Control Options for Product and Packaging Rotogravure Packaging and product rotogravure plants in the United States use a variety of control technologies. Control strategies are influenced by the composition of inks and other materials applied on the press, and regulatory requirements. In most cases, regulations presently in effect limit emissions of VOC. 4-33 ------- •p fl 8 E 0) •P to CO o 3 a (0 u "> Q • , M -M o c 0 •H a, o o •P o •P (0 P 0) e c 4-> O 0) 10 O U >i M C W 10 O to u >i Q) Vl M xJ a> 3 O •0 O O 0)^0) tj ^H li •H .p 3 -P cr ^ c 0) -H M C O o o to •H dp 4J &> O (0 C in iH -H •H -P ! .p 10 (fl C -H fc 0) X a > CD o o (0 E -P a> O C P O Q) 10 M O >i to c to (0 O 0) U >i ft X! Q) •C 3 O Q) O O LJ LJ Q) "H f^ ^\| D1 -P a> ^ c M -H 0) ro ;> (LJ ^H o c o O 10 <«> -H O 4J O1 0 10 C H H -H •H 4-> * -P to «J C -H V4 Q) X Q > 0) •o o C -P 10 0) O li ^j 3 <0 to k e o e -P « iH O C 4J o o a) to C k 0 >i Q) 10 C 10 to o rH 0) U >i 10 b b ^J Q^ j^j fl) o ty^ ^ 4J -0 3 O Q) O O .p Ul M 0) C -H X3 M 0) d 4J C & -P (0 Q) ^ C El M "!o > 0) 20 10 C H H -H •P -H .p 10 > -P 10 C 10 C -H O ^ Q) X U -O > Q) tj c 10 0) C •P O 10 -H ^M 1 \ • 1^1 ^* to a c M O >i O -H h 10 4-> Q) TJ (0 M O 0) U C C 0) O 0) &4 »O & ^ 0) •P (0 r4 c o a) e H JJ 0) O -H J to ^ w < CQ U 4-34 ------- Control devices presently in operation were, for the most part, specified and operated to meet VOC emissions requirements. Where ink systems are primarily based on non-HAP solvents, no data have been collected to demonstrate the effectiveness of existing control devices with respect to individual HAP. Where HAP (e. g. toluene) based inks are used, control device efficiencies are directly relevant to HAP control. The selection of ink is influenced by the substrate printed and the performance requirements of the packaging or product. Air pollution regulations in force at the time of construction of the facility or specification of the control device also influence the type of ink system. Control technologies presently in use among major sources include activated carbon solvent recovery systems, catalytic incinerators and oxidizers, and thermal incinerators and oxidizers. These devices are capable of controlling greater than 95 percent of most volatile organic compounds when properly designed and operated. Much of the variation in overall control efficiencies achieved with any of these control devices is due to variation in capture efficiency. Where presses are located within permanent total enclosures capture efficiencies are assumed to be 100 percent. In other cases, capture efficiencies depend on the type of capture devices and pressroom ventilation systems in use. Some plants have adopted waterborne ink technologies to reduce VOC emissions. In many cases, low VOC ink formulations are used with no control devices. Capture systems at these facilities serve to collect dryer exhausts and vent them to the atmosphere. Some formulations are HAP free; many low VOC waterborne ink systems do contain small percentages of HAP (typically glycols, glycol ethers or alcohols). Control options for packaging and product rotogravure plants are given in Table 4-9. In options A and B, a control device is used with different levels of capture efficiency. The control device can be selected based on the ink system in use, or if more 4-35 ------- 10 .p c 0) (0 4J O •O O •c c (0 c •H o 10 ft to o •H 4J § en 0) 1 1 •P tt •^ >1 CO Q) M 9 I t •P (X (0 o o U ,_J "^1 0) Q __J Control c o •H •P O § e o 0 O in M to to to 3 0) Q) H M O a ft -H > •P -C Q) W Q) T3 3 M flj -H iH 43 3 O X O1 M 0) 0) -P M C M 0 Q) «W O >i O M £ •a 4J J C -H •P 0) > m u Q) tl k M Q) -H H a ro Q) osur iH u c H rH id •p o EH p Q) c id ^ Q) ft rH « g w 0) * MAC O 4J -H - M C E O O Q) •p M fr to o c >i -P -H tO (0 TJ M C >i 0) 0) M c a Q) -H Q) • > O TJ 0) o c to O -H M 3 0) O M O -P C •H (0 -H •PPM c >i o e Q) rH C 0) > id -H P t-t p O 0) o i CO U -H W < n 0) c o z c ------- than one type of device is potentially suitable, on the basis of cost. As described above, all control devices presently in use in this segment of the industry can achieve efficiencies of more than 95 percent. Option C provides for the use of low HAP ink with no control, provided that emissions do not exceed those of plants using solvent based inks with a high HAP content using an efficient capture and control system. 4.3.3 Control Options for Wide-web and Sheet Fed Flexography Most flexographic printing facilities, and all flexographic printing facilities outside of the flexible packaging industry, operate without control devices. Control strategies are influenced by the composition of inks and other materials applied on the press, and regulatory requirements. Control devices presently in operation were, for the most part, designed and operated to meet VOC emissions requirements. Where ink systems are primarily based on non-HAP solvents, no data have been collected to demonstrate the effectiveness of existing control devices with respect to individual HAP. The selection of ink (and other materials such as adhesives, primers and varnishes) is influenced by the substrate printed and the performance requirements of the packaging or product. Air pollution regulations in force at the time of construction of the facility or specification of the control device also influence the type of ink system. Some plants have adopted waterborne ink technologies to reduce VOC emissions. In many cases, low VOC ink formulations are used with no control devices. Capture systems at these facilities serve to collect dryer exhausts and vent them to the atmosphere. Some formulations are HAP free; many low VOC waterborne ink systems contain small percentages of HAP (typically glycols, glycol ethers or alcohols). Many flexographic printers use solvent based formulations which are completely HAP free. In some cases, solvent based inks contain small percentages of the same HAP used in waterborne materials. Some of these facilities operate VOC control devices. In the 4-37 ------- absence of compound specific data on HAP control, HAP removal efficiencies are estimated on the basis of VOC removal efficiencies. Control technologies presently in use include activated carbon solvent recovery systems, catalytic incinerators and oxidizers, and thermal incinerators and oxidizers. These devices are capable of controlling greater than 95 percent of most volatile organic compounds when properly designed and operated. Much of the variation in overall control efficiencies achieved with any of these control devices is due to variation in capture efficiency. Where presses are located within permanent total enclosures capture efficiencies are assumed to be 100 percent. In other cases, capture efficiencies depend on the type of capture devices and pressroom ventilation systems in use. None of the flexographic facilities using control devices for materials applied on flexographic presses are major sources on the basis of reported HAP emissions. Control options for flexographic printing facilities are given in Table 4-10. In options A and B, a control device is used with different levels of capture efficiency. The control device can be selected based on the ink system in use, or if more than one type of device is potentially suitable, on the basis of cost. As described above, all control devices presently in use in this segment of the industry can achieve efficiencies of more than 95 percent, at high concentrations of HAP in the solvent laden air. (It may be difficult to reach this level of control device efficiency at lower HAP concentrations.) Option C provides for the use of low HAP ink with no control, provided that emissions do not exceed those of plants using solvent based inks with a high HAP content using an efficient capture and control system. 4.4 ENHANCED MONITORING 4.4.1 Enhanced Monitoring for Publication Gravure All existing publication rotogravure facilities monitor control system performance using liquid-liquid mass balances. 4-38 ------- U) -P c 10 -P C •H o •H "ft (0 X Q) (0 § •H 4J § U O H I 0) 1 4J M W 0) Captur Q) O •H (1) Q . O fj O U c o •H s B O 0 0 tn M (0 (0 U) 3 0) Q) H fc 0 ft ft -H 4J -O Q) 10 0) T3 (0 -H rH 0) 0) 4-> Ul C M O 0) «w D >i O -0 -P J C -H •P Q) > (0 U M Q) -H EH ft (0 0) closur c H r-l (0 o E-i 4J C 0) C g p 0) (0 E C 0) ^ O 4J -H ^ t\| f^ 0) •P ^ CP U) O C W 10 TJ M C >i O TJ 0) O C U O -H M 3 0) O M 0 4J C •H tO -H 4J -P ^1 c >i o) e (0 -H 4J •H P U U) O 10 C >i W O -H 01 < 03 0) C o H c 1C JC to to 0) iH tr> c •H c •H to c o o C 55 •H ^j li_j C O 0) U Q) (-1 10 0) & ft O 4-39 ------- These mass balances provide average recovery data averaged over the reporting period. Because the HAP emissions are recovered, rather than destroyed, any intermittent system failures, decreases in control device efficiency or increases in fugitive emissions will be reflected in the overall mass balance. This method provides an average of continuous overall efficiency (rather than an average of discrete measurements of control device efficiency). 4.4.2 Enhanced Monitoring for Product and Packaging Rotogravure Facilities operating solvent recovery systems monitor control system performance using liquid-liquid mass balances. These mass balances provide recovery data averaged over the reporting period. Because the HAP emissions are recovered, rather than destroyed, any intermittent system failures, decreases in control device efficiency or increases in fugitive emissions will be reflected in the overall mass balance. Since this method provides an average of continuous overall efficiency (rather than an average of discrete measurements of control device efficiency) enhanced monitoring is not recommended for this industry segment. Facilities operating thermal incinerators or catalytic incinerators must monitor control device performance. Continuous emission monitoring may not be reliable for emission streams in which the HAP present makes up a small percentage of the VOC present, as is the case in many emission streams from packaging and product rotogravure printing. The output of continuous emissions monitors may not reflect the HAP concentration of the emissions stream due to differences in response among the HAP, non-HAP VOC, and products of incomplete combustion. Continuous control device measurement should be required for facilities operating thermal incinerators or catalytic incinerators. Variations in combustion temperature affect the performance of these devices. The operators of thermal and catalytic incinerators should install, calibrate, maintain, and 4-40 ------- operate a temperature monitoring device in accordance with the manufacturer's specifications. The temperature should be maintained at a temperature equal to or higher than the temperature at which compliance was demonstrated. 4.4.3 Enhanced Monitoring for Wide-web and Sheet Fed Flexography Based on responses to the ICR, none of the flexographic printing facilities operating control devices had HAP emissions in excess of 25 tons per year of HAP or 10 tons per year of any specific HAP. Facilities affected by a MACT standard regulating HAP emissions which operate control devices should be subject to the same enhanced monitoring requirements as product and packaging gravure facilities (see Section 4.4.2). Facilities controlling HAP emissions through the use of low HAP ink formulations should maintain documentation confirming the HAP content of the materials applied on flexographic presses. In the event that specifications provided by ink suppliers are inadequate to establish the HAP content, additional compositional analyses should be conducted by the facility. 4-41 ------- 5.0 ENVIRONMENTAL AND ENERGY IMPACTS OF CONTROL OPTIONS 5.1 ENERGY IMPACT 5.1.1 Publication Rotogravure Energy requirements for implementation of the control options for publication gravure plants include electricity to collect and treat additional ventilation air, natural gas to heat air for desorption of HAP recovered by the concentrators, and additional steam required for regeneration of the incremental activated carbon and recovery of the incremental HAP. The control options will recover incremental amounts of toluene, which has a heating value but is not used as a fuel. Energy use has been estimated for each of the 27 publication rotogravure facilities. The sum of the increased energy requirements is given in Table 5-1. Control options B and C have equal energy requirements. Energy impact calculations were based on the assumption of 1.5 percent solvent retention in the substrate. Uncontrolled and unretained HAP is assumed to be available in pressroom air at 50 ppmv. Ventilation requirements are estimated based on the volume of air necessary to dilute the uncontrolled and unretained HAP to this level. Fan power requirements are based on moving 50 percent (Control option A) or 100% (Control options B and C) of the pressroom ventilation requirement through concentrator systems plus the desorption gas. The desorption gas flow rate is 10 percent of the gas treated. The concentrator is assumed to be 93 percent efficient (this assumption is subject to change, should test data become available); the incremental adsorption capacity devoted to the concentrated stream is assumed to be 98 percent efficient. 5-1 ------- Table 5-1. Energy Impact of Control Options for Publication Rotogravure Plants. Energy Impact Fan Power (kwhr/yr) Natural Gas (SCF/yr) Control Option A 26,100,000 553,000,000 Control Options B & C 52,100,000 1,100,000,000 The concentrator is assumed to be desorbed with 300 degree F air heated with natural gas at 90 percent efficiency. Incremental carbon capacity is desorbed with 2 pounds steam per pound of HAP, based on model plant calculations. Table 5-1 gives the energy impact of the control options, assuming natural gas fired boilers are used to generate incremental carbon regeneration steam. 5.1.2 Product and Packaging Rotogravure Energy requirements for implementation of the control options A and B for package and product gravure plants include electricity to collect and treat additional ventilation air and natural gas for auxiliary fuel required for HAP destruction. Energy use has been estimated for 36 package and product rotogravure facilities with large enough emissions to be covered under the MACT standard. The sum of the increased energy requirements for control options A and B have been estimated in Table 5-2. These estimates are based on improvements to capture (with incineration of the recovered fugitive emissions) at 28 facilities, and installation of capture systems and control devices at 6 presently uncontrolled facilities. Two facilities which apply materials which are less than 4 percent HAP, and have no control devices, are excluded from the estimate. Electricity and natural gas requirements have been based on the model plant calculations. Model plants with control devices had average electricity and gas requirements of 16 kwhr and 9000 SCF per pound of incrementally controlled HAP. Model plants 5-2 ------- Table 5-2. Energy Impact of Control Options for Product and Packaging Gravure Plants. Energy Impact Fan Power (kwhr/yr) Natural Gas (SCF/yr) Control Option A 47,000,000 1.8 E 10 Control Option B 70,000,000 3.0 E 10 without control devices had average electricity and gas requirements of 11 kwhr and 2000 SCF per pound of incrementally controlled HAP. Control option B provides overall control equivalent to 96.5 percent of HAP usage. This is consistent with a 98 percent efficient control device, allowing for 1.5 percent HAP retention in the printed substrate. Control option A provides for varying overall efficiencies depending on the capture efficiency of the existing system. HAP retention may vary, but this will have only a small effect on energy requirements. Control option C could represent a decrease in energy requirements if facilities which presently operate incinerators converted to ink formulations with lower HAP content. Under some circumstances, operation of existing incinerators would no longer be required. This would result in the elimination of all auxiliary fuel requirements. These energy savings would not be realized by facilities presently operating control devices for VOC control unless waterborne (low HAP, low VOC), formulations were used. The energy impact of this control option has not been estimated because it is impossible to predict what formulations would be used to comply. 5.1.3 Wide-web and Sheet Fed Flexography Energy requirements for implementation of the control options A and B for wide web flexography plants include electricity to collect and treat additional ventilation air and 5-3 ------- natural gas for auxiliary fuel required for HAP destruction. It is estimated that 50 facilities may have emissions large enough to be covered by the standard based on estimated "potential to emit". This includes all facilities providing responses to the ICR with HAP usage of at least 10,000 pounds in 1992. Some of these facilities may have permit restrictions or other limitations which would keep their potential to emit below 25 tons HAP per year (or ten tons of any single HAP). Of these facilities, 15 presently operate control devices. The following discussion assumes that the 35 flexographic printing facilities not presently operating control devices will comply with the standard by reducing their HAP usage and the remaining facilities will improve capture and control. The sum of the increased energy requirements for control options A and B have been estimated in Table 5-3. These estimates are based on improvements to capture (with incineration of the recovered fugitive emissions) at 15 facilities. Energy requirements will increase if facilities which presently have no control devices install them to meet the standard. Energy requirements may decrease somewhat if some of the facilities considered on the basis of HAP usage are not major sources by reason of limitations of their potential to emit. Electricity and natural gas requirements have been based on the model plant calculations. Model plants with control devices had average electricity and gas requirements of 30 kwhr and 5400 SCF per pound of incrementally controlled HAP. Control option B provides overall control equivalent to 93.5 percent of HAP usage. This is consistent with a 95 percent efficient control device, allowing for 1.5 percent HAP retention in the printed substrate. Control option A provides for varying overall efficiencies depending on the capture efficiency of the existing system. HAP retention may vary, but this will have only a small effect on energy requirements. 5-4 ------- Table 5-3. Energy Impact of Control Options for Wide-web and Sheet Fed Flexography. Energy Impact Fan Power (kwhr/yr) Natural Gas (SCF/yr) Control Option A 1,770,000 318,000,000 Control Option B 3,540,000 637,000,000 Control option C could represent a decrease in energy requirements if facilities which presently operate incinerators converted to ink formulations with lower HAP content. Under somecircumstances, operation of existing incinerators would no longer be required. This would result in the elimination of all auxiliary fuel requirements. These energy savings would not be realized by facilities presently operating control devices for VOC control unless waterborne (low HAP, low VOC), formulations were used. The energy impact of this control option has not been estimated because it is impossible to predict what formulations .would be used to comply. 5.2 AIR IMPACTS 5.2.1 Publication Rotogravure The major air impact of implementing the control options is reduced emissions of HAP to the atmosphere. Minor impacts are associated with the production and use of electricity and fuel required for fans, desorption gas heaters, and boilers generating steam for incremental carbon regeneration requirements. Table 5-4 lists air impacts for the control options. Impacts associated with electric utility generation are assumed to be 3.6 grams sulfur dioxide and 560 grams carbon dioxide per kwhr. 5.2.2 Product and Packaging Gravure The major air impact of implementing the control options is reduced emissions of HAP to the atmosphere. Minor impacts are associated with the production and use of electricity required 5-5 ------- Table 5-4. Air Impact of Control Options for Publication Rotogravure Plants. Air Impact HAP Eliminated (Ton/yr) Sulfur Dioxide Emitted (Ton/yr) Carbon Dioxide Emitted (Ton/yr) Control Option A 7,000 103 50,000 Control Options B & C 14,000 206 100,000 for fans and auxiliary fuel for incinerators. Table 5-5 lists air impacts for the control options. Estimates for options A and B are based on upgrades to 28 facilities presently operatingcontrol devices and installation of capture and control systems at 6 facilities. Estimates for option C are based on the 34 facilities considered for options A and B plus two additional facilities presently applying formulations containing less than 4 percent HAP. Impacts associated with electric utility generation are assumed to be 3.6 grams sulfur dioxide and 560 grams carbon dioxide per kwhr. 5.2.3 Wide-web and Sheet Fed Flexocrraphv The major air impact of implementing the control options is reduced emissions of HAP to the atmosphere. Minor impacts are associated with the production and use of electricity required for fans and auxiliary fuel for incinerators. Table 5-6 lists air impacts for the control options. Estimates for options A and B are based on upgrades to 15 facilities presently operating control devices. Estimates for option C are based on a total of 50 facilities (an additional 35 facilities not presently considered for options A and B are included). Impacts associated with electric utility generation are assumed to be 3.6 grams sulfur dioxide and 560 grams carbon dioxide per kwhr. 5-6 ------- Table 5-5. Air Impact of Control Options for Product and Packaging Rotogravure Plants. Air Impact HAP Eliminated (Ton/yr) Sulfur Dioxide Emitted (Ton/yr) Carbon Dioxide Emitted (Ton/yr) Option A 1800 1900 31000 Option B 2600 2800 47000 Option C 2400 NA NA 4A=Not available. Table 5-6. Air Impact of Control Options for Wide-web and Sheet Fed Flexography. Air Impact HAP Eliminated (Ton/yr) Sulfur Dioxide Emitted (Ton/yr) Carbon Dioxide Emitted (Ton/yr) Option A 29 7.0 20,000 Option B 59 14 39,000 Option C 830 NA NA NA=Not available. 5-7 ------- 5.3 WATER IMPACTS 5.3.1 Publication Rotogravure Water impacts resulting from implementation of the control options are insignificant. Small increases in boiler blowdown may be associated with the incremental increase in steam required for recovery of incremental HAP. This water will be of relatively high quality. 5.3.2 Product and Packaging Rotogravure and Wide-web and Sheet Fed Flexography Water impacts resulting from implementation of the control options are insignificant. Control option C does not assume conversion to waterborne inks. If waterborne inks are adopted, pressroom cleaning will be done with water which may generate an additional low volume wastewater stream. 5.4. SOLID WASTE IMPACT 5.4.1 Publication Rotogravure The impact of the control options on solid waste will be negligible. The incremental carbon will require replacement every five to ten years. It is expected that most of this material will be sold for reprocessing into other products and will not become solid waste. The concentrators are expected to last 15 years or longer. 5.4.2 Product and Packaging Rotogravure and Wide-web Flexoaraphy The impact of the control options on solid waste will be negligible. If catalytic incinerators are used, catalyst replacement may be necessary every ten years. Spent catalyst may require disposal as hazardous waste. 5-8 ------- 6.0 MODEL PLANT CONTROL OPTION COST 6.1 INTRODUCTION Model plants, and the criteria used to choose them have been described in Chapter 4. Control options applicable to specific segments of the printing and publishing industry have also been described in Chapter 4. This chapter describes the estimated costs of applying the control options to the model plants. 6.2 PUBLICATION ROTOGRAVURE Model plant specifications are given in Table 6-1. These are based on several assumptions. HAP retention in the web is assumed to be 1.5 percent of that used. This material is not emitted in the pressroom or dryer. Pressroom ventilation rates have been proposed based on the volume of air necessary to dilute the fugitive emissions to acceptable levels for the health and safety of the operators. This ventilation may be presently supplied by doors, windows and leaks to the atmosphere. Pressroom volumes have been assumed based on the number and size of the presses in the model plants. Corresponding air exchange rates are listed, however, only the assumed ventilation rate affects the amount of air to be treated. The pressroom volume and air exchange rates can vary to provide the assumed ventilation rate. The pressroom and control systems are assumed to operate 120 hours per week. The control options apply to incremental capture and control of fugitive emissions. The control options involve collecting and treating pressroom air containing fugitive HAP which escapes 6-1 ------- c o C o u Tf Q) (0 C o •H .p (0 u •H VM £ 4J TJ § Q •^ B B S ft. O ro O ro O O ro O ro JIB^ 4J VM -^ 0> 4 0) S5 Q M B B 0) W ft, O O o O O O ^ji rH O O 0 •k o o VO o o o o o ^ vO o o o o o in ^ CN CN o o o o o in ^ CN CN £ •^ .Q rH & rt B 3 X ro cr> o ^ CN rH CO CN in ^ in 00 CN in ^ in in ro ^9 ^ tr> in ro ^ oT f~l ^^ c E 2 8, M a 3 ^i • O 00 r- 0 Oi H • CO pm o O\ rH 00 __ 4P ^^ u 01 u •rl H 0) 3 tt S O • t- ff> O fx. Q\ o p«fc 0\ o f". o o fx. 0\ ^ 0P t^r $ 3 U VM H H 0 M 1 o • 00 fx o 00 00 CN in o> o oo CO CN in a\ ««^ . rH O C s ^ rH O O O 0 CN ro VO in o o 00 CN 0\ 0 VO o o o 0 o oo ffl rH o o o o CN fe rH CN ___ \|^ ^4 »^ ja •o 0) rH rH 0 M 4J C 0 u o o o •k o CO o ro o 0 o . CO VD t- o 0 CN f^ O ro 0 O O 0 O t^ ^ CN O 0 O O 00 O " ^^ £ rH ^ TJ 1 J li r4 1 0 o o % 0 rH CN O 0 o «t u> Q\ o o o vO 0> o o m ^ ^ ro ro O 0 in ^ n ro ••». 1^ ^ rH •s c ^j 01 M 0 o o 5J1 ro in CN O 0 CN O> ^f O o VO in CN O o o in in t- * rH O o o o £ X fl rH I J^ a S 0. o 4J 0 O O C3* in o o o * d ^ o o o CN ro ^* o o o o 00 o ^ rH O o o o 00 o rH «Mh fft rj ^•^ i rH Q Q 0 a a S 0. o VO o CN 0 ro M ««N Vl ^ 4) » 1 « £ O o o o fe o 4^1 in o o o ^ VO rH CN O o ^* ^ ^4* rH 0 o o 0 in 0 o o vO ro ^ £ u w 0) 4J « • 1 in o I 0) in CN • rH VO O 1 0) VO rH • vO VO O 1 0) fv • "* VO o 1 0) VO VO • co VO o 1 0) vO VO • VO VM u « rH U C o u § 0 rl B B 0) 14 ft. CN • ro in CN VO CN rH • O CN 00 VO ro ro CO CN ^^ c ft U C o u § 0 rl B B S ft. B •^ C O TJ 0) TJ B 0) 3 B rt QJ o r3 ^ go> c W H O -M dP O ID C • • BH r^ «H +J (d (0 C 3 O B ^> B CN ^ — 5? ^ • o a w ^ C M ^^ O CO CO •rl B >1 jj Q) rt id M TJ Eft in 0 0) M-l.CC C 4J 0 •rl -rl 0) -P CTJ rt O -rl W •rl B 01 rt p O rH 0 rH ^ id TJ u 4J 0) 0 B 4J 4J C 4J * •rl -rl M §4J C 0) 0) C >i U C 0) O O 4J 0 a TJ E TJ 0)-rl C B +1 * 0) rH ^ A 3 4J 0) TJ C §55 rH QJ o - > JQ TJ O 0) B M £ CO B 4J < B 0) C rl-rl • ft CO TJ ft. TJ 0) W 0) C Z E •* 3 «0 B 4J CO a 0) o> < M rH 6-2 ------- the existing capture system. Since the pressroom air is at relatively low concentration, cost calculations are based on use of a concentrator system. The assumed concentrator specifications are given in Table 6-2. Control option A has not been applied to model plants 1 and 3, as incremental HAP reduction would be negligible for these cases. The concentrator systems are assumed to be 93 percent efficient (this assumption is subject to revision if test data become available) and exhaust a stream of 10 percent of the volume of the treated pressroom air. This concentrated exhaust stream is assumed to be added to the carbon adsorption/steam regeneration solvent recovery system. The capital costs of these systems for the three control options are given in Tables 6-3 through 6-5. Concentrator system costs were based on telephone quotes from three vendors. An upgrade to the existing solvent recovery system to account for the increased capacity required to treat the concentrator exhaust is included in Tables 6-3 through 6-5. These costs are detailed in Tables 6- 6 and 6-7. The inclusion of solvent recovery system upgrade costs is conservative as existing solvent recovery systems may be adequate to treat the incremental concentrator exhaust flows. In this case, increased regeneration frequencies could be required. Control option C includes retrofit construction of a permanent total enclosure. These costs are estimated in Table 6-8 and included in Table 6-5. Total enclosure costs are based on the construction of two new walls and the presence of two existing walls. Depending on the existing structure, total enclosure costs could be higher or lower than those estimated. Total annual costs have been estimated for the three control options in Tables 6-9 through 6-11. These estimates include recovery of capital costs based on a 7 percent interest rate and a 15 year equipment life. Operating costs include utilities, labor, materials, tax, insurance and administration. Additional notes to the cost calculation tables are given in Table 6-12. Cost effectiveness of the control options applied to the model plants is given in Table 6-13. Cost effectiveness varies between 6-3 ------- •o Q> CO (0 c o •H •P id o •H O a) a w 0) U u 0) o lH 4J O y o -H 4J (0 U •H VO 0) H -Q < o »"4 4J fi •H 0 Vl 4J 8 n ^, CO Vl o Vl 4> 0) U O U in ' CN •P id cu iH w ^J Q 3C -VWM O O O k. 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Capital Costs of Concentrator/Solvent Recovery Systems for Control Option A at Model Publication Rotogravure Plants. Model Plant 2 4 5 Intake Rate (SCFM) Intake rate (ACFM) Exhaust rate (SCFM) Installed Cost — Note 1 Site Preparation-Note 2 Duct Length (ft) — Note 12 Duct Diameter (in) Duct Cost @$126/ft Solvent Recovery System upgrade Cost including duct and site Prep. Engineering, supervision, construction, field expenses, fee, start-up, performance test and contingencies-Note 3 300,000 327,473 30,000 $3,600,000 360,000 180 60 22,680 19,040 4,001,720 1,240,533 100,000 109,158 10,000 $1,200,000 120,000 60 60 7,560 7,955 1,335,515 414,010 300,000 327,473 30,000 $3,600,000 360,000 180 60 22,680 24,536 4,007,216 1,242,237 Total Capital Cost- Concentrator System 5,242,253 1,749,524 5,249,453 Capital Recovery factor-Note 4 Annualized Capital Cost 0.1098 $575,571 0.1098 $192,088 0.1098 $576,362 Solvent recovery system upgrade costs are detailed in Table 6-6. See notes to cost calculations in Table 6-12. 6-5 ------- o o M 4J O O W g a) •p w >i CO §; c H rH in t ON 03 in o 00 r~ in ro CN ON rH r~ in rH rH in <* ON 00 in r* ON CN ON ro £ u rt 0) 4J a rl 3 id 4J C H O O 0 • in o o VO i-t CN O « 0- rH O o o ** m o o vO ro X B (0 « rl 4J D 3 id A X H O o o o CO ^ vO o o 0 CN ON in CN «/> o o oo CN r» i-H 0 O o o 00 • VO v> o o o CN ro t vy H 0) 4J O 2 4J a o U TJ 0) rH rH « 4-> 0) e H O o o 00 » vO i/> o o CN ON in CN w o 03 CN r~ rH «/> O 0 o 00 Tt VO w o o CN ro ^ CN 01 4J g 1 0 •rH 4J id Ul « 8- U P 0) 4J -rl W O ro ro O in rH o CO o ro ro O ro CN rH 0) 4J 0 2 1 4J VM — ' A 1 S 4J U 3 Q O vO O vO O vO O vO O VO ^_^ C •H V4 0) 4-1 •^ Q 4J U Q O 00 in rH •» V> o o on 00 f-H V* 0 00 r^ ro O 00 in rH ** v> o 00 t~ ro 4-) VM ••». VO CN rH <2> 4J n 8 4J U Q CN t in ^ ro v> O ^ rH » rH t/> 0 o o in v> in CN r< vO CN v> o o o in v> 0) •0 id ij g i 4J a >i CO & 0) > 0 u & 4J 01 > rH O W CN CN rH ^ O CN r~ o 5t CN « oo 00 CN v> o VO oo oo ON t-l W in O ro VO ON rH t- v> o 00 O> ro 00 ^ W 01 4J •rl O •H « 4J U % ON •H •a c 3 0 rH -H U 4J C * •rl M a 4J O( n 0) U 04 00 r- CN ro ro CN CN v> <* H rH in in 00 C3 ro CN . CN V> 5t ro O O in rH wv ^ 0) 0) VM TJ - « a W 4-1 «• a m c c 01 o £ 4J •^ ft n x 0) •H 0) U ro > c i4 TJ Id 01 01 rH 6 4J aoi C o 3-4 O 2 a VM VM i VI 0 «• C 0) 0) O>0 ft^H C-rl U •H 4J » C (4 U (X 0) 0) 3 3 & 0) rl 1 C C 4J 4-> -H •H B> r! 4-> O> C «J C C O 4-1 0 H u n o o o « r~ ro 5J1 oT in in ro 00 1- r^ ro v> r* O in C3 VO CN ON in rH r> CN t oT Vl O 4-> a M « 0) U § u 4-1 n 8 rH « 4J -rl » -1 id 4J 4J O 0 S H w ao ON O ^J • O 03 ON O rH • o 00 ON O . O 03 ON O _j • O 00 ON O rH • O ^1 0) * 2 U 0 4-> U « VM & 0) & U 0) « rH « 4J •rl (X id U VO r~ rH VO ro O rH ro >» oo « rH * V1V CN O VO 00 CN rH in o in ro O H v> rH rH VO O) VD 4J m o u rH « 4J —1 & id U •§ N •rl rH «J 9 C rt • ft* 1 VO 01 rH * £H C •rl T5 Q) rH •rl id 4J 0) • n r\i U ^l rH 01 1 t-l vD Ml m 0) CD rH 4-1 XI a id O H U C 0) -rl •o n) m M C 2-3 3 4J U 0 rH >i« a u >i4J rl 0 0) 0 > u 80 0) 4J rl m 0) 4-> 4-> c o 0) C > rH 01 O 0) (0 (0 6-6 ------- 4J (0 U C o •H •p & C O o CO 6 o 4J 10 >i CO in l vo 0) i-l A m (0 i 4J C r, Is 10 +J (0 o n) 4J in «j. CO (N rH -P 0 rH CM H 0 1 O C o in o C VO rH CM O o ,3. rH O O O O m o o o VO CO E o w 0 0 0 c H if CM 00 in o 00 in CO CM CM rH c~ in rH rH in CM 00 in t- CM CM CM CO E I 0 ti Vl 0 0 H O o o ^ m 0 o VO rH CM 0 !• rH O 0 o ,3, in o o VD CO fe U w 0 41 0 Vl B 3 0 X W O C O oc VO O o o CM CM in cs o o 00 CM p^ rH CO 0 O o o 00 5* VO CO Q o o CM CO t CO rH 0 \| JJ a o u •8 rH rH 0 41 B C H O O o oc VO co- co o (N CM in cs CO- o co CN r- rH CO- O o 0 00 VO CO- o o CN CO ^* W CN 0 O 2 O •rl 41 0 Vl 1 Vl CM •rl W o CO CO o in «-i o ro 0 ro CO O ro CM rH 0 * 2 1 VM ~ ,£3 1 0 U Q O VO O VO O VO O vO O vO 'c •rl Vl 0 41 •rl a 4) 0 3 Q O CO IT r- ^i CO O o CM 00 rH CO O 09 r-- CO CO o 00 in H ^ CO o 00 CO CO VM VO CM rH Of B 8 U y Q CM ^ in ^T PI 0 rH ^T H CO O o o in CO in CM vo CM CO o o o in CO 0 TJ iti (4 3 B m 17 0 o U 0 rH 0 W CM CN ^T o CM * r- co- o CN ^ CO CO cs o co co H CO in O CO VD CM rH (^ CO O 09 CM CO CO CO ft 0 Vl CM 0 41 •H B •o C U % o< •rl •o rH U •rl •P B O O 00 CM CO CO CM * CM ^ H H ^T CM CO CO ^ ^ vO rH VO CO in in 09 O CO CN CM CO- ^f co 0 O in rH CO 0 0 •a - c B 0 0 * 0) 4^ C C B O 0 0 •rl O.4J supervis field ex formance -Note 3 - Vl B - C 0 0 C-rl U •rl 41 «. C Vl O ft 0 0 3 3 O> U H 1 C C 4J -P -rl •rl O V) JJ o>c 0 c C 0 4J 0 u u n u 0 o t- CO ^* ^ CM in in CO CO t- CO CO r- o in o vo CM CO CM in H r- CM ^ CM O ^ji rH O ^r CO VO CO- ^1 0 4) 1^ ^J C 0 U 8 8 rH 41 U rH 0 n 41 41 B 0 >i EH W 00 vO in rH CO to- ^ 00 CM CO CM CO co CM co CM CO- ^ o ^i ^i CO- ^i o ^ ^ v> 0 3 0 H 4> 38 EH 0 •rl 4J 4J C U 0 3 c ij 0 41 e B C c 0 0 CM 0 CO VO CM CO VO ^J» «» a\ V) 00 CO VO VO o CO ro CO 0 CM r- 00 CO CM v> f VO 00 rH ^ CM c» 00 rH 1^ CO ^« VO v> +J B 8 rH ^J •H U rH 41 0 H CO CM O . O 00 CM o . o 00 CM o rH o 00 CM o , 0 00 CM o . 0 ^* f) 4J o z Vl 0 1j 41 B 8 H 0 41 •rl ft 0 o lized 0 3 0 0 B 41 B O U 0 •o 0 Vl H! 3 E 41 B B Vl fll Q) 0 u M CN] C i 01 VO > rH 0) (0 A 0 EH «^ M 1 -rl VO 0 C rH O A — 1 0 -P EH 0 rH C 3 •rl O •d 0 0 U rH •rl 41 a B 41 O 0 U •0 0 0 -p 0 B 0 B 41 41 0 B C O U 0 0 !« ffl • O t- rH \| U VO 0 0 •H o H J C •rl 0 0 C rH 0 -rl S0 4J 0 0 CM T3 6-7 ------- Table 6-6. Capital Costs of Required Solvent Recovery System Upgrades for Control Option A at Model Publication Rotogravure Plants. Model Plant 2 4 5 Incremental Flow Rate (SCFM) Pressroom Concentration (ppm) Concentrator Exhaust Cone. (ppm) Incremental HAP Loading (Ib/hr) Adsorption Time (hr) Equilibrium Adsorptivity (Ib toluene/ Ib carbon) Working Capacity (Ib HAP/lb carbon) Carbon Required (Ib) Adsorber Volume Required (CF) Adsorber Length (ft) Adsorber Diameter (ft) Adsorber Surface (sf) Adsorber Cost ($1989) Adsorber Cost ($1993) Carbon Cost @$2.50/lb Adsorber Cost including carbon 30,000 36.8 342 140.6 2 0.31 0.154 1827 109.59 16 3 164.934 $14,389 $14,474 $4,566 $19,040 10,000 26.2 244 33.3 2 0.30 0.148 449 26.97 9 2 62.832 $6,791 $6,831 $1,124 $7,955 30,000 53.2 495 203.0 2 0.32 0.160 2532 151.95 22 3 221.4828 $18,099 $18,205 $6,331 $24,536 Note: Costs escalated to 1993$ using Marshall and Swift cost index factor of (394.4/392.1). 6-8 ------- o •0 PQ tQ c o •H I 4J O O 4-1 (A 4^ 10 C Q) (C (C Q) > o 04J o o j o C-H 0) 4-> > 1C •H O O-H W rH 0) (X ^ •H H 3 0) &-d 0) O -w u c o 0 41 CO 1 X Vl o •P ^J S4 0 CO s 3 Vl •«"4 C \|\| P3 U VO • O in r- • o * * o in rH • O in , o «A. C o Xt Vl id u XI ^4 ft. 9B X) rH — * £ u 5 u CT C Vl * 00 in in ^ H f> rH in 00 oo CM ro ^. rH ,_ XI i-H •o s •H & S c 1 0 ir • ro j^ CM in CM « 00 in 00 m VO CM • r- a\ H rt . o rH «<^ fa U o o ^ u Ql £ 0 1 ^ ^ 0) XI 0 m 41 CM CM on «H ft 1 z vo H ro M g Z _, ^J IH £ «. C S ^3 0 n * ^ CM CO pa g z ,J ro M g Z ^^ HH ^^ Vl 0) 4J Jg Q jQ 0 m •o rt ^ ^ f** in » i-l O CO VO m VO • in CM iH ro g 2 CM in 17i rH • VD CM CM CO E4 g Z CT n •^ 8 lj s tn * •Q S CO * rH i-H O ro CM VI in 5f VO h i-H rH • ro H g Z f. en ro 00 i-l to- n U g Z oT 00 O> •H _p O o u ft Vl 0 n •o rt VO rH fe ro CM to- ro rH t~ ^ «H H V> ro g O Z in O in ^ 03 rH to- ro U § n 0^ S ii ^ a 8 jj Vl 0 (0 •o < VO Cft ro * rH rH to CM ^ ^ CM VI ro g Z 0 CM CM 00 to ro P4 g Z X) o in CM ^£f ^J n 8 e Vl 0 CN in ^ ^ ro to 0 rH * ^> rH to- O O o in to in CM ^ VD CM to O o in c o Xt u o* c •H •o 3 rH u 4J a o u Q) •Q 0 a * rH CM ro ^ ^ ., vTi ro >4-4 O Vl o 4i U 10 H-l X 01 •o c •^ 4J m o u 4J co •o rH CM HI rH £ 1 CO VO Vl « 0) S H XI & (0 C H CD C V> CO ro C e» O CT» rl i— 1 4-J O rH •P 3 U Q) Id •P U a rH 4) « n u o CO U 0) O CD 4> 4-1 CD m 85 Q •• C 0) J 01 O 0) z u 6-9 ------- 0) 1 4-> 10 O O •H -P 4J O O KH 0) CO 4J 10 10 Q) O ^ w « (0 §• 10 10 U Q) (0 4-) (Q O U 10 4J 10 O 00 I VO vV rH A (0 o n X o in rH O X o CM rH 0 X o CM o X o CM O X o ^* CM «-^ 4J X 0 CM H O n X o CM rH O n X o CM H o m X 0 in H o X o in rH ,— . 4J M •w^ 10 C o •H 10 c 0) B •H Q rH H 10 O O H CO O O CM O O CM 0 O H H O O H H «-x [LI CO CO rH rH 10 JJJ O £4 1 (0 4) rtj iH 10 4-> O EH O H X vo o H X VO O rH X vo o 1-1 X vo o H X vo ^^ 4J SH" CO C 0 -H CO c 0) B •H Q JH O O Q 0) ^\| <0 J • X 00 „ X CO •* X 00 ^J, X CO ^> X CO s-.. 4-> +^ 10 c o -H CO c 0) •H Q j_i O O Q rH rH 10 B CO CO in in •> o\ CM • £ VO CM £ CM VO CM V> if o\ VO CM ^ CT> VO CM ^4 4J (0 O U rH rH 10 O in CO H O in 00 ^j o in CO ,_i o in 00 rH o in CO H 4-> CO 0 CJ ^1 o o Q 0) ^1 10 O vo H O VO H O VO H O VO H O VO H • 1 (0 o o fa o o 0 H rH 10 B w 00 VO in ». H n ^> o •" ^ 4J 10 O 0 H <0 ^J O EH 1, W, o c O -H O 5 O CO 0 0) -v.i-1 Cn f) O c i r* H M (0 *-H H X O 0) 0) O B C rH (0 O »Q ^H	4-1 1 CO CO 0) iH rH r4 O 0) rH O O CO fl3 C T3 3 SO 10 O 0) Cn o en > S r< VO 4J CO It rH • M CO • O rH 13 • O rH 0) 0) 13 10 13 13 3e 13 -H rH (0 CO rH Cp (0 C 0) tt) B •H JQ C W 4J 0 co o •H 4J 13 • X T3 CO 10 C C C B-H (0 O CO O •H -r-» Q) 4-> 0) M CUC r< 10 B O 10 > B 4J13 W ^3 pH ^4 CO B O 10 < 10 fiJ3 k 10 4J <0 Q 4J CO 8 C O •H 4-> 4-> CO B 0 U Cn B -H •0 • rH CM •H 0"i 3 a\ CQ rH CO - E >i 10 B 0) 10 £ (X -B • O H tj 10 CO 4J B 0) 10 Q) * r\ (£ • Pb CO •H rH . rH « -H A * O< B O tj I \ Q)-rH •H 13 10 M J5 rH B 10 0 3 r< B 1^ CO 4J4J CO CO O H rj m 6-10 ------- o •H •P (0 O -H Q) C O -H .p to (0 O o o «M 10 U O o to c o 4J O at vo 0) in I rt i rt CN 1 ^j « rH 0. ^ 0) I 0 ^ Q O r-l 0 U n 8 CN VO ro vD P-H in co- co 00 o CN cn iH CO- tH f^ in in P-* in to- m 0 0 rH a 4-> •H a id o •c 01 M •r4 rH « 9 < B .p B O U O* C id § VO 00 VD ^« tH VO in cn oo ^« vD 00 VO ^* tH in 0) JJ O Z O id ^i 0) u c s 1 ^> -r4 u u $ 01 rH H ro r^ on ^. ^« cn cn ,3. tH ro t^ cn 4* ^* vo 01 0 Z 0 ti ^1 ^ c 01 u c 0 u B u tH vo CN ^ H iH ro in CN vo oo CN o tH tH 0) 4J O Z 1 01 •o id kl s a ^i B W ft 0) > o o 0) (C 0) 4J (0 IT VO oo in in in cn tH CN VO vD 00 in r- 0) 4J o u 0 « rH 0\ e 4J 81 00 on r- oo ro ro on CN cn Cn I* 00 00 0) 4i O I JJ 01 ^ h 0 B •H > 1 (0 CN CN in ,j. vo cn O in tH CN 00 CN in ^i vo cn 0) O Z 14 Q ^^ 2 « u c c 0) ti •H « S CN CN in ^ vo cn O in iH CN 00 CN in ^ VO O tH 01 0 z 1 B rH 0 -H l< 0) 4> a S 00 r- cn on O CN tH CO On on VD O cn vo cn O CN •O C • id tH tH U 01 C -P « 0 9 1 B 01 C > M -H «. « S^ ^J 4J 0) rS C L) ^ Kg $"§ g ro cn 00 00 rH _j V) ro in O ^T cn ro w> in o on ro 00 rH tH CO- n 4J B O U rH 0 rj f* C < rH « J 0 H CO On • O on tH «/> ro t- CN H ro CO- CN ro on rH ro tH wv in rH 0 O z 4J •o 0 U C 0 s u ofi 4J 1 rH O n in ^* ^ 00 on cn to- O CO r- CN vD ro to- CN r- °l. tH in 0 rH CO- B a o u rH ^ 9 C 4J 0 Z t CM rH 1 vo 9) « ^ C B C o -H JJ id rH g rH 10 u 4J B O U O -P B tt 4J g (0 6-11 ------- c o •H 4J (0 U •H 0) •0 o 4-) (0 OQ O •H (0 4J 10 (0 3 C 10 4J O H I 0) r-l A ro •P C Q) I M V? in t PQ ^> 1 03 ro 1 00 CM 1 00 rH I n 4J e ro 00 ^ rH Sv CM O VO 00 CM 0 "S N *4 \|\| Annual n •P m o u en c \|\| Operat t-H to ro ^ to CM ^ ^1 r^ in o rH O in o r> rH VD ro ^T VO CM CM to r- rH in 0 4t 0 2 1 J^ O 4J It 4i C 0 U 0 u 1 41 •H u •H \|\| Electr 00 ro VO ro O in in ,4 vo rH to {••fc ^ o oo ro VO ro O O 01 VD CM VO 0 4J 0 2 1 V4 0 4J 0 U C 0 u B id O r- vo in CM r> VO in 0i 00 CM in rH in 00 rH r- 01 § .p >, &• II 02 0 1 « 0 «Steam- Upgrad ^ in ,.!" o rH in 00 00 00 rH ro ro 01 CM r- ^ in pT o rH p r- 0T f. 0 4J O 2 W Q f\ r-l & C •H \|\| Operat CM ro rH to rH ro ro ro r^T 0 O <^« ^ ^1 CM ro rH VO rH VO rH 00 0 2 U O H-rl 4J B •H rN C 4J f4 P ^ CM to (^ VO >* CM «/> 01 O CM 0 O ^ w- ro 00 ro ^ in in rH ro 0i 00 in * CM in ro CM ro t> rH a 4) a a r-t I c \|\| Total . oo 00 00 CM ^* ro «v 0i in r-T VD ^ •* to ^* ^ ro V* 00 f^ ^ r,T ro CM 00 rH CM rH in rH 0 4J O 2 \| JJ •rl •o 0 U ^1 0 8 A) Solven VO ro (• ^ CM H CM V> 01 in 00 ^T ro 01 0i rH 01 ^ rH in rH " VO in r-l CM CM CM t- in o rH VO rH a 0 u r-l « ^ C s. I M i to 0 X) id •H B C O 4J id •H 3 U id u Jj a 8 0 4> B 0 0 0 0 01 6-12 ------- C o •H 4J m u 0) •a 4J n) U C O 15 So. ll p o g cr> II (0 rH 10 4J H I 0) (0 EH in i O t 1 u 1 u CN 1 1 U 41 C « S! rH 01 "8 as ! 5 f^ 2 -p 8 CM ^> VD Os ro O H * CO OS (^ tH ^ CO 00 o iH ro CO o VO Os oT ro O tH O CM in ^T r^ CO ^) a 8 id U •8 N «H •H « 3 C rt Costs c •H 2 0 tH vO ro ^ vO CM ^ ^t r- m O iH O in O ^ VO ^T vO CM CN VO pT tH in 0) 41 O 1 U 0 41 a 0) u 8 ^i it U u 41 U 01 •H W CO ro vo ro O in in tH VO ^ VO r~ O iH oo ro vO ro 0 Os O vO CN VO 01 41 1 trator c u c 8 n IB O tH t- vO in CM r- vo in o. co CN in in 00 iH ^ r- o> % 41 u W r frH 23 8 « 01 kl 0) o> 41 04 W D ^ ^i in r- O iH in 00 CO CO iH ro ro Os* CM S in ,C o tH f^ f» Os r~ 0) \| Vj c? •H £ 0 CN ro H VO iH ro ro i^1 O O •» ^ CM H VO rH VO ^J1 iH 00 0) 1 1 H) O n •«H > y u CM O ro CO tH tH f. r- ro in VO CM CM ro CN o ro CO tH tH in in <- o O^ 0) 1 14 1 iJ 01 u S c 0) 41 •H It CN O m 00 tH tH l>^ r~ ro in VO CN CN ro CM o CO CO tH tH in in r- o tH O tH 0) 41 §. 1 i-l l^ -r4 14 0) 41 « in r~ CO r^ ro VO vo CM CM in tH CM in in tH tH in oo CO f^ ro OS ^i tH t^ CN •O C • « tH iH Q) U 0) S z 9 1 B 0) C > M -H 41 - « SiJ .. >iC 41- (•U f£ 0 Vl ro in ro CM t- * CM CO in ^y vO VO O O CO o CN vO Os in rH tH ro VO in VO ^ fe CN CO CM ro Os ON r- tH n 43 8 tH c < H « 41 0 H 00 CO 00 CN ^ ro Os ^f in pT VO CO VO ^ ro CO 00 r-- ro CM CO 00 r- tH CN tH CO in »H 0) 41 O z 1 41 "8 u covery S 41 0 > i-l 0 (0 in vo Os" CM tH CM VO OS O Os* ro Os CO VD in iH vO in tH CO ro in tH Mi 00 CN CN fe CM CO ^ in f~ pT vO tH CO Costs 3 e c 41 0) . CN 1 vO fl) w Q id H C a c 0 •H 41 id r~t 3 U tH id u a O u 0 41 ID 41 g ! 6-13 ------- Table 6-12. Notes to Control Cost Calculations for Model Publication Rotogravure Plants. Note Note Note Note Note Note Note Note Note Note Note Note Note Note Note 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. From telephone quotes; $12/SCFM installed price — modular: no economies of scale Arbitrarily assumed 10% of installed cost. 31% of installed cost, per EPA Handbook (EPA/625/6-91/014) 15 years at 7% Volume is 110% of intake rate, pressure drop =6 in. water, fan efficiency is 65%, electricity at 0.06/kwhr Desorption air at 300 degrees F. Desorption gas flow rate =10% intake flow rate. Gas at $5/MM Btu. 0.5 hr/shift per concentrator, $25/hr including overhead . 15% of operating labor 110% of operating labor Assumed equal to maintenance labor. 4% of total capital cost 30 ft length of 5 ft diameter duct in parallel. The existing adsorbers can be operated to handle the small additional loading. A nominal upgrade cost is given as a upper bound estimate. 0.3 Ib steam/lb carbon. Steam at $6/1000 Ib. Recovered toluene valued at $0.15/lb. 6-14 ------- 1 U CO % Q) e a) M u c rJ (0 O 4J W A 0) 4J -H 10 0) >iT3 (0 O 4-> (0 C to Q) tP U 0 C -P o o u « 4J U 0) 43 U 0) - CM rH ^ CM «> VO 0< O cn ro «/> vO in rH ^ VO in to- co in rH 00 CM CN CN in f- pT VO to- ^ a 8 rH 3 fj jg£ ro vo 00 rH rH f rH ^ CN in ^ ro rH in rH 00 CN CN ro rH ^T "c" ^ a a 0) c 0) > ^J u 0 IH H a O U 6-15 ------- $1500 and $14,000 per ton of HAP reduction. The cost per incremental ton of HAP reduction is highest at the model plants with high levels of baseline HAP control, as these plants have less fugitive emissions available for capture and treatment. The annual costs for these plants are lower than the annual costs for the model plants with low levels of baseline control as less additional air must be handled at the well controlled plants. 6.3 PRODUCT AND PACKAGING ROTOGRAVURE Model plant specifications are given in Table 6-14. These are based on several assumptions. HAP retention in the web is assumed to be 1.5 percent of that used. This material is not emitted in the pressroom or dryer. Pressroom ventilation rates have been proposed based on the volume of air necessary to dilute the fugitive emissions to 50 ppmv VOC. The concentration of HAP in the pressroom varies depending on the composition of the materials applied. Ventilation air to dilute fugitive emissions may be presently supplied by doors, windows, and leaks to the atmosphere. Pressroom volumes have been assumed based on the number and size of the presses in the model plants. The pressroom and control systems are assumed to operate 80 hours per week. Control options A and B, as described in chapter 4, apply to incremental capture and control of fugitive emissions from existing capture systems at the model plants. Control options A and B involve collecting and treating pressroom air containing fugitive HAP which escapes the existing capture system. Costs have been estimated on the basis of thermal incineration of this pressroom air stream. Specifications for thermal incinerators applicable to the model plants are given in Table 6-15. In many cases, catalytic incineration would be appropriate for the solvents in use. Catalytic incineration systems would have lower operating costs and might have total annualized costs than the estimates for thermal incineration systems. In some cases, concentrator systems (see Section 6.2) might be used to reduce the size and capital and operating costs of the incinerator. 6-16 ------- 0) b tp o •H tF (C n) 4J o s •o o (0 c o id u •H o 0) (X CO tH O4 rH ! I U) 0) 10 EH in ^ ro CM H .p g i-l 0. rH 0) 1 &l C •H t7> 0 •X U o. g -,_! Bu ^^ i-H •rl O TJ 0 O jQ O iff c U •- ***** 0 M It $J< fit V o, a a u r^ 9 rtTJ C O o 4J rl 4J a W vO ^t 00 o VO H 00 ^»^ ^ „ ~»» ao a C o •rl 41 0 -p W ^^ m 0) o m 0) u Oi X O o CM rH O CM r- O O in ro t-H X X O VO 0 0 f) fl X X o o rH X 0 ro O CM X 0 in 0 0 O ro H X O ^ CM X ^J in U C 0) u IH HH M U Q f^ 0 ^J 8 o o o 0\ (•I. in oo ^ u c 0) u IH H j^ 0 H I O o o o o o o o o o 00 m rH o 0 o in vO f^ ^, 0 0) J5" •8 I-l rH O H 4J C 8 Oi in r- 01 o o o in rH 0 0 o fe Oi o o o ro O O in ro tH H 0 ^1 ]Q 0) ^ j^ ^f & 1 in CM o f iQ o o o in 00 0 0 0 rH 0> in o O o Ol ro O 0 in tH CM rH M 0 0) IS" g Q g B V rl Oi o 4J § O o o o C3 in CM * CM O O O O O (•. O o o in vo p^ ^ 0 0) A "8 ft <-t o VI 4J C 0 § o in CM ^ CM O O in fe t- ro O O O ^ CM tH O 0 O in ^H O o in ro tH M 0 0) ^ % c id 4-J & § o in i* ^ fx ^ tH O 0 m ^ CM rH CM O O O . CO 00 o o 0 in Ol rH O o in H CN tH (^ 0 01 JQ C Q w V V s Oi 0 •U § o in o in o in o in o in I , u c o u ^ g Q Q VI o a 0) Oi t- • •H CM O • 0 CM in • r- ro O d j O o in Oi , u c o o Oi g Q Q m ID 0) Vl Oi , 0) I-l •Q rt u -rH •H 0 ^J g II •». z 6-17 ------- c •H o» (0 r O R) •O C 10 O 3 •o o rH a " CN CO tH f» O VO Ch (^ VO 0 iH CO CN in CN Ch CN VO in «^i CO r- ro S fc O W 0) 4) C o •H ^J tf rH 4> 01 > iH Ch in ro id 0) c u c M o 4» 8 > ro rH O CN CO O O in CN t^ o o in in Ch CN O O in Ch tH 0 in t- o VD t. ^ J3 O ^ 01 C u c M O 0, a CN * O in CO o in CN 0 oo CN in CN in 00 tH ro rH r- r- in t. ^ JO fm^ O 41 C 8 04 si rH a c g jj u M 00 VO 0 ^ 03 vO ro • Ch ^ji • VO • u <4H HH M rH o ^J C S t-t (Q ^j C \| (^ U H ^ f ct ^J CO CO rH o> rH o 14 ^) c s iH »-l gj 1^ 01 s 1 z oa c o 4 o rH O ^) c o u 1 1 M O ^ \|^ g •^ U c H rH \| fj 01 H in ^ ro CN iH 4> C rH 0. tH 0) s CO Ch r- rH • rH 0^ 00 rH • CN 1 1 A O< 0) M ^j rH 3 U 01 rH g g > CN 00 tH r- 0 vO Ch (^ VD 0 tH CO ^> CN in CN Oh CN VO in 4ji 00 1- ro § O w 0) « c o •rl ^J H] rH •rl i i 0) > CN 00 tH r. 0 VO (^ VO 0 tH CO ^p CN in CN CN VO in qji CO (^ co g o CO r? ^ ^ H jj o g£ u g g H O in r- (^ rH O O m CN tH CN O O O oo co p* o o o in Oh O o in rH CN «H ^j ^ A O 4> a 0) c •H 0 C M O 4J g > in CN o ,). vo O o o in 00 o o o tH Ch in o o o Ch ro O O in tH CN tH jj ^ a u 0 ^) 4 V4 0) c •H U c H O & S ^ CN 00 O VO o in P* o 03 O in «* tH VO in O in 0 r- ro in CN "S- in rH tH j. ^ a rH O l^ 4> e 8 04 g rH fO 41 C i rl U M VO ro tH 00 VD • ro in • 00 CO • CM • u •rl MH IH H rH O ^ c o u rH id 41 C 1 rl U M * Ch 00 <» ff> CO Oh 00 Oh rH 2 41 C 0 u rH rH ^ (4 0) I z iH CO oo II S S3 Q> 41 a) 41 0) id ^j' ,c 1u Ul m #> •H in Oh y u > o1 C a. a> 2 u C H-4 O id CN V] Ch « II C Z H s o -~ c •^4 01 c c 0) O 3 -rl rH 41 0 « ^J «— t f-l m 41 •H C 0) ^ SC E o .. o E o y 0 O 0) D VI < Ct, 6-18 ------- The capital costs of these systems for control options A and B are given in Tables 6-16 and 6-17. These costs are based on the OAQPS Control Cost Manual1. The capital cost for control option B includes retrofit construction of a permanent total enclosure. The basis of this cost estimate is given in Table 6-18, and included in Table 6-17. Total enclosure costs are based on the construction of two new walls and the presence of two existing walls. Depending on the existing structure, total enclosure costs could be higher or lower than those estimated. Total annual costs have been estimated for control options A and B in Tables 6-19 and 6-20. These estimates include recovery of capital costs based on a 7 percent interest rate and a 15 year equipment life. Operating costs include utilities, labor, materials, tax, insurance and administration. Cost effectiveness of the control options applied to the model plants is given in Table 6-21. Cost effectiveness varies between $10,000 and $48,000 per ton of HAP reduction. The cost per incremental ton of HAP reduction is highest at the model plants with high levels of baseline HAP control, as these plants have less fugitive emissions available for capture and treatment. The annual costs for these plants are lower than the annual costs for the model plants with low levels of baseline control as less additional air must be handled at the well controlled plants. Control option C involves the use of low HAP ink. The adoption of this control option could, in some cases, represent a net savings over baseline levels of control. The applicability of this option depends to a large extent on the type of printing and the performance requirements of the product or package. Some facilities, printing on both porous and non-porous substrates report either zero or very low HAP use as a proportion of total materials applied on rotogravure presses. Where feasible, conversion to low HAP inks could result in substantial reductions in operating costs. Cost reductions from conversion to low HAP inks have not been calculated, because low HAP inks may still 6-19 ------- (X n) O vo H VD 0) 10 EH in v M CM rH \|\| Model Plant rH ff> in m CM o 00 Oi ro ro o f» O ^ 04 rH 01 VO t rH ri 01 01 ffl CO rH £ u to S •s 4J \|\| Incinerator Ir in r- 00 n r» o in 01 vo O rH O O O c 0! ft O O in r~ 01 o in r> o VO H >i J3 r-l Vl 0 l« 8 •* u M o 4J i n rH 0 CM n o o in CM ^ o 0 in m & CM o o in 0> rH O tn r~ o VO M >i A rH Vl O 4J « 0) -rl u H o 4i eu ^ in 01 in 0i in 0« in 0i in 01 <#> S U 01 Control EfficJ o r» o i~ o t^ o r~ O r~ 4> 0) a >iO) H rH « id •rl B H •rl * X C 3 O Incinerator, i \|\| instrumental rH t^ 0i in 0> CO ro rH in O rH <* ro n in <* rH t ro rH ro O i-l 01 01 CO o 0. 4J B 8 § •H 4J « \|\| Direct Install o r- rH 01 0. ro •* VO CO 0 rH CO f^ rH O in rH CM r~ in vo 0 rH 01 ** CO ro 01 4J n s o •rl •y « rH rH \|\| Indirect Instz o 0i 0i rH ro VO «r 0 m ro in <* <• CO «* CO r^ ro r ro ^ r» CM o ro O H Site Preparatj t ro O t» ^1 in p» co 01 01 0i in 01 o 5T CO CM 00 VO CO r* 00 in ro CO vo r- rH in v> to 00 01 H Total Costs (3 vo o CO o CM VO to o rH O 00 VO 0< rH rH O 5* 01 ro ** rH r^ VO VO r- 0i * r- 00 in «v ro 0> 01 I Total costs (] 00 01 o • 0 oo 0. o • o CO 01 o • o CO 01 o • o 00 01 o • 0 Factor > 1H Capital Recovc ^ vo rH 03 vo to- VO r- vo ** f- tn 01 M ro o .-1 CN in CM ro r^ c- o in • VO .p a 8 i-i o 4i •rl \|\| Annualized cai o -o •ri I-H J 0) -0 «d -ri c t-t o c u c ~i o * •H +J X a o T) •H 3 0) O> ft rl B C •M id -r< ^ a A n rH C 3 •ton •H O ro ui - o 0i 4J O>U 0i U C rH fl).rl rH U • 0 01 0) C 4J +J 01 O»rH u en) 0) B -rl O Vi 0) 4J o 01 TJ C 0) 3 0 -H u B O> U 4> c en at •rl -rl C 0 r-l « U C O - id O 4J • js o n — 0)0 >. C 4-> 01 00 tn 4J -rl 01 rH U 4J O am c s rH (0 M O, i-l P rt foundation, su Indirect insta art-up, perfori 3-90-006, Janu 9/852.0). on includes painting. tor fees, st al (EPA 450/ (Factor=966. •H -o u g 4J C « C X « « M 0) 0) Direct Instal] for ductwork, expenses, cont Control Cost I Swift Cost Inc 6-20 ------- •H u 10 •o c 13 0 0) "88 «0 10 C rH O <0 U C •H I U c m H 4-> C H (0 «JH 0) u O 41 ^ 14 0) c u H 0 41 o > in CM o ^ VD O O C V 00 0 o 0 rH ON in o o o en ro 0 o in H CN rH t. ,>« ft f-t J^l O 41 }4 0) •H U H 0 41 04 £ in en in in ON in on in ^p ^ o c 0) u •H VM H 0 W 41 C 8 o r- o o o o 4P ^ u 0) Recov ^J id 0) •. 00 00 en m -P CD 8 S o 00 ro vc r- VC f c VO f- in 00 CM 00 00 o 0 CN o o VO ro -P S 0) M VW ^J C TJ g, * •H X &3 0) CO SOI a? •H n rH •H ^ K e 3 0 ^+» erato rumen C 41 •H n u c H r> ^ r- r- ro O in o r- CN n 00 CM r- 00 VO CN CN r-\| VO O O 00 o 41 n 0 u c •H 4J 4 rH rH £ n M 41 U 0) M O ON r^ r- oc r CM CM rH CO ON in CO r-- rH r- ro CM ^ VO o VD H rH rH 4J a 8 o 41 rH rH a n c M 41 U 0) L4 •rH •0 c M n it o CO ro t~ VO rH rH rH in ro ao 00 O CM o o VO c o 41 01 CM 01 u r- m in O in vo in vo CM rH t* n H in 00 on vo o en a\ VO VD in rH VO in 00 00 on rH 0) 41 D 0 u 4J C 0) E & W iH rt ^j H 00 VO CM 00 ro r- VO 00 00 0 00 00 O> rH rH ^ n ON o< in vo oo on vo v> CO 0» H a 4J B o u 41 c 5 1 -H iH rt ^> o H 00 CN CO CN on Oi Oi CN rH IN VO rH 00 VO in rH H <> CN Ch ^^ ^ i^ ri on an rH ^ 01 3 a 0 rH U C rH fQ 41 0 § 0 E 14 CN in in VD vo t- in 00 f~ ro ro 00 on ro CN ro rH ^^ CN on CN 00 o c* oo i?' ro ff* r-i o* c •o inclu 1 1 o 0 u CO en o rH d CO en 0 d 00 en o fH d 00 0> o ^ d 00 tr> 0 d u o 4J O &4 ^ (^ O O u rH 4J u « U VO rH ^i oo 0 in in H on «/> ON ro in CN rH O> in 0 O CN 0 rH 00 ^ a O u •H id 4J "ft U N rH id 3 C 5 M.^ £gS>, c «o v^ CO) 2.O^ •HO O • Ol-H rH U) CM ^J (M ^J* If) - O 4J 00 rH 3 0 <^ U 41 U . U C C VO J 0 0) rH ON U U C Id II 0) Id 3 W rH - E C O 0) o> C id 4J 2 HI ^« T\ 5 rT B •••H CM Id C U 4J fe O 0) B) — •H 0) • 0 JJ C O O X S^ 01 0) O>-H rH "O vi c o o c Q) 41 C U M 0) 41 - CO O< C 4> CTJ-H O 0 •H 3 -P U •HrH C W •O O O CM 41 CCU O"U Id -H < -H £ -DOS 4J C W * a a e no o TJ 4J U •• C h 41 n a Q C O (U Pl 0 0) ID rH 3 -P A id 0) IB £ rH (0 01 •.rH 4J M c * n at 04J 0 o s •H CO U O 41 C C ON -i U a) v> •H Q) 4J ro CO "O ft ON 0) C O C rH 3 ft-H rH 3 S 0 O • 1 O 41 C O>4J »H •H C K rH TJ •H Id O 01 C 4J -P « -•* a « ft CO U IH a ID n rHTJ 0) C 0) « C VM o 41 Id -H CO n w 4J -P C - 0 ft 0 M U U 3 O 4J 0 ffl CO • O ? M O ~ OJ JJ JJ IB O M u c o> •H 3 0 C ON P TJ U 0 rH 6-21 ------- I 0) <0 •H tP (0 ^ O (0 •g (0 U 3 TJ O LI O «M (0 4J 10 O U •P U s 4J (0 O 0) Li 3 (0 o rH U c H (0 o • 00 H vo Q) H (0 CO C o •H S H O M 4J O U in ^ CO CM H 4J C (0 rH DH rH 0) ? £ O CO X O CM H O n X 0 in H O CO X o 0 H O n X O in O n X o ^» f\i »^i ^^ 4J S^ 10 0 •H CO C 0) g •H Q rH H (0 * O CO X o CM H O CO X O vo o CO X o CO o n X o CM rH O CO X o o -— •» 4J MH •^ CO c o •H CO C 0) E •H O rH H (0 5 O O CM f^ O o CO VO o o a\ CO o 0 H CO 0 o CM o H ^•^ frl CO 10 rH rH (0 o e i (0 0) rtj H <0 4J O EH O rH X VO 0 H X VO o T-t X VO o rH X VO O H X vo ,— » ^j H n CM H 00 in in o\ CM H CM CM CO v> 4J (0 0 O rH rH 10 O in CO H O in CO rH O in 00 H O in CO H o in 00 4-> 10 0 CJ LI o o Q 0) (0 o vo H 0 vo H O VO H 0 VO rH O VO H 4-> CO O U ^1 O 0 o rH rH e CO ^* CO CM ^ CO CM {^^ 0^ o^ ^ CM w rH ^ CM VO H CO VO in rH CO H n CM o\ CO vr 4J CO O 0 rH (0 4J O EH TJ 0) 0) rH C O rH O O rH 4J (0 TJ e c -co 4J O M rJ (0 0 TJ 5 0) r C co 0) O^M co (0 TJ — TJ Q) >; M 4J O «J O O J3 ll fj ^^ 4J C W ^-H C 0) TJ 0 4J 3 O (0 H CPU Q) 0) C H * O t7< Q) 4J (0 e irt (y CO O M H C «H rH 10 (0 10 TJ ^"(0 O Q) 4J Q) O M O - O TJ CO C rH O E rH O 3 • (0 C ft ^ C rl Q) co E Q) C rH _ 4J TJ I in W 0) LI •HTJ o * XTJ OH 0) «J TJ 0) 0) O tt) Q) 4-> O 10 0) • • ^J ^Q Q^ (0 3 CM 10 O O * w^ •HOC) 4J TJ TJ VO Q. -H rH EH CO 1 3 H M W ttf Q) O W E C O < CO O TJ rH (0 3 C i4j 4-> (Q ,_! in ------- •H tr (0 .* o 10 •o (0 U o iH 0) 4J O id -H (o a fc O o 4J -H (0 O fc H 0) -P c c •H O H I W (0 0) c (0 0) 0 5 «tl ^ (0 rH 4J tr to o O 4J ro g «J O • Oi H I VO 0) H (0 in „ ro CM rH 4i rH n. 1 Model ] in n O VO VO CM i-H t-- S •o 0) •rl 1 U 1 Electrj oc CM r« * vO t-l in vo CO ro rH CM £ u W 2 1 B o \|\| Natura] IT CM co r- ro o CD VO 1 rH 0 1 4> B S •rl \|\| ElectrJ t- o r- r- CN r- CO CM rH ro CM O vo 00 n t-H vD rH O CTi CM iH CM en rH IH CM 0) 8 B id o VO co CO rn vo 00 ro vo 00 CO vo 00 00 m vo 00 CO 14 01 0 u a ,j lH oo rH m 00 t^ ro co rH oo rH rn co rH I lance Labor-Note 4 0) S oc t- n CO r» oo 1-1 ro CO i-t t- ro 00 rH r- ro >i in 0) 4J I rH 4> X 0) u 0) c •rl S ro cr> VO m «- vo o< VO ro r- vO ro vo > vO 0) S z •2 \| Overhei CM ro 00 CM CM CM o vO ro vO CO VD vO CM O O in CM u r- 0) 1 B B 0 1 Other c vc CO VO VO vO ** in CM CM 0 rH CM in CM ? O in vo > L Recovery t v£ ro CM \f „ in r- vo vo CM in cs rH 0 O O 00 CM 8 rH i 1 Total ; i 0.* 0 h M 0) •o ft oi a n 0 ID £ 0) &J rH ftt- rH U C C •no in 41 rH i c u •H C 0) hrough effici ft O 0 4> •o i sl 3 fa B B fl) • 1 inch pr exchanger > • Fan power based on * i 70% efficient heat < Lcity cost - 0.06/kWhi INote 1. througl Electri * O W ^». ro O 0 O CO- id a & a 0) S lours rH H Iegrees F O o rH O U 1 CM 0) I j labor •rH a 1 VM O in rH rH rviso 1 W •+^ VO CM H JJ VM 1 Operator labor 0.5 1 ro 0) ^J Q £ vO CM JJ VM -H a in Maintenance labor 0 0) ^j Q C rH 01 u ntenan •rl O rH Q d) L assumed Maintenance materia in 0 I B rH mater nance IV •rl a 3 rH ft M \| rH VM o Overhead assumed 601 vo 0) 4> "ft u rH JJ 0 vw 0 0) A O 41 assumed ranee B c id 0) S £ 0 ft a. Administrative chare 0) 4i 0 O z u 6-23 ------- tn c •H o> a u (0 cu •o c (0 4J u 3 o M OH 0) • •C ffl s§ •P-H (0 -P Q. CO O rH O H •P O (0 H M -P Q) C C O O C I in H.P (0 C e io C H 0) 04 € 0) r-l rH 3 o > HH (0 M (Q tp •P O 10 -P O O u os 10 I < 10 •P O EH o fN VO 0) rH rQ (0 in ^i ro CM rH 41 a rH ft 4 fH 0) 1 ^ O\ r\i IN at rH a> « r- •^ P CM ao VO ^t ^r rH O rH CM ro •Sfc P* in CM ^i ^ in rH ^ M •o 0) Vl -r» & & >1 41 ••H U Vl 41 U 01 rH H CO p^ in j ro 00 CM ro O ff\ CM CM VO S f U W •O 0) Vl •H & (C 0) id O ^ « Vl 3 * 8 O at CM 00 VO in in at VO o to at in CM o to O ro CO ro Vl rl ^, tO- t-H 0) 41 0 I 41 m B u •^ Vl -p u 0) rH W ^ rH CM ,3, ro " CM CM VD in (N VO o CM CM * CM CM a> CM o 00 in ^* ro vO ^« ro Vl rl ^^ V» . CM - Note 41 CD 0 u n u vO ao CO ro VO CO CO ro vO CO CO ro vO CO CO ro vO CO ro Vl £1 >^ t/v ro 01 41 Jg 1 1 D« C •^ > « Vl § CO rH r- ro 00 rH r» ro 00 rH (^ ro 00 rH r>- ro 00 rH ro Vl ^t ^fc to «• 0) 41 0 K 1 Vl 0 $ r3 0) U « f* 0) J c •^ ni 00 rH t ro 00 rH r~ ro 00 H r- ro 00 rH ro 00 rH ro Vl ^ ^ v> in 0) O 2 rH i 0) u f4 0) 41 C ft a s ro 0\ r- VO ro at VO ff> VO ro at vO ro VO n ^ ^^ t» VO 01 41 f i w 0) Vl o CO in at CM CM in ro CM ro o CM r- 5 in m r- t-H ro vO I? r- CM Vl ^t ^ w r+> 0) a n o VI 0) I F. vO rH ^ 00 o in in rH at ro in CM rH Ot in o o CM o rH CO Vl £>1 ^ t» Recovery ^ « 4J •rl & U VO rH ro ^T rH VO in o> rH \|C ro oo oo ro in CO rH r- CM in CM rH in 00 r- in CM CM rH in 41 0) 8 rH « I s «« rH id e a O Vl o o 0) n M Vl o o n A Vl H Oir- H £ t C C ••H 0 —4 in 41 H « •a qj C Oi ft O^ w O 8 . lj!S Vl VO 0) C II •H O ti c u •-H C 0) £ -H IT U 3 "4 Vi VM £ 01 41 a. o Vl O a c lj 4 3 &4 n n S« M * ft Q) Vl £ C !£ O * X ,-J (1 Ift "^ w ^** SO . o C 41 0 « H TJ £ -P 0 n n 41 o id c o A 0) •rl >, Vl 0 41 Fan powe 70% effi lectrici .£M * J* 3 • 0) O Vi • fe CJ CO 1 — ro 0 O w 41 id n a U) 14 « 0) j^ 0) o a Vl o rH rH V n Vi 0) •o o o 5j- rH JJ C o Operati CM tt I O^ •H Id nj 0) Oi o VM 0 df in H It 14 rH s^ 1^ O 0) •rl > Vl 3 W • VI VO at CM rH ^y 4J 41 VM •H £ O Vl £ in O VI & a rH Operator ro • Vl 0) O 41 a o Vl id £ u 0) --I 41 a Vl Administ cost. ^J 0)-rl 2 U 6-24 ------- (0 o M 4J O U (0 1 o u .p C (0 0) CO ** 0« rH * P O •as «H * °^ U3 S-0 0» X 0) T in n ** •* CO in r- vo 2 vo in v ^ 0) ^ V H H 0 «» O t (0 (0 0) C 0) •H .p u 0) w H ^j W 0 U ffl C o -H ^J a o r-\| 0 J^ 4J C O u • OS CO 0 VO o in t-> 0 CO 0 in «g< >. H VO in o in o r- n vo CM t in H H ^^ j^ ^, s^ JQ »«• C 0 •H 4J U 3 •0 0) <\| 3 VD i-l r> •" H VO •co- in o> H t>T n CO CO in .. CO f-H (^ v Ct in 4J O O rH <0 3 C C O o OJ o M in PI t^ o N 00 VO » 0> CM 00 n CM ^t VO f» CO CO c" o EH (Q (0 0) C 0) -H 4J U 0) 4H H ^j (0 0 U 6-25 ------- require operation of a control device to meet VOC emissions standards established by other regulations. 6.4 WIDE-WEB AND SHEET FED FLEXOGRAPHY Model plant specifications are given in Table 6-22. These are based on several assumptions. HAP retention in the web is assumed to be 1.5 percent of that used. This material is not emitted in the pressroom or dryer. Pressroom ventilation rates have been proposed based on the volume of air necessary to dilute the fugitive emissions to 50 ppmv VOC. The concentration of HAP in the pressroom varies depending on the composition of the materials applied. Ventilation air to dilute fugitive emissions may be presently supplied by doors, windows, and leaks to the atmosphere and by exhaust fans discharging directly to the atmosphere. Pressroom volumes have been assumed based on the number and size of the presses in the model plants. The pressroom and control systems are assumed to operate 80 hours per week. Control options A and B apply to incremental capture and control of uncontrolled emissions and fugitive emissions at the model plants. Control options A and B involve collecting and treating pressroom air containing uncontrolled HAP (model plants 1 and 2) or fugitive HAP which escapes the existing capture system (model plant 3). Costs have been estimated on the basis of thermal incineration of this pressroom air stream. Specifications for thermal incinerators applicable to the model plants are given in Table 6-23. In many cases, catalytic incineration would be appropriate for the solvents in use. Catalytic incineration systems would have lower operating costs and might have lower total annualized costs than the estimates for thermal incineration systems. In some cases, concentrator systems (see Section 6.2) might be used to reduce the size and capital and operating costs of the incinerator. The capital costs of these systems for control options A and B are given in Tables 6-24 and 6-25. These costs are based on 6-26 ------- X 0) rH O (0 o •H 4J (0 U U 0) a CO 4J C m 0) I CM CM I VO Q) n j c 41 rH 0. rH 0 1 j? 04 5 fe! ^L Vl g 0. Q c D ^ U id 04 rH — 1 O ON n I-l rH 5 rH 3 X O Vl a w VO v^ VO V0 •», VD : CM rH a C 0 •JjJ 41 (0 a 0 m a 0 Vl h o n X o ON X O in VT* X 0 in O X O O* X 0 rH 41 VM X ^ M X 41 a c o n c 1 Q £ Q Vl a n 0 Vl a. o o CO o in » rH O 0 0 O 0 00 O O 0 cT o in Vl id 0 >i A 0 D H O O o o rH » rH O o 0 o in in o o 0 in CM Vl a) Q) ft 0 n i o o 00 o o 0 0 0 rH o o 0 rH CM Vl id 0 >1 A 0 n D i oo o o t1 u 0 u — 1 «M H 0 Vl -P 3 „ 0 o ^, u c 0 —I u «H VM VM H 0 U > 0 Q rH O Vl ^J 0 u ro O O ^ U 0 U i }r •o 0 c fd 4J £ § O in O 00 CM o in f^ ^ rH 4f in in CM vo CM Vl id 0 >i ifl g Q 0 Vl 0) a 0 Vl ft 0 41 1 o ifl o in 0 m H •^ C O ^J 4 Vl c 0 u o u £5 0 Q Vl o tt 0 Vl 04 rH ON rH ON VO ft ft C o jj 4] Vl « 0 u § u s 0 Q u m n S a. i IM O g in o rH Vl a a ID 0 0 e vt 3 ft 0) m 0 1 1 • 0 H »H • n 00 41 00 3 « o^ S T> 0 «"e « > 0TJ U Sum "0 * rH 4J >i >i« 0 0 -P ^ Id M x vi 0 1 41 On COO 0 ft a 3- a g ™^ O ^t ? • S c JE H H -» 0 •a vi rH 0 4J o e c C-rl O « u JC 4^ jj « n 0VIC n ^ a -ri •H 4J •d c S D rH jjj 3 ft •O OT3 3 3 0*00) n C Q 6-27 ------- Table 6-23. Incinerator Specifications for Flexography Control Options. Thermal Incinerator — Control Option A Model Plant 1 2 3 VOC Molecular Weight Ventilation Rate Incinerator Intake VOC to Incinerator HAP to Incinerator Incremental HAP Control Incremental Control Efficiency New Overall Control SCFM SCFM lb/yr Ib/yr lb/yr % % 35.5 19,899 9,950 12,313 10,343 9,825 46.8 46.8 66.8 232,654 116,327 270,875 49,250 46,788 46.8 46.8 87 92,492 46,246 140,250 1,020 969 12.1 85.1 Thermal Incinerator — Control Option B Model Plant 1 2 3 VOC Molecular Weight Ventilation Rate Incinerator Intake VOC to Incinerator HAP to Incinerator Incremental HAP Control Incremental Control Efficiency New Overall Control SCFM SCFM lb/yr lb/yr lb/yr % % 35,5 19,899 19,899 24,625 20,685 19,651 93.6 93.6 66.8 232,654 232,654 541,750 98,500 93,575 93.6 93.6 87 92,492 92,492 280,500 2,040 1,938 24.2 97.2 Assume: HAP is methanol (MW=32) , Non-HAP VOC is ethyl acetate (MW=88.1) Pressroom ventilation incinerator efficiency = 95%. 6-28 ------- Table 6-24. Capital Costs for Thermal Incinerators at Model Flexographic plants - Control Option A. Model Plant 1 2 3 Incinerator Intake VOC to Incinerator HAP to Incinerator Control Efficiency Heat Recovery Costs (1988$) Incinerator, auxiliary instrumentation, sales freight SCFM lb/yr Ib/yr % % 9,950 12,313 10,343 95 70 116,327 270,875 49,250 95 70 46,246 140,250 1,020 95 70 equipment tax, and Direct Installation Cost Indirect Installation Cost Site Preparation Total Costs (1988$) Total Costs (1993$) 257,811 77,343 79,921 25,781 440,856 500,311 476,716 143,015 147,782 47,672 815,185 925,120 378,535 113,560 117,346 37,853 647,294 734,588 Capital Recovery Factor Annualized capital cost 0.1098 $54,934 0.1098 $101,578 0.1098 $80,658 Direct Installation includes foundation, supports, handling, erection, electrical, piping, insulation for ductwork, and painting. Indirect installation cost includes engineering, construction and field expenses, contractor fees, start-up, performance test, and contingencies. Costs based on OAQPS Control Cost Manual (EPA 450/3-90-006, January 1990) . Costs escalated to 1993$ using Marshall and Swift Cost Index (Factor=966. 9/852.0) . 6-29 ------- Table 6-25. Capital Costs for Thermal Incinerators at Model Flexographic plants - Control Option B. Model Plant 1 2 3 Incinerator Intake SCFM VOC to Incinerator Ib/yr HAP to Incinerator Ib/yr Control Efficiency % Heat Recovery % 19,899 24,625 20,685 95 70 232,654 541,750 98,500 95 70 92,492 280,500 2,040 95 70 Costs (1988$) Incinerator, auxiliary equipment, instrumentation, sales tax and freight Direct Installation Cost Indirect Installation Cost Site Preparation Total Equipment Costs (1988$) Total Equipment Costs (1993$) Permanent Total Enclosure (1993$) Cost including PTE (1993$) 306,588 91,976 95,042 30,659 524,265 594,967 28,284 623,251 566,916 170,075 175,744 56,692 969,427 1,100,162 28,284 1,128,446 450,156 135,047 139,548 45,016 769,767 873,577 28,284 901,861 Capital Recovery Factor Annualized capital cost 0.1098 $68,433 0.1098 $123,903 0.1098 $99,024 Direct Installation includes foundation, supports, handling, erection, electrical, piping, insulation for ductwork, and painting. Indirect installation cost includes engineering, construction and field expenses, contractor fees, start-up, performance test, and contingencies. Permanent total enclosure costs based on assumptions in following table. Costs based on OAQPS Control Cost Manual (EPA 450/3-90-006, January 1990) . Costs escalated to 1993$ using Marshall and Swift Cost Index (Factor=966. 9/852. 0) . 6-30 ------- the OAQPS Control Cost Manual2. The capital cost for control option B includes retrofit construction of a permanent total enclosure. The basis of this cost estimate is given in Table 6-26, and included in Table 6-25. Total enclosure costs are based on the construction of two new walls and the presence of two existing walls. Depending on the existing structure, total enclosure costs could be higher or lower than those estimated. Total annual costs have been estimated for control options A and B in Tables 6-27 and 6-28. These estimates include recovery of capital costs based on a 7 percent interest rate and a 15 year equipment life. Operating costs include utilities, labor, materials, tax, insurance and administration. Cost effectiveness of the control options applied to the model plants is given in Table 6-29. Cost effectiveness varies between $30,000 and $60,000 per ton of HAP reduction for model plants 1 and 2. For model plant 2, a large part of the cost may be justified on the basis of non-HAP VOC control. Costs per ton of HAP reduction at model plant 3 are extremely high because of the dilute nature of the fugitive HAP. This type of plant would be expected to meet the standard by reducing the HAP content of its ink, or limiting its potential to emit in some other way. Control option C involves the use of low HAP ink. The adoption of this control option could, in some cases, represent a net savings over baseline levels of control. The applicability of this option depends to a large extent on the type of printing and the performance requirements of the product or package. Some facilities, printing on both porous and non-porous substrates report either zero or very low HAP use as a proportion of total materials applied on flexographic presses. Where feasible, conversion to low HAP inks could result in substantial reductions in operating costs. Cost reductions from conversion to low HAP inks have not been calculated, because low HAP inks may still require operation of a control device to meet VOC emissions standards established by other regulations. 6-31 ------- Table 6-26. Total enclosure Construction Costs for Flexographic Plants - Control Option B. Wall Dimensions (ft) Wall Dimensions (ft) Total Area- Two Walls (SF) Large Door Dimensions (ft x ft) Small Door Dimensions (ft x ft) Wall Cost Large Door Cost Small Door Cost Total Cost 150 x 30 90 X 30 7200 6 X 10 8X4 26274 1850 160 $28,284 Assumptions: Two existing walls, two walls to be constructed, one large door and one small door to be added. 8" concrete (sand aggregate) block, 3/8" mortar joint, tooled one side. Large door-Aluminum door and frame including hardware and closer. Small door-16 gauge steel, 5" deep. Costs from Waier, Phillip R. et al., Construction Cost Data, 51st Annual Company, 1992. Means Building Edition, R. S. Means 6-32 ------- Table 6-27. Total Annual Costs for Thermal Incinerators at Model Flexographic Plants - Control Option A. Model Plant Electricity Required Natural Gas Required Electricity Cost-Note 1 Gas Cost - Note 2 Operating Labor-Note 3. Maintenance Labor-Note 4 Maintenance Mat'1-Note 5 Overhead-Note 6 Other costs-Note 7 kW SCFM $/yr $/yr $/yr $/yr $/yr $/yr $/yr 40.7 123 10,185 92,660 3,886 3,718 3,718 6,793 20,012 475.7 1436 119,069 1,078,176 3,886 3,718 3,718 6,793 37,005 189.1 569 47,334 427,316 3,886 3,718 3,718 6,793 29,384 Capital Recovery $/yr\| 54,934 \| 101,578 \| 80,658 Total Annual Cost \|l95,906 \|1,353,943\|602,807 Note 1. Fan power based on 4 inch pressure drop through incinerator and 15 inch pressure drop through 70% efficient heat exchanger. Fan/motor efficiency = 60%. Operation 4171 hours per year. Electricity cost = 0.06/kWhr. Note 2. Operation at 1400 degrees F, 4171 hours per year. Gas at $0.003/SCF. Note 3. Operator labor 0.5 hr/shift at $12.96/hr. Supervisory labor = 15% of operating labor. Note 4. Maintenance labor 0.5 hr/shift at $14.26/hr. Note 5. Maintenance material assumed equal to maintenance labor. Note 6. Overhead assumed 60% of labor plus maintenance materials. Note 7. Administrative charges, property taxes and insurance assumed to be 4% of total capital cost. 6-33 ------- Table 6-28. Total Annual Costs for Thermal Incinerators at Model Flexographic Plants - Control Option B. Model Plant Electricity Required Natural Gas Required Electricity Cost-Note 1 Gas Cost-Note 2. Operating Labor-Note 3. Maintenance Labor-Note 4 Maintenance Mat'1-Note 5 Overhead-Note 6 Other costs-Note 7 kW SCFM $/yr $/yr $/yr $/yr $/yr $/yr $/yr 81.4 247 20,369 185,311 3,886 3,718 3,718 6,793 24,930 951.5 2872 238,138 2,156,352 3,886 3,718 3,718 6,793 45,138 378.2 1138 94,669 854,631 3,886 3,718 3,718 6,793 36,074 Capital Recovery $/yr\| 68,433 \| 123,903 \| 99,024 Total Annual Cost I 317,158 [2,581,646 \| 1,102,513 Note 1. Fan power based on 4 inch pressure drop through incinerator and 15 inch pressure drop through 70% efficient heat exchanger. Fan/motor efficiency = 60%. Operation 4171 hours per year. Electricity cost = 0.06/kWhr. Note 2. Operation at 1400 degrees F, 4171 hours per year. Gas at $0.003/SCF. Note 3. Operator labor 0.5 hr/shift at $12.96/hr. Supervisory labor = 15% of operating labor. Note 4. Maintenance labor 0.5 hr/shift at $14.26/hr. Note 5. Maintenance material assumed equal to maintenance labor. Note 6. Overhead assumed 60% of labor plus maintenance materials. Note 7. Administrative charges, property taxes and insurance assumed to be 4% of total capital cost. 6-34 ------- Table 6-29. Cost Effectiveness of Control Options A and B for Control of Model Flexographic Printing Plants. Model Plant 1 2 3 Control Option A HAP Reduction (lb/yr) Annual Cost Cost Effectiveness ($/Ton) 9,825 $195,906 39,879 46,788 $1,353,943 57,876 969 $602,807 1,244,184 Control Option B HAP Reduction (lb/yr) Annual Cost Cost Effectiveness ($/Ton) 19,651 $317,158 32,279 93,575 $2,581,646 55,178 1,938 $1,102,513 1,137,784 6.5 REFERENCES U. S. Environmental Protection Agency. OAQPS Control Cost Manual, Fourth Edition. EPA-450/3-90-006, January, 1990. p. 3-42 to 3-58. U. S. Environmental Protection Agency. OAQPS Control Cost Manual, Fourth Edition. EPA-450/3-90-006, January, 1990. p. 3-42 to 3-58. 6-35 ------- TECHNICAL REPORT DATA (Please read Instructions on reverse before completing) 1 REPORT NO EPA-453/R-95-002a 2. 4 TITLE AND SUBTITLE National Emission Standards for Hazardous Air Pollutants: Printing and Publishing Industry Background Information for Proposed Standards 7. AUTHOR(S) 9 PERFORMING ORGANIZATION NAME AND ADDRESS U.S. Environmental Protection Agency Emission Standards Division (MD-13) Office of Air Quality Planning and Standards Research Triangle Park, NC 27711 12 SPONSORING AGENCY NAME AND ADDRESS Director Office of Air Quality Planning and Standards Office of Air and Radiation U.S. Environmental Protection Agency Research Triangle Park, NC 27711 3. RECIPIENT'S ACCESSION NO. 5. REPORT DATE February 1995 6. PERFORMING ORGANIZATION CODE 8. PERFORMING ORGANIZATION REPORT NO. 10. PROGRAM ELEMENT NO. 1 1 . CONTRACT/GRANT NO 13. TYPE OF REPORT AND Final 14. SPONSORING AGENCY EPA/200/04 PERIOD COVERED CODE 15. SUPPLEMENTARY NOTES 16. ABSTRACT National emission standards for the control of hazardous air pollutants from the printing and publishing industry are being proosed under the authority of Section 112 of the Clean Air Act. This document contains background information and environmental and cost impact assessments of the regulatory alternatives considered in developing the proposed standards. 17. KEY WORDS AND DOCUMENT ANALYSIS a DESCRIPTORS Air Pollution Printing Publishing Rotogravure Flexography Hazardous Air Pollutants 18. DISTRIBUTION STATEMENT Release Unlimited b. IDENTIFIERS/OPEN ENDED TERMS Air Pollution control 19. SECURITY CLASS (Report) Unclassified 20. SECURITY CLASS (Page) Unclassified e. COSATI Field/Group 21. NO. OF PAGES 176 22. PRICE EPA Form 2220-1 (Rev. 4-77) PREVIOUS EDITION IS OBSOLETE -------


        United States
        Environmental Protection
        Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EPA-453/R-95-002a
February 1995
        Air
                 MAR 3 °
ERA    National Emission
        Standards for Hazardous
        Air Pollutants:
        Printing and Publishing Industry
        Background Information for
        Proposed Standards
                                       ENVIRONMENTAL
                                         PROTECTION
                                          AGENCY
                                        DALLAS, TEXAS

                                        LIBRARY

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                                 EPA-453/R-95-002a
 National Emission Standards for
    Hazardous Air Pollutants:
Printing and Publishing Industry
  Background Information for
      Proposed Standards
          Emission Standards Division
     U.S. ENVIRONMENTAL PROTECTION AGENCY
           Office of Air and Radiation
      Office of Air Quality Planning and Standards
      Research Triangle Park, North Carolina 27711
              February 1995

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This report has been reviewed by the Emission Standards Division of the Office of Air Quality Harming and
Standards. EPA. and approved for publication. Mention of trade names or commercial products i$ not intended
to constitute endorsement or recommendation for use.  Copies of this report are available through the Library
Services Offices (MO-35). U. S. Environmental Protection Agency. Research Triangle PartX N.C. 27711. or from
National Technical Information Services. 5285 Port Royal Road. Springfield. Virginia 22161.

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                        TABLE OF CONTENTS
1.0 INTRODUCTION                                              1-1
     1.1 OVERVIEW                                             1-1
     1.2 PROJECT HISTORY                                      1-1
          1.2.1 Background                                    1-1
          1.2.2 Data Gathering                                1-3
          1.2.3 Emissions and Control Data                    1-4
     1.3  REFERENCES                                          1-4
2.0  THE PRINTING AND PUBLISHING INDUSTRY                     2-1
     2.1 INTRODUCTION                                         2-1
     2.2 GRAVURE PRINTING                                     2-2
          2.2.1 Publication Rotogravure                       2-3
          2.2.1.1  Process Description                        2-3
          2.2.1.2  Profile of the Publication Rotogravure
               Segment                                        2-4
          2.2.1.3 HAP Use and Emissions                       2-4
          2.2.1.4 Baseline Emissions                          2-6
     2.2.2 Packaging and Product Gravure                      2-6
          2.2.2.1 Process Description                        2-10
          2.2.2.2 Profile of the Package/Product
               Rotogravure Segment                           2-11
          2.2.2.3 Hap Use and Emissions                      2-11
          2.2.2.4 Baseline Emissions                         2-20
     2.2.3  Intaglio Plate Gravure                           2-20
2.3  FLEXOGRAPHY                                             2-22
     2.3.1.   Wide Web (and Sheetfed) Flexographic Printing   2-22
          2.3.1.1 Process Description                        2-23
          2.3.1.2 Profile of Wide Web Flexographic Segment   2-23
          2.3.1.3 HAP Use and Emissions                      2-24
          2.3.1.4 Baseline Emissions from Wide Web
               Flexographic Segment                          2-40
     2.3.2 Narrow Web Flexographic Printing                  2-40
2.4 LITHOGRAPHY                                              2-41
     2.4.1 Sheet-fed Lithography                             2-42
     2.4.2 Non-Heatset Web Lithographic Printing             2-42
                               iii

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     2.4.3 Heatset Web Lithographic Printing                 2-43
2.5.LETTERPRESS                                              2-44
     2.5.1 Non-heatset Letterpress                           2-44
     2.5.2 Heatset Letterpress                               2-45
2.6 SCREEN PRINTING                                          2-45
2.7 OTHER PRINTING PROCESSES                                 2-46
2.7 REFERENCES                                               2-46
3.0  CONTROL TECHNOLOGY AND PERFORMANCE OF CONTROLS           3-1
3.1 INTRODUCTION                                              3-1
3.2 CAPTURE SYSTEMS                                           3-1
     3.2.1 Publication Rotogravure                            3-2
     3.2.2 Product and Package Gravure                        3-2
     3.2.3 Wide-web Flexographic Printing                     3-3
3.3 CONTROL DEVICES                                           3-3
     3.3.1 Carbon Adsorption                                  3-3
     3.3.2 Thermal Incineration                               3-4
     3.3.3 Catalytic Incineration                             3-4
3.4 PERFORMANCE OF CONTROLS                                   3-5
     3.4.1 Publication Gravure                                3-5
     3.4.2 Product and Packaging Gravure                      3—7
     3.4.3 Wide-web Flexographic Printing                    3-10
3.5 LOW HAP AND HAP-FREE INKS (AND OTHER MATERIALS)           3-15
     3.5.1 Publication Rotogravure                           3-16
     3.5.2 Product and Packaging Rotogravure                 3-16
     3.5.3 Wide-web Flexographic Printing                    3-17
3.6 REFERENCES                                               3-19
4.0 MODEL PLANTS, CONTROL OPTIONS, AND ENHANCED MONITORING    4-1
4.1 INTRODUCTION                                              4-1
4.2 MODEL PLANTS                                              4-1
     4.2.1 Publication Rotogravure Model Plants               4-1
     4.2.2 Product and Packaging Gravure Model Plants         4-3
     4.2.3 Wide-web and Sheet Fed Flexography Model Plants    4-4
4.3 CONTROL OPTIONS                                          4-31
     4.3.1 Control Options for Publication Rotogravure       4-31
                                iv

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     4.3.2 Control Options for Product and Packaging
     Rotogravure                                             4-33
     4.3.3 Control Options for Wide-web and Sheet Fed
     Flexography                                             4—37
4.4 ENHANCED MONITORING                                      4-38
     4.4.1 Enhanced Monitoring for Publication Gravure       4-38
     4.4.2 Enhanced Monitoring for Product and Packaging
     Rotogravure                                             4-40
     4.4.3 Enhanced Monitoring for Wide-web and Sheet Fed
     Flexography                                             4-41
5.0 ENVIRONMENTAL AND ENERGY IMPACTS OF CONTROL OPTIONS       5-1
5.1 ENERGY IMPACT                                             5-1
     5.1.1 Publication Rotogravure                            5-1
     5.1.2 Product and Packaging Rotogravure                  5-2
     5.1.3 Wide-web and Sheet Fed Flexographv                 5-3
5.2 AIR IMPACTS                                               5-5
     5.2.1 Publication Rotogravure                            5-5
     5.2.2 Product and Packaging Gravure                      5-5
     5.2.3 Wide-web and Sheet Fed Flexography                 5-6
5.3 WATER IMPACTS                                             5-8
     5.3.1 Publication Rotogravure                            5-8
     5.3.2 Product and Packaging Rotogravure and Wide-web
     and Sheet Fed Flexography                                5-8
5.4. SOLID WASTE IMPACT                                       5-8
     5.4.1 Publication Rotogravure                            5-8
5.4.2 Product and Packaging Rotogravure and
     Wide-web and Sheet Fed Flexography                       5-8
6.0 MODEL PLANT CONTROL OPTION COST                           6-1
6.1 INTRODUCTION                                              6-1
6.2 PUBLICATION ROTOGRAVURE                                   6-1
6.3 PRODUCT AND PACKAGING ROTOGRAVURE                        6-16
6.4 WIDE-WEB AND SHEET FED FLEXOGRAPHY                       6-26
6.5 REFERENCES                                               6-35

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                          LIST  OF TABLES



Table 2-1.  Publication Gravure Plants  	 2-5

Table 2-2.  Packaging/Product Gravure Responses 	  2-12

Table 2-3.  Rotogravure Facilities Printing on Paper and
     Cardboard	2-14

Table 2-4.  Rotogravure Facilities Printing Exclusively on
     Foil and Film	2-15

Table 2-5.  Rotogravure Facilities Printing Vinyl Products.  2-16

Table 2-6.  Rotogravure Facilities Printing on Paper or
     Cardboard and Foil or Film	2-17

Table 2-7.  Rotogravure Facilities Printing Miscellaneous
     Products	2-18

Table 2-8.  Baseline Emissions from Product and Packaging
     Rotogravure Responses	2-21

Table 2-9.  Baseline Emissions from Major Sources in the
     Product and Packaging Rotogravure Industries	2-21

Table 2-10.  Wide-Web Flexographic Printing Responses.  . .  2-25

Table 2-11.  Baseline Emissions from Flexographic Printing.  2-41

Table 3-1.  Overall Control Efficiencies Reported for
     Publication Gravure Plants	3-7

Table 3-2. Overall Efficiencies Reported for Product and
     Packaging Gravure Facilities with Control Systems. . .  3-10

Table 3-3. Control Device Efficiencies Reported for
     Packaging and Product Gravure" Facilities with Control
     Systems	3-11

Table 3-4.  Overall Efficiencies by Industry Segment for
     Packaging and Product Gravure Facilities with Control
     Systems	3-11

Table 3-5.  Control Devices in Use by Flexographic
     Printers	3-13

Table 3-6.  Overall Efficiencies Reported for Flexographic
     Facilities with Control Systems	3-15
                               vi

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Table 4-1. Publication Rotogravure Model Plants	4-2

Table 4-2. HAP Use by Rotogravure Facilities Printing on
     Paper and Cardboard	4-5

Table 4-3. HAP Use by Rotogravure Facilities Printing
     Exclusively on Foil and Film	4-8

Table 4-4.  HAP Use by Rotogravure Facilities Printing Vinyl
     Products	4-9

Table 4-5. Model Plant Specifications for Product/Packaging
     Rotogravure	4-10

Table 4-6. HAP Use on Flexographic Presses	4-12

Table 4-7.  Model Plant Specifications for Flexography. .  .  4-30

Table 4-8.  Control Options for Publication Rotogravure
     Plants	4-34

Table 4-9.  Control Options for Packaging and Product
     Rotogravure Plants	4-37

Table 4-10.  Control Options for Flexographic Printing
     Plants	4-40

Table 5-1.  Energy Impact of Control Options for Publication
     Rotogravure Plants	5-2

Table 5-2.  Energy Impact of Control Options for Product and
     Packaging Gravure Plants	5-3

Table 5-3.  Energy Impact of Control Options for Wide-web
     and Sheet Fed Flexography. .	5-5

Table 5-4.  Air Impact of Control Options for Publication
     Rotogravure Plants	5-6

Table 5-5.  Air Impact of Control Options for Product and
     Packaging Rotogravure Plants	5-7

Table 6-1.  Publication Rotogravure Model Plant
     Specifications Used for Control Option Costing	6-2

Table 6-2.  Publication Rotogravure Control Device
     Specifications used for Control Option Costing	6-4

Table 6-3.  Capital Costs of Concentrator/Solvent Recovery
     Systems for Control Option A at Model Publication
     Rotogravure Plants	6-5


                               vii

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Table 6-4.  Capital Costs of Concentrator/Solvent Recovery
     Systems for Control Option B at Model Publication
     Rotogravure Plants	6-6

Table 6-5.  Capital Costs of Concentrator/Solvent Recovery
     Systems for Control Option C at Model Publication
     Rotogravure Plants	6-7

Table 6-6.  Capital Costs of Required Solvent Recovery
     System Upgrades for Control Option A at Model
     Publication Rotogravure Plants	6-8

Table 6-7.  Capital Costs of Required Solvent Recovery
     Upgrades for Control Options B and C at Model
     Publication Rotogravure Plants	6-9

Table 6-8.  Capital Costs of Permanent Total Enclosure for
     Control Option C at Model Publication Rotogravure
     Plants	6-10

Table 6-9.  Total Annual Costs for Control Option A at Model
     Publication Rotogravure Plants	6-11

Table 6-10.  Total Annual Costs for Control Option B at
     Model Publication Rotogravure Plants	6-12

Table 6-11.  Total Annual Costs for Control Option C at
     Model Publication Rotogravure Plants	6-13

Table 6-12.  Notes to Control Cost Calculations for Model
     Publication Rotogravure Plants	6-14

Table 6-13.  Cost Effectiveness of Concentrator Systems for
     Incremental Control of Publication Rotogravure Model
     Plants	6-15

Table 6-14.  Model Plant Specifications for Product and
     Packaging Rotogravure	6-17

Table 6-15.  Incinerator Specifications for Product and
     Packaging Rotogravure Control Options	6-18

Table 6-16.  Capital Costs for Thermal Incinerators at Model
     Product and Packaging Rotogravure Plants - Control
     Option A	6-20

Table 6-17.  Capital Costs for Thermal Incinerators at Model
     Product and Packaging Rotogravure Plants - Control
     Option B	6-21

Table 6-18.  Total Enclosure Construction Costs for Product
     and Packaging Rotogravure - Control Option B	6-22

                               viii

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Table 6-19.  Total Annual Costs for Thermal Incinerators at
     Model Product and Packaging Rotogravure Plants -
     Control Option A	6-23

Table 6-20.  Total Annual Costs for Thermal Incinerators at
     Model Product and Packaging Rotogravure Plants -
     Control Option B	6-24

Table 6-21.  Cost Effectiveness of Control Options A and B
     for Incremental Control at Model Product and Packaging
     Rotogravure Plants	6-25

Table 6-22.  Model Plant Specifications for Flexography.  .  6-27

Table 6-23.  Incinerator Specifications for Flexography
     Control Options	6-28

Table 6-24.  Capital Costs for Thermal Incinerators at Model
     Flexographic plants - Control Option A	6-29

Table 6-25.  Capital Costs for Thermal Incinerators at Model
     Flexographic plants - Control Option B	6-30

Table 6-26.  Total Enclosure Construction Costs for
     Flexographic Plants - Control Option B	6-32

Table 6-27.  Total Annual Costs for Thermal Incinerators at
     Model Flexographic Plants - Control Option A	6-33

Table 6-28.  Total Annual Costs for Thermal Incinerators at
     Model Flexographic Plants - Control Option B	6-34

Table 6-29.  Cost Effectiveness of Control Options A and B
     for Control of Model Flexographic Printing Plants. .  .  6-35
                               IX

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                         1.0 INTRODUCTION
1.1 OVERVIEW
     Section 112 of the Clean Air Act  (Act) requires that the
U. S. Environmental Protection Agency  (EPA) establish emission
standards for all categories of sources of hazardous air
pollutants  (HAP).  These national emission standards for
hazardous air pollutants (NESHAP) must represent the maximum
achievable  control technology (MACT) for all major sources.  The
Act defines a major source as:
     ...any stationary source or group of stationary sources
     located within a contiguous area and under common control
     that emits or has the potential to emit, in the aggregate,
     10 tons per year or more of any hazardous air pollutant or
     25 tons per year or more of any combination of hazardous air
     pollutants.
     In July 1992, the Documentation for Developing the Initial
Source Category List1  was published.   "Printing/Publishing
(Surface Coating)" was included as a source category.  The
Printing and Publishing Industry NESHAP project will establish
standards for major sources in this source category.
     The purpose of this document is to summarize the background
information gathered during the development of the printing and
publishing industry NESHAP.
1.2 PROJECT HISTORY
1.2.1 Background
     The printing industry can be divided by technology,
substrate or type of product.  Further divisions and industry
segments can be identified in each of the major industry
divisions.  Many manufacturing processes include printing
operations as one step in the production process.  It is

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estimated that more than 60,000 establishments in the U. S.
operate printing presses2.   This  estimate  excludes plateless
printing establishments.
     The printing industry can be divided by technology into six
different segments: gravure, flexographic, lithographic,
letterpress, screen, and plateless (xerographic, electrostatic,
magnetic, thermal, ink-jet, etc).  The technology (i. e. the type
of press equipment) dictates the types of inks and coatings which
can be used.  This defines to a large extent the type of HAP
involved, the emissions and the control techniques which are
applicable.
     The printing industry can also be divided by the type of
substrate that is printed.  Among the flexible substrates, paper,
foil and films are printed.  Paper can be further classified in
many ways, including coated vs. uncoated.   Films include
polyethylene and a number of other polymers.  Rigid substrates
include cardboard and vinyl.  A given substrate may be printed
using different technologies depending on factors such as the end
use, quality requirements, quantity,  cost and environmental
considerations.  Textiles are specifically excluded from the
printing source category.
     The printing industry can be additionally divided by the
type of product.  In general, the end use falls into the broad
categories of publication, packaging or product.  Publication
printing includes newspapers, magazines, books and advertising.
Packaging includes paper, plastic and foil bags and wrappers, and
cardboard cartons.  Products include wall and floor covering,
greeting cards and paper towels.   Various technologies can be
used to print specific items within the broad categories.
     In 1978, a control technique guidelines (CTG)  document was
established for the control of VOC from rotogravure and
flexographic printing operations3.  New  source performance
standards (NSPS) for VOC emissions from publication rotogravure4
were proposed October 28, 1980 (45 FR 71538) and promulgated
November 8, 1982 (47 FR 50644).  NSPS for VOC emissions from
                               1-2

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rotogravure printing and coating of flexible vinyl5 were proposed
January 18, 1983  (48 FR 2276) and promulgated June 29,  1984  (49
FR 26885).  In  1993, a draft CTG document was published for  the
control of VOC  emissions from offset lithographic printing6.
None of these efforts were specifically directed towards HAP,
however, many HAP of concern in the printing and publishing
industry are VOC and the same control devices used to limit  VOC
emissions are also applicable to control of HAP.
     HAP are present in some of the inks, coatings, primers  and
adhesives applied on printing presses, and are also present  in
some of the materials used for cleaning press parts.  Aromatic
(e. g. toluene), aliphatic and oxygenated hydrocarbons  make  up
the majority of the HAP used in the printing industry.  HAP  use
associated with various printing technologies and industry
segments is discussed in Chapter 2.
1.2.2  Data Gathering
     In 1993, a questionnaire was developed by EPA and  the
Gravure Association of America (GAA), to determine HAP  use and
control in the publication rotogravure segment.  Responses to
this questionnaire were voluntarily provided to EPA by  all
publication rotogravure facilities operating in the U.  S.
     Two additional questionnaires were developed by EPA, GAA,
and the Flexible Packaging Association (FPA), to determine HAP
use and control by product and packaging rotogravure facilities
and flexographic printing facilities.  These questionnaires  were
included with information collection requests (ICR) sent out
under the authority of section 114 of the Act.  Most of the
recipients opted to complete the questionnaires in lieu of the
ICR.   Questionnaires were sent to approximately 90 companies
thought to operate product or packaging rotogravure presses,  and
approximately 370 companies thought to operate wide-web
flexographic presses.
     In addition to information obtained from these
questionnaires,  several site visits were made to printing
facilities.   Also, the EPA has met with multiple trade
                               1-3

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organizations and industry representatives over the past several
years.

1.2.3 Emissions and Control Data

     The available emissions and control information for the

printing and publishing industry has been summarized in Chapter
3.  Most of the information collected is based on calendar year

1992, and is representative of current practices.  In some

segments of the industry, there has been a shift away from HAP to
non-HAP VOC and waterborne materials.  Control efficiency data

are relevant to current conditions for the purpose of MACT

determination.
1.3  REFERENCES
1.   U. S. Environmental Protection Agency.  Documentation for
     Developing the Initial Source Category List: Final Report.
     Publication No. EPA-450/3-91-030.  Research Triangle Park,
     NC  July 1992.

2.   U. S. Environmental Protection Agency.  Use Cluster Analysis
     of the Printing Industry—Draft Final report.  Washington,
     DC.  May 26, 1992.  182 pp.

3.   U. S. Environmental Protection Agency.  Control of Volatile
     Organic Compound Emissions from Existing Stationary Sources-
     Volume VIII: Graphic Arts-Rotogravure and Flexography.
     Publication No. EPA-450/2-78-033.  Research Triangle Park,
     NC.  December, 1978.  52 pp.

4.   U. S. Environmental Protection Agency.  Publication
     Rotogravure Printing-Background Information for Proposed
     Standards.  Publication No. EPA-450/3-80-031a.  Research
     Triangle Park, NC.  October, 1980.

5.   U. S. Environmental Protection Agency.  Standards of
     Performance for New Stationary Sources; Flexible Vinyl
     Coating and Printing Operations. 48 FR 12.  January 18,
     1983. p.2276 et. seq.

6.   U. S. Environmental Protection Agency.  Draft-Control of
     Volatile Organic Compound Emissions from Offset Lithographic
     Printing.   Research Triangle Park, NC.  September, 1993. 234
     pp.
                               1-4

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           2.0  THE PRINTING AND PUBLISHING INDUSTRY

2.1 INTRODUCTION
     The printing industry can be divided by technology,
substrate or type of product.  Further divisions and industry
segments can be identified in each of the major industry
divisions.  Many manufacturing processes include printing
operations as one step in the production process.  It is
estimated that more than 60,000 establishments in the U. S.
operate printing presses1.   This  estimate excludes  plateless
printing establishments.
     The printing industry can be divided by technology into
six different segments: gravure, flexographic, lithographic,
letterpress, screen, and plateless (xerographic,
electrostatic, magnetic, thermal, ink-jet,  etc).  The
technology (i. e. the type of press equipment) dictates the
types of inks and coatings which can be used.  This defines to
a large extent the type of HAP involved, the emissions and the
control techniques which are applicable.
     The printing industry can also be divided by the type of
substrate that is printed.  Among the flexible substrates,
paper, foil and films are printed.  Paper can be further
classified in many ways, including coated vs. uncoated.  Films
include polyethylene and a number of other polymers.  Rigid
substrates include cardboard and vinyl.  A given substrate may
be printed using different technologies depending on factors
such as the end use, quality requirements,  quantity, cost and
environmental considerations.  Textiles are specifically
excluded from the printing source category.
                              2-1

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     The printing industry can be additionally divided by the
type of product.  In general, the end use falls into the broad
categories of publication, packaging or product.  Publication
printing includes newspapers, magazines, books and
advertising.  Packaging includes paper, plastic and foil bags
and wrappers, and cardboard cartons.  Products include wall
and floor covering, greeting cards and paper towels.  Various
technologies can be used to print specific items within the
broad categories.
     Because inks and other HAP containing materials are
customized for particular printing technologies in terms of
viscosity (e. g. gravure and flexographic inks are relatively
fluid, lithographic, letterpress and screen inks are
relatively viscous) and chemical compatibility (e. g.
flexographic plates are incompatible with aromatic solvents)
HAP emissions will be discussed in terms of printing
technology.   It should be recognized that in many cases the
same product can be produced by more than one technology
(e. g. newspapers are produced by lithography, letterpress,
and flexography).
2.2 GRAVURE PRINTING
     Nearly all gravure printing is done by rotogravure.
Gravure printing is a printing process in which an image (type
and art) is etched or engraved below the surface of a plate or
cylinder.  On a gravure plate or cylinder, the printing image
consists of millions of minute cells.2   Gravure  requires very
fluid inks which will flow from the cells to the substrate at
high press speeds.  In addition to inks, other materials
including adhesives, primers, coatings and varnishes may be
applied with gravure cylinders.  These materials dry by
evaporation as the substrate passes through hot air dryers.
Solvent borne or waterborne ink systems can be used but these
ink systems are not interchangeable.  Both the printing
cylinders and the drying systems are specific to the solvent
system in use.  The evaporated components of the ink and other
                              2-2

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materials may contain HAP to varying extents.  Additional HAP
may be present in solvents used to clean presses and press
components.  Rotogravure can be divided into the publication
and product/packaging segments.  Because of the expense and
complexity of rotogravure cylinder engraving, it is
particularly suited to long run printing jobs.
2.2.1 Publication Rotogravure
     Publication rotogravure printing focuses on magazine,
catalog and advertising insert printing.  In 1993, there were
27 publication rotogravure plants in the U. S.  These plants
were operated by six corporations.  These plants all use
toluene/xylene based ink systems, and operate solvent recovery
systems based on carbon adsorption with steam regeneration.
Recovered solvent is sold back to the ink manufacturers.
Press capture systems vary depending on the age of the press.
Press and cylinder technologies, products, inks and control
systems are discussed in the Background Information Document
for New Source Performance Standards for Publication
Rotogravure Printing3.  Capture technologies  and capture
efficiency testing are discussed in The Measurement Solution:
Using a Temporary Total Enclosure for Capture Efficiency
Testing4.
2.2.1.1  Process Description.  On a gravure cylinder, the
printing image consists of millions of minute cells which are
engraved into the surface of the cylinder5.   Different  colored
inks are applied in succession as the web passes from station
to station.  A separate cylinder, ink supply and dryer are
required for each station.   After the ink is applied at each
station, the web is dried before being printed by the next
station.  Typically, four stations are required to print each
side of the web.   Publication gravure presses in operation in
the U.  S.  have up to 16 stations.  Gravure requires very fluid
inks which will flow from the cells to the web at high press
speeds.  The ink dries by evaporation as the substrate passes
through hot air dryers.
                              2-3

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     Publication gravure presses in the United States use
solvent borne ink systems exclusively. Because of the expense
and complexity of rotogravure cylinder engraving, it is
particularly suited to long run printing jobs.  It is
generally believed in the industry that publication gravure
equipment is capable of higher quality printing than competing
processes.
2.2.1.2  Profile of the Publication Rotogravure Segment.
There are 27 publication gravure plants in the United States.
These plants are owned by six companies, none of which are
small businesses.  All 27 plants are major sources for
hazardous air pollutants.  Some of these companies operate
additional printing processes using technologies other than
rotogravure.  In some cases, these other processes are
conducted at separate locations.  All of the plants
voluntarily provided responses to a list of questions
developed by the EPA and the Gravure Association of America.
     The information in this section is based on these
responses.  Seventeen of the responses are in the public
docket; the remaining ten responses contain some confidential
business information.  A list of plant locations and owners is
given in Table 2-1.
2.2.1.3 HAP Use and Emissions.  All of the U. S. publication
gravure plants use solvent based ink systems.  The primary
solvent is toluene, a HAP.  At some plants xylenes and ethyl
benzene, also HAP, are present in the solvent blend and are
used, emitted, recovered and handled in the same manner as
toluene.  The plants purchase ink containing solvent and add
additional solvent to obtain the desired viscosity.  Ink is
applied to the web which then passes through a dryer, where
the solvent is evaporated into heated air.  The web then
travels to the next press station where the process is
repeated with a different color.  Most of the evaporated
solvent is recovered using activated carbon solvent recovery
systems.  The recovered solvent is reused; excess solvent is
                              2-4

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 sold back to the  ink manufacturers.   Additional solvent  (of
 the same composition as the solvent in the ink) is used for
 cleaning gravure  cylinders and other press components.
             Table 2-1. Publication Gravure Plants
Company Name
City
State
Brown Printing Company
R. R. Donnelley Printing Company
R. R. Donnelley Printing Company
R. R. Donnelley Printing Company
R. R. Donnelley Printing Company,
R. R. Donnelley & Sons Company
R. R. Donnelley & Sons Company
R. R. Donnelley & Sons Company
R. R. Donnelley & Sons Company
R. R. Donnelley & Sons Company
R. R. Donnelley & Sons Company
R. R. Donnelley & Sons Company
Quad / Graph ics
Quebecor Printing Atglen Inc.
Quebecor Printing Buffalo Inc.
Quebecor Printing Dallas Inc.
Quebecor Printing Dickson Inc.
Quebecor Printing Memphis Inc.
Quebecor Printing Memphis Inc.
Quebecor Printing Mt. Morris Inc.
Quebecor Printing Providence Inc.
Quebecor Printing Richmond Inc.
Quebecor Printing San Jose Inc.
Ringier America Inc.
Ringier America, Inc.
World Color Press, Inc.
World Color Press, Inc.
Franklin
Casa Grande
Lynchburg
Newton
Des Moines
Mattoon
Reno
Warsaw
Spartanburg
Lancaster
Chicago
Gallatin
Lomira
Atglen
Depew
Dallas
Dickson
Baltimore
Memphis
Mt. Morris
Providence
Richmond
San Jose
Corinth
Evans
Salem
Dyersburg
KY
AZ
VA
NC
IA
IL
NV
IN
SC
PA
IL
TN
WI
PA
NY
TX
TN
MD
TN
IL
RI
VA
CA
MS
GA
IL
TN
     All of the U. s. publication gravure plants account for
solvent on the basis of liquid-liquid mass balances.
Emissions are calculated taking into account ink purchases,
solvent purchases and sales, and changes in inventory over a
suitable time frame.  All solvent losses are counted as
emissions whether they result from pressroom capture losses,
control device losses, retention in the finished publications
or evaporation from uncontrolled equipment (including proof
presses).
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     HAP emissions result from incomplete recovery of captured
HAP, and from incomplete capture.  Activated carbon solvent
recovery systems are suitable for control of toluene and
similar aromatic solvents.  High control efficiencies can be
achieved, however some solvent is unavoidably emitted as a
result of thennodynamic limitations (the toluene-
carbon/toluene-air equilibrium)  and flow irregularities (e. g.
channelling through the carbon bed).   Some HAP is not captured
in the dryer exhaust.  This includes HAP which evaporates from
the ink fountains into the pressroom,  HAP which is evaporated
from the web in the dryers but is then swept out of the dryer
as the web travels towards the succeeding press station, HAP
which remains in the web after the last drier which evaporates
during additional processing (slitting, folding, stitching,
etc.) and HAP which leaves the plant trapped in the magazine,
catalog or advertising insert.
     Additional HAP is emitted from proof presses, which in
some plants are uncontrolled, gravure cylinder cleaning, other
parts cleaning, storage tank evaporation and breathing losses
and ink mixing operations.  These sources are relatively minor
by comparison, however, they are reflected in the overall
efficiencies determined from liquid-liquid mass balances.
2.2.1.4. Baseline Emissions.  There are 27 publication gravure
plants in the United States.  All of the plants voluntarily
provided responses to a list of questions developed by the EPA
and the Gravure Association of America.  The information in
this section is based on these responses.  Seventeen of the
responses are in the public docket; the remaining ten
responses contain confidential business information.  A total
of 38,400,000 pounds (19,200 tons) of HAP was emitted in 1992.
The HAP is primarily toluene; some plants report using a
mixture containing mixed xylenes and ethyl benzene.
2.2.2 Packaging and Product Gravure
     The gravure printing operation is, in many cases, a
relatively small part of the total package or product
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production process.  This section briefly describes the
various types of packages and products that include gravure
printing in their manufacture, and notes what production steps
are required in addition to the gravure printing step.
     Folding Cartons.  Folding carton packages are used for a
wide variety of products including wet and dry foods,
beverages, bakery items, and candy.  They are also used for
nonfood products such as detergents, hardware, paper goods,
cosmetics, medical products, tobacco products, and sporting
goods.
     The folding carton is made from one of several grades of
paperboard.  It may be printed, laminated or coated, or may be
shipped unprinted to be used with another label or wrapper.
Besides printing, operations in the manufacture of folding
cartons include creasing, trimming, die-cutting, coating, and
gluing.  The cartons are shipped flat, to be assembled and
filled by the customer.  In addition to gravure printing,
flexography is used for folding cartons.  Letterpress use has
declined.  Most of the gravure presses used for folding carton
printing are web-fed.  However, some folding carton presses
are sheet-fed, with only one or two print stations.6
     Flexible Packaging.  Flexible packaging, by one
definition, consists of "converted materials intended to
package and display products weighing less than 25 pounds."7
The word "converted" in this use is an industry-specific term
that refers to the fact that flexible packaging materials
start out as rolls of paper or foil, or beads of plastic
resin,  and are "converted" into a package or roll of packaging
material.  Flexible package manufacturers are sometimes
referred to as "converters".  The ratio of gravure printing to
flexographic printing among converters is approximately
20:80,*  it  is, however,  an important component of the  gravure
printing industry.   Converters produce a wide range of non-
rigid packages made of paper,  plastic film, foil laminates,
and combinations of these substrates.
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     One portion of the flexible packaging industry provides
fully printed packaging materials (designated "preformed
specialty bags") to contract packagers.  Another portion
provides combination or laminated materials (designed
converted wrap) for printing and/or final packing by captive
packaging operations.  Applying coatings is a major capability
of flexible packaging converters, so the same facilities may
be used to manufacture non-packaging materials such as gift
wraps and hot stamp foils.9
     Labels and Wrappers.  Labels and wrappers include roll
and sheet labels applied to cans, unprinted cartons, composite
cans, bottles and other containers, tags, and self-adhesive
label products.  Paper is the common substrate, but laminates
and foil are also used.  The industry makes a distinction
between labels and wrappers, which are package components,
from a product that becomes the entire package and should be
called a flexible package.  This is because of the distinction
of SIC codes that apply (see above).  However, it is suggested
that product shipment reports are probably based more on the
substrate (i.e., paper for labels and wrappers; plastic film
for flexible packages) than on a precise definition of end
use.10
     One interesting manufacturing technique used in making
labels is the use of combination gravure/flexo presses.  The
manufacturer uses a gravure cylinder for "halftone" material
and for coating operations, and uses a flexographic cylinder
for typographic material that might have frequent changes."
     Gift Wraps.  About 90 percent of all gift wraps are
printed.  They are produced by greeting card companies and by
label and flexible packaging firms.  Because gravure printing
is particularly suitable for producing the continuous patterns
used on gift wrap, it accounts for 60 to 70 percent of the
market.12  Historically a significant portion of the gift wrap
was made from laminated foil, as are many flexible packaging
materials.  Although foil gift wrap is no longer a significant
                              2-8

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product, it is the reason why flexible package manufacturers
often print gift wrap.13
     Wallcoverings.  The wallcovering industry is a
traditional user of gravure.  The principal types of
wallcoverings are prepasted paper, prepasted paper-backed
vinyl, fabric-backed vinyl, and specialty items (e.g.,
metallics, grass cloth, rice paper).  Gravure printing is
typically used to print only the vinyl wallcoverings.14
     The steps in manufacturing wallcoverings include printing
the paper and laminating it to the backing sheet.  A special
effect that may be added in some cases is "registered
embossing" to add texture.  It is usually done in line with
the laminator.15
     Vinyl Printing.  These products consist of auto
upholstery, furniture upholstery, tablecloths, decorative
trim, and shower curtains.  Gravure dominates this product
area because of the complex repeat patterns (e.g., woodgrain),
and the requirement, in many cases, for overcoating that is
readily applied using a gravure cylinder.  Printing is
performed on unsupported vinyl, supported vinyl (backed with
fabric or paper), and paper substrate that is then coated with
vinyl.l6
     The manufacturing steps typically consist of printing,
coating, embossing, and other finishing.  In some cases items
that are screen printed or flexographically printed are still
coated using a gravure process.17
     Decorative Laminates.  These products consist of solid,
thermoset laminates used in furniture and construction, and
other laminates, principally wood grain veneers, widely used
in furniture.  The dense sheets consist of many layers of
polymer-saturated paper.  The top sheet is a translucent sheet
impregnated in melamine, laid over a printed or solid
pigmented pattern sheet.  Heat and pressure are both used to
produce the final product.18
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     Floor Coverings.  Gravure presses are used to decorate
and apply texture and finish to sheet vinyl floor coverings.
Rotary screen printing is sometimes used in combination with
gravure.  Gravure is also used to print transfer papers used
to decorate vinyl tile, and some tile products are printed
using "offset/gravure," a hybrid press type using a gravure
cylinder offsetting to a rubber image carrier.19
     Tissue Products.  Some type of printing process is used
to apply color patterns to paper towels, bathroom tissue, and
napkins.  The older paper mills producing tissue products were
typically equipped with gravure presses.  Today, that
production accounts for less than 5 percent of the total
production.20
     Miscellaneous Specialty Products.  Other miscellaneous
and specialty products that require a printed patter are also
produced using gravure printing.  One such product is
cigarette tipping paper, the paper with a cork-like or other
pattern that is wrapped around cigarette filters.
2.2.2.1 Process Description.  The rotogravure printing process
is described in section 2.2.1.1.  Product and packaging
rotogravure differs from publication gravure with respect to
the materials used, the applicable control devices, and the
decreased importance of the actual printing process in an
overall manufacturing process.
     Packaging and product rotogravure printing uses a wide
variety of different ink systems, including the aromatic HAP
based ink systems common to publication gravure, solvent based
non-HAP ink systems, and waterborne ink systems.  Numerous
specially mixed colors are applied at various times in this
industry segment, in contrast to the publication segment which
primarily applies four basic colors.  In addition a wider
range of materials are applied with gravure cylinders in this
segment of the industry.  A variety of coatings, adhesives and
primers are applied at print stations on rotogravure presses.
     Because of the variety of materials applied, the approach
                              2-10

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to HAP and VOC control in packaging and product gravure
facilities varies.  In addition to the activated carbon based
solvent recovery systems used by the publication segment,
packaging and product gravure facilities also use a variety of
thermal and catalytic oxidizers.  Many facilities operate
without significant HAP use and do not have control devices.
     Printing is only one stage (often minor) in
manufacturing.  In many cases, operations such as laminating,
cutting, folding and calendering make up a greater proportion
of the value of the product or package than the printing
operation.
2.2.2.2 Profile of the Package/Product Rotogravure Segment
     As of 1994, the Gravure Association of America (GAA)
estimated that rotogravure printing operations were conducted
at 400 locations within the U. S.21  The EPA sent an
information collection request (ICR) to approximately 80
parent companies thought to operate rotogravure printing
equipment.  Responses pertaining to rotogravure operations at
more than 100 locations were received.  In lieu of completing
the ICR, nearly all of the companies chose to respond to a
simplified question list developed by EPA with the assistance
of GAA and the Flexible Packaging Association (FPA).  A list
of companies from which usable information was received is
given in Table 2-2.  These responses are included in the
project docket.  Specific descriptions of printed products and
packaging are given for five substrate categories in Tables 2-
3 through 2-7.
2.2.2.3 Hap Use and Emissions.  In product and packaging
gravure facilities, HAP is contained in both the printing inks
and in other materials (adhesives, coatings)  that are applied
as part of a continuous manufacturing process.  One survey
showed that the weight of coatings and lacquers applied in
gravure packaging plants was almost as much as the weight of
the ink.22  The predominant type of ink is based on
nitrocellulose resin,  with some polyamide inks.   Solvent
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  Table 2-2.  Packaging/Product  Gravure Responses (See Codes
                           Following Table).

Company Name                                Location                Code

AMGRAPH Packaging,  Inc.VersaillesCTM
Alcan Foil Products                      Louisville          KY    F
Alford Packaging                         Baltimore           MD    P
Allied Stamp Corporation                 Sand Springs        OK    P
Alusuisse Flexible Packaging,  Inc.        Shelbyville         KY    M
American Fuji Seal, Inc.                 Anaheim             CA    F
American Fuji Seal, Inc.                 Fairfield           NJ    F
American Greetings                       Corbin              KY    P
Avery Dennison                           Clinton             SC    M
Avery Dennison                           Framingham          MA    P
Avery Dennison                           Schereville         IN    V
Avery Dennison Corporation               Pasadena            CA    W
Butler Printing & Laminating,  Inc.        Butler              NJ    V
CPS Corporation                          Franklin            TN    M
Cello-Foil Products, Inc.                 Battle Creek        MI    M
Chiyoda America Inc.                     Morgantown          PA    P
Cleo, Inc.                               Memphis             TN    P
Columbus Coated Fabrics                  Columbus            OH    V
Congoleum Corporation                    Marcus Hook         PA    V
Congoleum Corporation                    Mercerville         NJ    V
Constant Services,  Inc.                   Fairfield           NJ    V
DRG Medical Packaging                    Madison             WI    M
Decor Gravure Corporation                Bensenville         IL    V
Decorating Resources                     Clifton             NJ    F
Decorative Specialties International,  Inc.Johnston            RI    P
Decorative Specialties International,  Inc.Reading             PA    M
Decorative Specialties International,  Inc.West Springfield    MA    V
Dinagraphics                             Norwood             OH    W
Dittler Brothers                         Atlanta             GA    W
Dittler Brothers                         Oakwood             GA    W
Dopaco, Inc.                             Downingtown         PA    P
Dopaco, Inc.                             Saint Claries       IL    P
Dopaco, Inc.                             Stockton            CA    P
Eskimo Pie Corporation                   Bloomfield          NJ    M
Federal Paper Board Co., Inc.             Durham              NC    P
Federal Paper Board Co., Inc.             Wilmington          NC    P
Fleming Packaging Corporation            Peoria              IL    M
Fres-Co System USA, Inc.                 Telford             PA    F
GenCorp Inc.                             Jeannette           PA    F
GenCorp Inc.                             Salem               NH    V
GenCorp Polymer Products                 Columbus            MS    V
Graphic Packaging Corporation            Franklin            OH    M
Graphic Packaging Corporation            Lawrenceburg        TN    P
Graphic Packaging Corporation            Paoli               PA    P
Gravure Carton & Label                   Surgoinsville       TN    P
Gravure Packaging,  Inc.                   Richmond            VA    P
Hallmark Cards                           Kansas City         MO    P
Hallmark Cards                           Leavenworth         KS    P
Hargro Flexible Packaging                Edinburgh           IN    M
Hargro Packaging                         Flemington          NJ    M
International Label Company              Clarksville         TN    P
International Playing Card & Label  CompanyRogersville         TN    P
J. W. Fergusson and Sons,  Inc.           Richmond            VA    M
JSC/CCA                                  Carol Stream        IL    P
JSC/CCA                                  Lockland            OH    P
JSC/CCA                                  North Wales         PA    P


                                   2-12

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  Table 2-2.   Packaging/Product  Gravure Responses (concluded)
JSC/CCA
JSC/CCA
James River Corporation
James River Paper Company
James River Paper Company
James River Paper Company
James River Paper Company
James River Paper Corporation
Jefferson Smurfit Corporation
Jefferson Smurfit Corporation
Johio, Inc.
Koch Label Company, Inc.
Lamotite, Inc.
Lux Packaging Ltd.
Mannington Mills, Inc.
Mundet-Hermetite Inc.
Newco Inc.
Orchard Decorative Products
Orchard Decorative Products
Package Service Company
Paramount Packaging Corporation
Paramount Packaging Corporation
Paramount Packaging Corporation
Quick Roll Leaf Manufacturing Company
Reynods Metals Company
Reynolds Metals Company
Reynolds Metals Company
Riverwood international USA, Inc.
Riverwood International USA, Inc.
Riverwood international USA, Inc.
Roslyn Converters Inc.
Scientific Games, Inc.
Scientific Games, Inc.
Screen Art
Screen Art
Shamrock Corporation
Shamrock Corporation
Smurfit Flexible Packaging
Smurfit Laminations
Somerville Packaging
Stone Container Corporation
Technographics Printworld
The C. W. Zumbiel Company
Union Camp Corporation
Union Camp Corporation
Union Camp Corporation
Vernon Plastics Company
Vitex Packaging, Inc.
Waldorf Corporation
Waldorf Corporation
Wrico Packaging

P^Paper/Cardboard only
F«Film/Foil only
V=Vinyl product
M=Paper/cardboard AND Foil/film
W=miscellaneous, NEC
Santa Clara         CA    P
Stone Mountain      GA    P
Hazelwood           MO    M
Darlington          SC    P
Fort Smith          AR    P
Lexington           KY    P
Portland            OR    M
Kalamazoo           MI    P
Chicago             IL    P
Jacksonville        FL    W
Dayton              OH    M
Evansville          IN    M
Cleveland           OH    W
Waco                TX    P
Salem               NJ    V
Buena Vista         VA    P
Newton              NJ    V
Blythewood          SC    M
St. Louis           MO    M
Northmoor           MO    M
Chalfont            PA    F
Longview            TX    F
Murfreesboro        TN    F
Middletown          NY    F
Richmond            VA    F
Downingtown         PA    M
Richmond            VA    M
Bakersfield         CA    P
Cincinnati          OH    P
West Monroe         LA    P
Colonial Heights    VA    P
Alpharetta          GA    W
Gilroy              CA    W
Fulton              NY    M
Moorestown          NJ    F
Greensboro          NC    M
Greensboro          NC    P
Schaumburg          IL    M
Elk Grove Village   IL    M
Newport News        VA    P
Louisville          KY    P
North Monroe        NC    W
Cincinnati          OH    P
Asheville           NC    M
Englewood           NJ    P
Spartanburg         SC    P
Haverhill           MA    V
Suffolk             VA    M
Chicago             IL    P
Saint Paul          MN    P
Chicago             IL    M
                                   2-13

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10 10 (X
0) 0)
• g g W
U <0 (0 U
C O O-H
H X!
O O ft
«>-H -H 10
0) 
-------
systems include aromatic, aliphatic and oxygenated hydrocarbon
solvent inks, and water-based inks.
     Due to the wide variety of ink types and colors that are
used in this segment of the printing industry, ink is
typically received in drum (or smaller container sizes) and
tote bins.  Only rarely is bulk ink received and stored in
tank farms.
     About 60 percent of the coatings used are petroleum-based
waxes and hot melts.  About 35 percent of the coatings are
extrusion coatings, typically low density polyethylene (LDPE).
The remaining 5 percent are solution coatings, typically
applied to flexible packaging.  The 25 percent of theextrusion
coatings that are not LDPE consist of polyvinyl chloride
(PVC), polyvinyl acetate (PVA), ethylene vinyl acetate (EVA)
copolymers, high density polyethylene, and polypropylene.23
     Folding Cartons.  About half of the ink used for folding
cartons is nitrocellulose based.  The remainder is alcohol
solvent and water based.  On a weight basis, coatings and
lacquers are about equal to ink use.24
     Flexible Packaging.  Solvent-based, nitrocellulose resin
ink is the predominant type.   Coatings and lacquers are only a
third of the ink use, by weight.25  Some flexible packaging
printers have switched from the traditional toluene solvent to
non-HAP solvents such as iso- and normal-propyl acetate.26
The use of water-based inks in this industry segment is
growing.  At one company, all HAP except for glycol ethers
have been eliminated.27
     Labels and Wrappers.  Nitrocellulose resin inks account
for about half the inks used in this industry segment, with a
wide variety of ink types accounting for the rest.  Coatings
and lacquers amounted to about 1.5 times the weight of ink
used.28
     Vinyl Products.  In response to the ICR, vinyl product
manufacturers reported use of methyl ethyl ketone, and methyl

                             2-19
-------
isobutyl ketone as the major HAP present in materials applied
with rotogravure presses.  Significant quantities of toluene
and xylene were also used.
2.2.2.4 Baseline Emissions
     HAP emissions data are available for most of the
facilities submitting data in response to the ICR.  In some
cases, responses were received, however, the HAP emissions
data were not usable.  This resulted from missing or ambiguous
answers to questions relating to HAP usage and control
efficiency.  Specific data on control efficiency for HAP are
not available.  Data have been analyzed on the assumption that
overall HAP control efficiency is equivalent to reported
overall efficiency.  These data are most often based on tests
or vendor guarantees relating to VOC.  In many cases, HAP
makes up only a minor proportion of the VOC used on-press.
     Baseline emissions calculated from the responses to the
ICR are given in Table 2-8.  Analogous information given
in Table 2-9 pertains to major sources as determined on the
basis of actual HAP emissions.  When potential-to-emit is
considered there are more major sources.  An upper bound on
baseline emissions can be estimated by assuming that there are
400 product and packaging gravure facilities and that the
facilities providing usable data in response to the ICR are
representative of the total population.  In this case,
baseline emissions from product and packaging gravure would be
approximately 32,000,000 Ib/yr.  It is more likely that
responses were obtained from larger facilities within the
industry, and that baseline emissions are much lower.
2.2.3  Intaglio Plate Gravure
     Intaglio plate gravure or engraving, uses a flat copper
plate on a sheetfed press.  This process is used for currency,
postage stamps, securities and stationery29.  It makes up a
small proportion of the gravure printing segment.
                             2-20
-------
Table 2-8. Baseline Emissions from Product and Packaging
                 Rotogravure Responses.
Industry Segment
Paper /Cardboard Only
Foil/Film Only
Paper /Cardboard/ Foil/ Film
Vinyl Product
Miscellaneous
Total
Number of Usable
Responses
40
10
27
10
9
96
HAP Emissions
(Ib/yr)
2,004,000
597,900
2,598,000
896,500
1,465,000
7,561,000
Table 2-9. Baseline Emissions from Major Sources in the
      Product and Packaging Rotogravure Industries.
Industry Segment
Paper /Cardboard Only
Foil/Film Only
Paper / Cardboard/ Foi 1 / Fi 1m
Vinyl Product
Miscellaneous
Total
Number of Usable
Responses
16
4
9
3
4
36
HAP Emissions
(Ib/yr)
1,811,000
581,100
1,257,000
822,500
1,418,000
5,890,000
                          2-21
-------
2.3  FLEXOGRAPHY
     Flexographic printing is considered to be the application
of words, designs and pictures to a substrate by means of a
printing technique in which the pattern to be applied is
raised above the printing plate and the image carrier is made
of rubber or other elastomeric materials.30  It has been
estimated that there are 1,587 plants in the U. S. with
flexographic presses.31  The major applications of
flexographic printing are flexible and rigid packaging; tags
and labels; newspapers, magazines, and directories; and paper
towels, tissues etc.  Because of the ease of plate making and
press set up, flexographic printing is more suited to
shortproduction runs than gravure.  It is estimated that 85
percent of package printing is done by flexography.32
     Flexographic inks must be very fluid to print properly.
Flexographic inks include both waterborne and solvent based
systems.  Solvents used must be compatible with the rubber or
polymeric plates; thus, aromatic solvents are not used.  Some
of the components of solvent based flexographic ink include
ethyl, n-propyl and i-propyl alcohols; glycol ethers,
aliphatic hydrocarbons, acetates and esters.33
     Flexographic printing can be divided between publication
and packaging/product printing.  An alternate approach, and
the one chosen for this project, is to divide between wide web
and narrow web equipment with an 18 inch web width being an
arbitrary cutoff between the two categories.  Additional
distinctions can be made on the "basis of web vs. sheetfed
press equipment.
2.3.1.  Wide Web (and Sheetfed) Flexocrraphic Printing
     Wide web flexographic presses are used to print flexible
and rigid packaging; newspapers, magazines, and directories;
and paper towels, tissues etc; and printed vinyl shower
curtains and wallpaper.  Corrugated cartons are one of the few
substrates printed by sheetfed f lexography.34  Substrates
include polyolefins, polystyrene, polyesters, glassine,
                             2-22
-------
tissue, sulfite, kraft and other paper stocks, aluminum foil,
paperboard, corrugated, folding cartons, gift wraps, paper
cups and containers.35
2.3.1.1 Process Description.  Flexographic presses can be
divided into three main types depending on the relative
relationship of the print stations.  Stack presses have
individual print stations oriented vertically with the unwind
and rewind sections on the same side of the print stations.
Stack presses are easily accessible for rapid changeovers
between pressruns.  Common impression presses have the print
stations around the circumference of a single large impression
cylinder.  The web is constantly supported between print
stations, which is an advantage for printing on stretchable
materials.  In-line presses have the print stations in a
horizontal row (the geometry is similar to rotogravure
presses).  These presses have an advantage when used with
additional converting (such as cutting, gluing and laminating)
equipment.36
2.3.1.2 Profile of Wide Web Flexoaraphic Segment.  Most wide
web flexographic printing facilities produce various types of
packaging.  Flexible packaging producers often operate both
flexographic and rotogravure presses at the same facilities;
the selection of equipment for a particular job depends on
length of run,  quality requirements and substrate.  The
printing component makes up a relatively minor part of the
value of some types of packaging.   Facilities that produce
corrugated cartons and paper bags may not consider themselves
to be printers.   Large paper companies often operate many
small facilities at locations around the country to serve
local markets.
     Newspaper production makes up a small proportion of
flexographic printing facilities.   There are 35
flexographically printed newspapers in the U. S.37  This
number is expected to grow as newspapers replace aging
                             2-23
-------
letterpress equipment.  Several large newspaper chains use
flexographic presses at multiple locations.
     The EPA sent an information collection request (ICR)  to
approximately 380 parent companies thought to operate
flexographic printing equipment.  Approximately 100 of these
facilities were found to operate only narrow web presses;  no
information was collected from narrow web printers other than
their names, addresses and numbers of employees.  Responses
pertaining to wide web flexographic printing operations at
approximately 500 facilities were received.  In lieu of
completing the ICR, nearly all companies chose to respond to a
simplified question list developed by EPA with the assistance
of the Flexible Packaging Association (FPA).   A list of the
names and locations of facilities submitting information is
given in Table 2-10.  These responses, with the exception of
confidential business information, are included in the project
docket.
2.3.1.3 HAP Use and Emissions.  HAP emissions result from
components of ink (and other materials applied with
flexographic plates, including varnishes, primers, and
adhesives) and solvents used to clean presses and equipment.
In the past, flexographic platemaking systems commonly used
HAP; these systems are becoming rare as improved HAP free
platemaking technologies have become available.  Within the
converting industry, printed substrates are formed or
purchased then printed and converted to packaging such as bags
or boxes.  In many cases, the printing operation is a
relatively small part of the processing which may include film
blowing, laminating, coating, adhesive application, and
cutting.  Some or all of these processing operations are done
at flexographic press stations or in-line with the presses.
Converting operations done in conjunction with flexographic
printing may result in additional HAP emissions.
     Most flexographic printing (including all flexographic
newspaper and corrugated carton printing) is done with
                              2-24
-------
      Table  2-10.   Wide-Web  Flexographic Printing Responses.
Name

Abbott Box Co. Inc.
Action Packaging

Acorn Corrugated Box Co.

Advance Packaging Corporation


Advance Packaging Corp.

Akron Beacon Journal

All-Pak, Inc.

Alusuisse Flexible Packaging, Inc.

Alusuisse Flexible Packaging, Inc.

Alusuisse Flexible Packaging, Inc.

American Greetings Corp

American Greetings Corp.
American National Can/Food Plastics

American National Can/Food Plastics

American National Can/Food Plastics
American National Can/Food Plastics

American National Can/Food Plastics

American National Can/Food Plastics
American National Can/Food Plastics

American National Can/Food Plastics

American Packaging Corp.

American Packaging Corp.

American Packaging Corp.

American Packaging Corp.

Amko Plastics, Inc.

Anagram International, Inc.

Arcata Graphics\Kingsport

Arcon Coating Mills,  Inc.

Arkansas Poly, Inc.

Atlanta Film Converting Co, Inc.
Address

58 Teed Drive, Randolph, MA  02368
667 Atkins Avenue, Brooklyn, NY
11208
5133 H. 65th Street, Bedford Park,
IL  60638
4450 36th Street, SE, P.O. Box
888311, Grand Rapids, MI
49588-8311
2400 E. High St., P.O. Box 730,
Jackson, MI  49203
44  East Exchange St., Akron, OH
44309
5383 Truman Drive, Decatur, GA
30035
1403 Fourth Ave.,New Hyde Park, NY
11040
5303 St. Charles Road, Be11wood, IL
60104
6700 Midland Industrial Drive,
Shelbyville, KY 40065
P.O. Box 1570, Corbin, KY
40702-5851
Hwy. 11 E ByPass, Afton, TN 37616
1300 S. River St., Batavia, IL
60510
1500 E. Aurora Ave., Des Moines, IA
50313
271 River St., Menasha, WI 54952
150 26th Ave. SE, Minneapolis, MN
55414
201 W. Madison St., Mount Vernon,
OH 43050
1815 Marathon Ave.,Neenah,WI 54956
6590 Central Ave., Newark, NJ
94560
3600 Alabama Ave.,St. Louis Park,
MN 55416
2900 Grant Ave., Philadelphia, PA
19114
125 W. Broad St., Story City, IA
50248
200 Continental Dr., Columbus, WI
53925
777 Driving Park Ave., Rochester,
NY 14613
12025 Trilon Road, Cincinnati, OH
45246
7700 Anagram Drive, Eden Prairie,
MN  55344
P.O. Box 711, Press and Roller
Streets, Kingsport, TN  37662
3067 New Street, Oceanside, NY
11572
1248 So. 28th Street, Van Buren, AR
72956
1132 Pryor Rd., P.O. Box 6756,
Atlanta, GA  30315
                                   2-25
-------
      Table 2-10.   Wide-Web Flexographic Printing Responses
                               (continued).
Automated Packaging Systems,  Inc.

Automated Label Systems Co.

Avery-Dennison, K & M Division

Avery-Dennison

Bagcraft Corporation of America

Bancroft Bag, Inc

Banner Packaging, Inc.

Bell Packaging Corp

Bingo Paper Inc.

Bomarko, Inc

Bonar Packaging, Inc.
Bryce Corporation

BRC, A Division of Bryce Corporation

Bryce Corporation

Johnson Bryce Corp.

Bryce Dixico

Tennessee Packaging

Koch Container
All-Size Corrugated Prods.

Buckeye Container

Buckeye Packaging

Burrows Paper Corporation

Burrows Paper Corporation

Cadillac Products, Inc.

Cadillac Products, Inc.

Cadillac Products, Inc.

Cello-Wrap Printing Company,  Inc.

Central States Diversified, Inc.

Champion International Corp.

Champion International Corp.
13555 McCracken Road,  Garfield
Heights, OH  44125
8400 Darrow Road,  twinsburg,  OH
44087
4100 Hwy 45 North, Meridian,  MS
39305
4350 Avery Drive,  P.O. Box 547,
Flowery Branch, GA  30542
3900 West 43rd St., Chicago,  IL
60632
425 Bancroft Blvd, West Monroe, LA
71291
3550 Moser Street, Oshkosh,  WI
54901
3102 S. Boots St., Marion, IN
46953
801 River Drive So., Great Falls,
MT 59405
1955 North Oak Road, P. O. Box K,
Plymouth, IN 46563
2410 N. Lyndon, Tyler, TX  75702
450 S. Benton St., Searcy, AR
72143
75 Isabelle Street, Buffalo,  NY
14207-0007
4505 Old Lamar and 3861 Delp
Street, Memphis, Tennessee  38118
4224 Premier Street, Memphis, TN
38118
1300 South Polk St., Dallas,  TX
75224
Hwy 11 Longmeadow Rd,  Sweetwater,
TN  37874
777 Old Dutch Road  14564
P.O. Box 4544, Lancaster, PA
17604
P.O. Box 16, 326 N. Hillcrest
Drive, Woostor, OH  44691
12223 Marlboro Avenue, Alliance, OH
44601
101 Commerce Drive, Mt. Vernon, OH
43050
1722 53rd Street,  Fort Madison, IA
52627
840 Woodrow St., S.W., Atlanta, GA
30310-3431
2005 S. Main St.,  Paris, IL
61944-2950
7000 East 15 Mile Rd,  Sterling
Heights, MI  48311-8012
110 N. Main, P.O.  Box 32,
Farmersville, TX  75442
5221 Natural Bridge, St. Louis, MO
63115
155 East Hanover Ave,  Morristown,
NJ  07960
1500 South 14th Street, Clinton, IA
52732
                                   2-26
-------
      Table 2-10.  Wide-Web Flexographic  Printing Responses
                               (continued).
Champion International Corp.

Champion International Corp.

Champion International Corp.

Charleston Packaging Company, Inc.

Clark Container, Inc.

Cleo, Inc.

Compak, Inc.

Webcor Packaging Corp.

Crystal Tissue

Castle Rock Container Company

C. P. C. Packaging, Inc.
Cryovac Division

Cryovac Division

Cryovac Division

Bemis Company, Inc.

Bemis Company, Inc.
Bemis Company, Inc.

Bemis Company, Inc.

Bemis Company, Inc.
Bemis Company, Inc.
Bemis Company, Inc.

Bemis Company, Inc.

Bemis Company, Inc.

Bemis Company Inc.

Bemis Company, Inc.

Bemis Company, Inc.
Bemis Specialty Films

Bemis Curwood

Bemis Curwood
Bemis Milprint
Bemis Milprint

Cello-Foil Products,  Inc.
7920 Mapleway Drive, Olmsted Falls,
OH  44138
1901 Windsor Place, Fort Worth, TX
76110
600 Dairy Pak Road, Athens, GA
30607
4229 Domino Ave, North Charleston,
SC  29405-7486
P.O. Box 160, Bates Crossing
Industrial Park, Lyles, TN  37098
3963 Vernal Pike, Bloomington, IN
47402
8789 E. Lansing Road, Durand, MI
48429
1220 N. Center Road, Burton, MI
48509
1118 Progress Way, Maysville, KY
41056
P.O. Box 530 - Grove Street, Adams,
WI  53910
214 Brace Ave., Eluria, OH  44035
1301 West Magnolia Avenue, Iowa
Park, TX  76367
1125 Wilson Avenue, S.W., Cedar
Rapids, IA  52406
P.O. Box 338 (803 N. Maple St.),
Simpsonville, SC  29681
1401 West 3rd Avenue, Crossett, AR
71635
1975 Latham St., Memphis, TN 38106
2705 University Ave., Minneapolis,
MN 55418
3514 South 25th St., Omaha, NE
68105
Sloan St., Peoria, IL 61603
Chapel Place, Pepperell, MA 01463
55 South Atlantic St., Seattle, WA
98124
1401 West 4th Plain Blvd,
Vancouver, WA 98660
1000 East 13th St., Wichita, KS
67214
1350 North Fruitridge Ave., Terre
Haute, IN 47808
Rt. 12 West,  P.O. Box 475,
Flemington, NJ  08822
Jaycee Drive, Hazleton, PA 18201
2450 Badger Avenue, Oshkosh, WI
54904
19th  and Wall Sts., Murphysboro,
IL 62966
718 High St., New London, WI 54961
590 Woodrow St., Denmark, WI 54902
1309 HWY 61 North, Lancaster, WI
53813
155 Brook Street, Battle Creek, MI
49017
                                   2-27
-------
      Table 2-10.
Wide-Web  Flexographic Printing Responses
         (continued).
Custom Poly Bag,  Inc.

Dart Container Corporation

Deco Paper Products,  Inc.

Design Containers,  Inc.

Dixico, Inc.

Dynamic Packaging,  Inc.

Eisenhart Wallcoverings  Co.

Eskimo Pie Corporation

Equitable Bag Co.,  Inc

Excelsior Transparent  Bag  MFC Corp.

Fabricon Products

Fabricon Products

Spec-Fab

Fleetwood Container &  Display

fp Webkote, Inc.

Spiralkote, Inc.

Flex-Pak, Inc.

Flexo Transparent,  Inc.
Focus Packaging,  Inc.

Fort Wayne Newspapers

Frank C. Meyer Company,  Inc.

Gateway Packaging

Gentry Poly Specialties, Inc.

Georgia-Pacific Corp.

Georgia-Pacific Corp.

Georgia-Pacific
Georgia-Pacific Corp

Georgia-Pacific Corp

Georgia-Pacific
                   9465 Edison Street, NE, Alliance,
                   OH  44601
                   60 E. Main Street, Leola, PA
                   17540
                   1028 South Eighth Street,
                   Louisville, KY  40203
                   2913 West Side Blvd., Jacksonville,
                   FL  32209
                   276 S. Parkway West, Memphis, TN
                   38109
                   7875 School Road, Cincinnati, OH
                   45249
                   400 Pine Street, P.O. Box 464,
                   Hanover, PA  17331
                   118 J.F. Kennedy Dr. North,
                   Bloomfield, NJ  07003
                   7600 Empire Drive, Florence, KY
                   41042
                   159 Alexander Street, Yonkers, NY
                   10701
                   1721 W. Pleasant, River Rouge, MI
                   48218
                   4101 North American Street,
                   Philadelphia, PA  19140
                   1818 Rowland Street, Riverton, NJ
                   08077
                   2721 E. 45th Street, Vernon, CA
                   90058
                   1016 S. W. Adams St., Peoria, IL
                   61602-1694
                   1200 Central Florida Parkway,
                   Orlando, FL  32809
                   555 Branch Drive, Alpharetta, GA
                   30201
                   28 Wasson St, Buffalo, NY  14210
                   5207 Richland Ave., Kansas City, KS
                   66106
                   600 W. Main St., Fort Wayne, IN
                   46801
                   585 S. Union Street, Lawrence, MA
                   01843
                   P.O. Box 29, Granite City, IL
                   62040
                   P.O. Box 688, Route 2, Gentry, AR
                   72734
                   1500 Orchard Hill Drive, LaGrange,
                   GA  30240
                   327 Margaret Street, Plattsburgh,
                   NY  12901
                   P.O. Box 3333, Crossett, AR  71635
                   17 Forester Ave, Warwick, NY
                   10990
                   P.O. Box 919, Palatka, FL
                   32178-0919
                   RR6 Box 8, Riverside Lane,
                   Brattleboro, VT
                                   2-28
-------
      Table 2-10.  Wide-Web Flexographic Printing Responses
                               (continued).
Georgia-Pacific

G-P Albany Plant

G-P Asheboro Plant

G-P Augusta Plant

G-P Bradford Plant

G-P Buena Park Plant

G-P Canton Plant

G-P Chicago Plant

G-P Cincinnati Plant

G-P Circleville Plant

G-P Cleveland Plant

G-P Cleveland Plant

G-P Doraville Plant

G-P Dubuque Plant

G-P Franklin Plant

G-P Huntsville Plant

G-P Kansas City Plant

G-P Lake Placid Plant

G-P Madera Container Plant
G-P Martinsville Plant

G-P Memphis Plant

G-P Milan Plant

G-P Modesto Plant

G-P Monticello Plant

G-P Mt. Olive Plant

G-P Mt. Wolf Plant

G-P Olympia Plant

G-P Ooltewah Plant

G-P Oshkosh Plant
300 H. Laurel Street, Bellingham,
WA  98225
405 Maxwell Drive, Albany, GA
31701
200 McDowell Road, Asheboro, NC
27203
Perkins & New Savannah Rd, Augusta,
GA   30913
One Owen's Hay, Bradford, PA
16701
6300 Regio Avenue, Buena Park, CA
90620
2820 Hinfield Way, Canton, OH
44705
440 Bast 138th Street, Chicago, IL
60627
220 West North Bend Road,
Cincinnati, OH  45216
2850 Owens Road, Circleville, OH
43113
4660 Brook Park Road, Cleveland, OH
44142
4200 Old Tasso Road, Cleveland, TN
37311
4600 NE Expressway, Doraville, GA
30340
2150 Kerper Boulevard, Dubuque, IA
52004
210 Grove Street, Franklin, MA
02038
3420 Stanwood Boulevard,
Huntsville, AL  35811
8600 Northeast 38th Street, Kansas
City, MO  64161
400 S.R. 70 West, Lake Placid, FL
33852
24600 Avenue 13, Madera, CA  93637
US 200 and Route 970, Martinsville,
VA  24112
611 Winchester Road, Memphis, TN
38116
951 County Street, Milan, MI
48160
2400 Lapham Drive, Modesto, CA
95354
823 North Cedar Street, Monticello,
IA  52310
Old Rt. 66 and 8th Street, Mt.
Olive, IL  62029
25 Walnut Street, Mt. Wolf, PA
17347
1203 Fones Road, Olympia, WA
98501
5201 Ooltewah-Ringwold Road,
Ooltewah, TN  37363
413 East Murdock Avenue, Oshkosh,
WI  54902
                                   2-29
-------
      Table 2-10.   Wide-Web Flexographic Printing Responses
                               (continued).

G-P Owosso Plant                        465 S.  Delaney Road, Owosso,  MI
                                        48867
G-P Schenectady Plant                   Building  801  Corporations Park,
                                        Schenectady,  NY   12302
G-P Sheboygan Plant                     1927 Erie Avenue,  Sheboygan,  WI
                                        53082
G-P So. San Francisco Plant             249 East  Grand Avenue,  So. San
                                        Francisco,  CA 94080
G-P Spartanburg Plant                   3100 Southport Road, Spartanburg,
                                        SC 29304
G-P Valdosta Plant                      Highway 31 South,  Clyattville, GA
                                        31601
G-P Warren County Plant                 U.S. Highway  1, Hanson, NC  27553
G-P West Monroe Plant                   400 Central Street, West Monroe, LA
                                        71292
G-P Waxahachie Plant                    5800 Hwy  35 East,  Waxahachie, TX
                                        75165
Gilman Converted Products               3201 McRae Highway, Eastman,  GA
                                        21023
Glenroy, Inc.                           W158 N9332 Nor-X-Way Ave., P.O. Box
                                        534, Menomonee Falls, WI
                                        53052-0534
Graphic Packaging Corporation           708 South Avenue,  Franklin, OH
                                        45005
Graphic Packaging Corp.                 Mathews and Cedar Hollow Road, P.O.
                                        Box 500,  Paoli, PA 19301
Greif Bros. Corp                        2750 -  145th  Street West,
                                        Rosemount,  MM 55068-4998
Gulf Coast Plastics Div.  Dairy-Mix,  Inc.9314 Princess Palm Ave., Tampa, FL
                                        33619
Gulf States Paper Corp.                 244 Warner Road,  Maplesville, AL
                                        36750
H. S. Crocker Co., Inc.                 12100 Smith Drive, Huntley, IL
                                        60142
Hallmark Cards                          Select  Drive, Leavenworth, Kansas
Hallmark Cards                          Eisenhower Road,  Leavenworth,
                                        Kansas
Hargo Flexible Packaging Corp           County  Line Road,  Boyertown,  PA
                                        19512
Hargo Flexible Packaging Corp           1501 North Seventh Street,
                                        Harrisburg, PA  17102
Hargro Flexible Packaging               U.S. 31 North, P.O. Box 188,
                                        Edinburgh,  IN 46124
Hargro Health Care Packaging            3500 N. Kimball Avenue, Chicago, IL
                                        60618-5508
Home Plastics, Inc.                     5250 NE 17th  St,  DesMoines, IA
                                        50313
Huntsman Packaging Products, Corp       8039 S. 192nd Street, Kent,
                                        Washington 98032-2162
Carolina Printing & Converting InterflexRt. 4 Box 4 Highway 268 West,
                                        Wilkesboro, NC  28697
International Paper                     310 Airport Drive, Presque Isle, ME
                                        04769
International Paper                     Auburndale
International Paper                     Carson
International Paper                     Chicago
International Paper                     Cincinnati
International Paper                     Dallas


                                   2-30
-------
      Table 2-10.
                     Wide-Web Flexographic  Printing Responses
                               (continued).
International Paper
International Paper
International Paper
International Paper
International Paper
International Paper
International Paper
International Paper
International Paper
International Paper
International Paper
International Paper
International Paper
International Paper
International Paper
International Paper
International Paper
International Paper
International Paper
International Paper
International Paper-Bag Pack
International Paper-Bag Pack
International Paper-Bag Pack
International Paper-Bag Pack
International Paper-Bag Pack
International Paper-folding Cartons
International Paper—Label Div
International Paper-Specialty Div.
International Paper-Specialty Div.
International Paper-Specialty Div.
International Paper-Specialty Div.
Interstate Packaging Corp.
James River Paper Company
James River Paper Co

James River Paper Co.

James River Paper Co
                       Inc
                       Inc.
James River Paper Co.,

James River Corp. Location 571

James River Paper Co

James River Corporation

James River Corp

James River Corp

James River Corp

James River Paper Co.,
                                        Detroit
                                        Edinburg
                                        El Paso
                                        Fond du Lac
                                        Geneva
                                        Georgetown
                                        Minneapolis
                                        Mobile
                                        Modesto
                                        Mt. Carmel
                                        Nashville
                                        Putnam
                                        Russellvile
                                        San Jose
                                        Shreveport
                                        Spring Hill
                                        Statesville
                                        Stockton
                                        Tallman
                                        Hooster
                                        Camden
                                        Jackson
                                        Mobile
                                        Pittsburg
                                        Wilmington
                                        Hopkinsville
                                        Peoria
                                        Menasha
                                        Lancaster
                                        Kaukauna
                 Knoxville
                 P.O.  Box 271,  Coldenham Road,
                 Walden,  NY  12586
                 Camas Mill;  4th and Adams;  Canvas,
                 HA  98607
                 P.O.  Box 500,  126 A Avenue,
                 Darlington,  SC  29532
                 James River  Corporation, 605
                 Kuebler  Rd.,  Easton,  PA  18042
                 4411  Midland Blvd.,  Fort Smith,  AR
                 72904
                 1505  West Main Street,  Greensburg,
                 IN  47240
                 310 McDonnell Blvd.,  Hazelwood,
                 63042
                 451 Harbison Rd., Lexington, KY
                 40511
  Creative Expressions3500 North Arlington Ave.,
                 Indianapolis,  IN  46218
                 Canal Plant,  258 River  Street,
                 Menasha,  WI   54952
                 River Road and Grantham Lane,
                 Castle,  DE  19720
                 400 Island Avenue,  Parchment, MI
                 49004
Inc.              North Portland Plant, 3400  N.
                 Marine Drive,  Portland,  OR   97217
                                                                       MO
                                                                     New
                                   2-31
-------
      Table 2-10.   Wide-Web Flexographic Printing Responses
                               (continued).

James River                             2424  SE Holgate,  Portland, OR
                                        97202
James River - Specialty Tabletop        18554 S.  Susana Road, Rancho
                                        Dominguez, CA
James River Corp.                       2101  Williams  Street, San Leandro,
                                        CA 94577
James River Paper Co.                   210 Kansas City Ave., Shreveport,
                                        LA 71107
James River Corp - Wausau Plant         200 West  Bridge Street, P.O.  Box
                                        1047,  Wausau,  WI   54402-1047
Smurfit Flexible Packaging              1228  E Tower Road, Schaumburg, IL
                                        60173-4386
Jefferson Smurfit Corp                  170 Lisle Road, Lexington, KY
                                        40511
Jefferson Smurfit/Container Corp.  of America601 Monster Road, SW, Renton,
                                        WA 98055
Smurfit Flexible Packaging              7074  W. Parkland  Ct, Milwaukee, WI
                                        53188
Jefferson Smurfit Corp                  301 S Butterfield Road, Muncie, IN
                                        47303
Jefferson Smurfit Corp                  12005 N.  Burgard  Road, Portland, OR
                                        97203
JSC/CCA                                 99 Harris Street,  Fulton, NY
                                        13069
JSC/CCA                                 8440  Tewantin, Houston, TX  77061
Jefferson Smurfit Corp./Container  Corp.  of AmericaShawnee & Ridge Road,
                                        Muskogee, OK   74401
Jefferson Smurfit Corp                  Sixth and Zschokke, Highland,  IL
                                        62249
Jefferson Smurfit Corp                  122 Quentin Ave.,  New Brunswick, NJ
                                        08901
Jefferson Smurfit Corp./Container  Corp.  of America577  Goddard Ave.,
                                        Chesterfield,  MO   63005
Jefferson Smurfit/Container Corporation  of America265  W Trigg Avenue,
                                        Memphis,  TN  38106
Jefferson Smurfit Corporation           3505  Tree Court Industrial Blvd.,
                                        St. Louis, MO  63122
Jefferson Smurfit Corporation           201 S. Hillview Drive - Milpitas,
                                        CA 95035
Jefferson Smurfit Corp.                 4600  Newlon Rd.,  Ft. Smith, AR
                                        72914
Jefferson Smurfit Corp.                 6701  South Freeway, Fort Worth, TX
                                        76134
Jefferson Smurfit Corp.                 3  N.  Sherman Street, Anderson, IN
                                        46016
Jefferson Smurfit                       111 Folmar Parkway, Montgomery, AL
                                        36105
Jefferson Smurfit Corp                  75 Cascade Blvd,  Milford, CT
                                        06460
JSC/CCA                                 100 McDonald Boulevard, Aston, PA
                                        19014
Jefferson Smurfit                       41 Campion Road,  New Hartford, NY
                                        13413
Jefferson Smurfit Corporation           12200 Westport Rd., Louisville, KY
                                        40245
Jefferson Smurfic Corp                  8209  CR 131, Wildwood, FL  34785
Jefferson Smurfit Corporation           365 Audubon Road,  Wakefield,  MA
                                        01880


                                   2-32
-------
      Table 2-10.  Wide-Web Flexographic  Printing Responses
                               (continued).
Jefferson Smurfit Corp

Jefferson Smurfit Corp
                                        4512 Anderson Road, Knoxville, TN
                                        37918
                                        2200 Industrial Dr., P.O. Box 2277,
                                        Jonesboro, AR72402
Jefferson Smurfit/Container Corp.  of  America2601 S. Malt Ave., Los Angeles,
                                        CA 90040
Container Corporation of America        6541 Eastern Avenue, Baltimore, MD
                                        21224
Jefferson Smurfit/Container Corporation  of AmericalSS N. Smith Street,
Jefferson Smurfit Corp

Jefferson Smurfit Corp.

JSC/CCA

Container Corporation of America

JSC/CCA
Jefferson Smurfit Corporation

Jefferson Smurfit
Jefferson Smurfit Corportion

Jefferson Smurfit Corp

Jefferson Smurfit Corp

Jefferson Smurfit Corporation

Jefferson Smurfit Corporation

Jefferson Smurfit Corp

Jefferson Smurfit Corp

Jefferson Smurfit Corp./CCA

Packaging Unlimited, Inc.


Jefferson Smurfit Corporation

John H. Harland Company
Kookaburra USA LTD

Kleartone, Inc.

Lin Pac, Inc.

Lin Pac

Longhorn Packaging,  Inc.

Macon Telegraph
Mafcote Industries
                                        Corona, CA  91720
                                        301 E  144th Street, Dolton, IL
                                        60419
                                        2743 South Pierce Street, Dallas,
                                        TX  60419
                                        2525 S. Sunland Avenue, Fresno, CA
                                        93725
                                        9960 Alliance Road, Cincinnati, OH
                                        45242
                                        975 North Freedom, Ravenna, OH
                                        1201 East Lincolnway, LaPorte, IN
                                        46350
                                        N Pt.  Blvd., Winston Salem, NC
                                        1720 Ninth Avenue, Humboldt, TN
                                        38343
                                        1601 Tri View Avenue, Sioux City,
                                        IA  51103
                                        Pearl  and Central, Lancaster, NY
                                        14086
                                        775 South Linwood Road, P.O. Box
                                        1268,  Galesburg, IL  61402-1268
                                        JSC Preprint, 9960 Alliance Road,
                                        Cincinnati, OH  45242
                                        1125 Haley Road, Murfreesboro, TN
                                        37133-0638
                                        460 N  Belcrest, Springfield, MO
                                        65808
                                        662 Washburn Switch Rd., Shelby, NC
                                        28150
                                        P.O. Box 5102, Pta de Tierra
                                        Station, San Juan, Puerto Rico
                                        00906
                                        2101 Rossville Ave, Chattanooga, TN
                                        37408
                                        293 Miller Rd, Decatur, GA  30035
                                        1 Commerce Drive S, Harriman, NY
                                        10926
                                        695 Summer Avenue, Westbury, NY
                                        11590
                                        4200 Cambridge Road, Fort Worth, TX
                                        76155
                                        5725 Commerce, Morristown, TN
                                        37814
                                        110 Pierce Ave., San Antonio, TX
                                        78208
                                        120 Broadway, Macon. GA 31213
                                        4525 N. Euclid Ave., St. Louis, MO
                                        63115
                                   2-33
-------
      Table 2-10.   Wide-Web Flexographic Printing Responses
                               (continued).
Mafcote/SWACO

Mail-Well Envelope

Maine Poly, Inc.
Malnove, Inc.

Marglo Packaging Corp.
                                        101 Ascher  Street., Quitman, MS
                                        38355
                                        4500 Tiedeman  Road, Cleveland, OH
                                        44144
                                        P.O. Box  8,  Route  202, Greene, ME
                                        4115 University  Blvd. Court West,
                                        Jacksonville,  FL  32217
                                        1522 Old  Country Road, Plainview,
                                        NY  11803
Massillon Container                     49 Ohio Street,  Navarre,  OH  44662
McClatchy Newspapers, Inc., dba The Modesto Beel325 "H"  Street, Modesto, CA
                                        95354
McClatchy Newspapers, Inc. dba The Fresno Beel626 E Street, Fresno, CA
                                        93786
Mead Packaging                          1105 Herndon Street, NW,  Atlanta,
                                        GA  30318
Menasha Corporation                     Menasha Packaging  - Neenah Plant,
                                        1645 Bergstrom Rd., Neenah, WI
                                        54957
Miami Herald Publishing  Co.            One Herald  Plaza,  Miami,  FL 33032
Mid-West Poly Pak, Inc.                 P.O. Box  35, 89  Marion Street,
                                        Doylestown,  OH  44230
Milwaukee Container                     2800 W. Custer Avenue, Milwaukee,
                                        WI  53209
M.T.P. Industries, Inc. (Mason Transparent Pkg)1180 Commerce Avenue, Bronx,
                                        NY  10462
Neenah Printing - Wide Web Flexo Plant  1257 Gillingham  Road, Neenah, WI
                                        54957-0425
                                        4848 South  Hoyne Avenue,  Chicago,
                                        IL  60609
                                        701 "A" Street NW  / Box 583,
                                        Auburn, WA   98002
                                        2275 Commerce  Drive, Fremont, OH
                                        43420
                                        2901 45W  Bypass, Humboldt, TN
                                        38343
                                        1201 North  Main  Street, Viroqua, WI
                                        54665
                                        38 Depot  Street, Nichols, WI
                                        54152
                                        Operator-1051  Bloomfield  Rd.,
                                        Bardstown,  KY  40004
Midwest Film Corp

Mohawk Northern Plastics, Inc.

Moore, Business Forms and Systems

NCR Corp.

NCR - B.F.D.

Nichols Paper Products Co.,  Inc.

Owens-Illinois, Inc.

Package Printing Co., Inc.

Package Products Flexible Corporation
Packaging Corp of America
Packaging Corp of America
Packaging Corp of America
Packaging Corp of America
Packaging Corp of America
Packaging Corp of America
Packaging Corp of America
Packaging Corp of America
Packaging Corp of America
Packaging Corp of America
Packaging Corp of America
Packaging Corp of America
                                        33 Myron Street,  West  Springfield,
                                        MA  01089
                                        2203 Hawkins St.,  Charlotte  NC
                                        28203
                                        Akron,  OH
                                        Arlington,  TX
                                        Ashland,  OH
                                        Atlanta,  GA
                                        Buffalo,  NY
                                        Burlington,  WI
                                        Colby,  WI
                                        Denver,  CO
                                        Garland,  TX
                                        Gas City, IN
                                        Goldsboro,  NC
                                        Grafton,  WV
                                   2-34
-------
      Table 2-10.
           Wide-Web Flexographic Printing Responses
                     (continued).
Packaging
Packaging
Packaging
Packaging
Packaging
Packaging
Packaging
Packaging
Packaging
Packaging
Packaging
Packaging
Packaging
Packaging
Packaging
Packaging
Packaging
Packaging
Packaging
Packaging
Packaging
Packaging
Packaging
Packaging
Packaging
Packaging
Packaging
Packaging
Packaging
Packaging
Packaging
Packaging
Corp of America
Corp of America
Corp of America
Corp of America
Corp of America
Corp of America
Corp of America
Corp of America
Corp of America
Corp of America
Corp of America
Corp of America
Corp of America
Corp of America
Corp of America
Corp of America
Corp of America
Corp of America
Corp of America
Corp of America
Corp of America
Corp of America
Corp of America
Corp of America
Corp of America
Corp of America
Corp of America
Corp of America
Corp of America
Corp of America
Corp of America
Industries,  Inc.
Packaging Materials Incorporated

Packaging Products Corp.

Packaging Products Corporation

Packaging Products Corp.

Packaging Specialties, Inc.

Pacquet Oneida, Inc.

Paramount Packaging Corp.

Paramount Packaging Corp.
Paramount Packaging Corp.

Paramount Packaging Corp.

Percy Kent Bag Co., Inc.

Phoenix Packaging

Phoenix Products Co.,  Inc.
Grandville, MI
Hanover, PA
Harrisonburg, VA
High Point, NC
Honea Path, SC
Jackson, TN
Jacksonville,
Knoxville, TN
Lancaster, PA
Los Angeles, CA
MarshalItown, IA
Miami, FL
Middletown, OH
Milwaukee, WI
Minneapolis, MN
Morganton, NC
Newark, OH
Newberry, SC
Northhampton, MA
Omaha, NE
Opelika, AL
Phoenix, AZ
Pittsburgh, PA
Piano, TX
Plymouth, MI
Richmond, VA
Salisbury, NC
Syracuse, NY
Trexlertown, PA
Vincennes, IN
Winter Haven, PL
2450 Alvarado Street, San Leandro,
CA  94577
62805 Bennett Avenue, Cambridge, OH
43725
1807 Parrish Drive, Rome, GA
30161
999 Lee Street, Elk Grove Village,
IL  60007
6800 W. 61st St., Mission, KS
66202
P.O. Box 360, 1663 Armstrong Ave.,
Fayetteville, AR  72702-0360
10 Clifton Blvd., Clifton, NJ
07015
800 Jordan Vally Rosad, Longview,
TX 76508
202 Oak Ave. Chalfont, PA 18914
720 Eagle Blvd. Shelbyville, TN
37160
106 Samsonite Blvd, Murfreesboro,
TN 37130
5910 Winner Road, Kansas City, MO
64125
10949 91st Ave, N, Maple Grove, MN
55369
6161 N. 64th Street, Milwaukee, WI
53218
                                   2-35
-------
      Table 2-10.   Wide-Web Flexographic Printing Responses
                               (continued).

Pioneer Balloon Company                 2400 Pioneer Drive, El  Dorado, KS
                                        67042
Viskase Corp.                           24th and  O'Neal  Streets,  P.O. Box
                                        250, Centerville,  IA  52544
Plastic Packaging Corp                  750 South 65th Street,  Kansas City,
                                        KS  64111
Plastic Packaging, Inc.                 1246 Main Ave.,  S.E., P.O. Box
                                        2029, Hickory, NC  28603
Plicon Corp.                            6001 River Road, Suite  300,
                                        Columbus, GA  31904
Poly Plastic Packaging, Inc.             510 Industrial Avenue,  P.O.  Box
                                        219, Boynton Beach, FL  33425
Poly Plastic Packaging, Inc.             36-36 36th Street, Long Island
                                        City, NY   11101
Polyflex Film & Converting,  Inc.         1301 Hwy  51 N, Summit,  MS 39666
Press Telegram                          604 Pine  Avenue, Long Beach,
                                        California 90844
Procter and Gamble Co.                   512 Liberty Expressway, Albany, GA
                                        31703
Procter and Gamble Co.                   Mehoopany,  PA 18629
Procter and Gamble Co.                   501 Eastman Ave.,  Green Bay, WI
                                        54302
Procter and Gamble Co.                   800 North Rice Ave., Oxnard, CA
                                        93010
Providence Journal Company              210 Kinsley Avenue, Providence, RI
                                        02903
Rand -Whitney/Northeast Container       45 Industrial Way, Dover, NH 03820
Rand -Whitney/Southeast Container Corp.  455 Narragansett Park
                                        Dr.,Pawtucket, RI  02861
Rand -Whitney Container Corp.            Agrand St., Worcester,  MA 01607
Rex-Rosenlew International,  Inc.         1308 Blair Street, Thomasville, NC
                                        27360
The Robinette Company                   250 Blackley Road, Bristol,  TN
                                        37625
Rock-Tenn Company                       329 Industrial Park Road, Harrison,
                                        AR  72601
Rock-Tenn Company                       525 West  19th Street, Chattanooga,
                                        TN  37408
Rock-Tenn Company                       4691 Lewis Road, Stone  Mountain, GA
                                        30086
Rock-Tenn Company                       302 Hartman Drive, P.O. Box  997,
                                        Lebanon,  TN  37087
Rock-Tenn Company                       Forest Hills School Road,
                                        Marshville, NC  28103
Rock-Tenn Company                       105 Tote  - M Avenue, Eutaw,  AL
                                        35462
Rock-Tenn                               198 Commerce,  Conway, AR  72032
Rock-Tenn Company                       6702 Hwy. 66W, Greenville, TX
                                        75402
Rock-Tenn Company                       302 Hartman Drive, P.O. Box  997,
                                        Lebanon,  TN  37087
R. R. Donnelley 6 Sons Company          Lancaster West Plant, 1375
                                        Harrisburg Pike, Lancaster,  PA
                                        17601
Sealright Packaging Company             814 South First  Street, Fulton, NY
                                        13069
Sealright Packaging Co.                 2925 Fairfax Road, Kansas City, KS
                                        66115


                                   2-36
-------
      Table 2-10.
Wide-Web Flexographic Printing Responses
          (continued).
Sealright Packaging Co.

Venture Packaging

Jaite Packaging

Packaging Industries, Inc.

Selig Sealing Products, Inc.
Solar Press

Solo Cup Company

Solo Cup Company

Southern Colortype Co., Inc.

Specialty Container Corporation

Standard Packaging & Printing Corp.
The Standard Register Company

Sunrise Packaging, Inc.

Superpac, Inc.

Susan Crane, Inc.

Teepak, Inc.

Tennessee Press, Inc.

Toph

Toph

Uniflex, Inc.

Union Camp Corp. - Container Division

Union Camp Corp

Union Camp Corp

Union Camp Corp.

Union Camp Corporation

Union Camp  Corp.

Union Camp Corp

Union Camp Corp

Union Camp Corp
                   4209 E. Noakes Street, Los Angeles,
                   CA  90023
                   1600 Hestinghouse Blvd., Charlotte,
                   NC  28273
                   1972 Akron-Peninsula Road, Akron,
                   OH  44313
                   2450 Alvarado Street, San Leandro,
                   CA  94577
                   342 E. Wabash, Forrest, IL  61741
                   1500 Shore Road, Naperville, IL
                   60563-1799
                   1951 Highway 304, Belen, New Mexico
                   87002
                   1501 E. 96th Street, Chicago, IL
                   60628
                   2927 Sidco Drive, Nashville, TN
                   37204
                   1608 Plantation Rd., Dallas, TX
                   75235
                   NC Hwy 73W, Mt. Gilead, NC  27306
                   Industrial Avenue, Rocky Mount, VA
                   24151
                   2025 W. South Branch Blvd., Oak
                   Creek, WI  53154
                   1220 Industrial Boulevard,
                   Southampton, PA  18966
                   8107 Chancellor Row, Dallas TX
                   75247
                   915 N. Michigan Avenue, Danville,
                   IL  61832
                   1400 Sixth Avenue, Knoxville, TN
                   37917
                   1120 Heritage Drive, Osage, IA
                   50461-0119
                   1001 Rialto Rd., Covington, TX
                   38019
                   474 Grand Blvd., Westbury, NY
                   11590
                   1975 Lakeside Parkway SW 314,
                   Tucker, GA  30084
                   W. Lathrop Ave., Savannah, GA
                   31402
                   345 Cedar Springs Rd., P.O. Box
                   5497, Spartanburg, SC  29302
                   Hazleton Plant, Maplewood Drive,
                   Hazleton, PA  18201
                   501 Williams Street, Toman, WI
                   54660
                   901 Commerce Circle, Shelbyville,
                   KY  40065
                   10801 lona Ave., Hanford, CA
                   93230
                   3100 Jim Christal Rd., Denton, TX
                   76207
                   2200 D. Avenue East, Freeman Field,
                   Seymour, IN  47274
                                   2-37
-------
      Table 2-10.   Wide-Web Flexographic Printing Responses
                               (continued).
Union Camp Corp                         3055 Sweeten  Creek Rd., Asheville,
                                        NC  28813
Union Camp Corp.                        Cloverdale  Rd.,  P.O.  Box 278,
                                        Sibley, IA  51249
Union Camp, Inc.                        1829 Hwy. 35S, Monticello, AR
                                        71655
Union Camp Corp                         Rt.  2,  Box  433K, Tifton, GA   31794
Union Camp Corp., Richmond Retail Pkg.   2801 Cofer  Road, Richmond, VA
Union Camp Corp

Viskase Corp.

Vitex Packaging, Inc.

Waldan Paper Services, Inc.

Ward/Kraft, Inc.

Western Publishing Co., Inc.

Beach Products
Wabash Pioneer Container Corp.

Westvaco Envelope Division


Westvaco Envelope Division

Westvaco Envelope Division

Westvaco Envelope Division

Westvaco Envelope Division

Westvaco Envelope Division

Westvaco Envelope Division

Westvaco Envelope Division

Westvaco - Flexible Packaging

Westvaco Container Division

Westvaco Container Division

Westvaco Container Division

Westvaco Container Division

Westvaco

Westvaco Container Division

Westvaco Container Division
Westvaco Container Division

Westvaco Container Division
23224
1304 Arthur K. Bolton Parkway,
Griffin, GA  30223
24th & O'Neal Streets, P.O.  Box
250, Centerville,  IA  52544
1137 Progress Road,  Suffolk, VA
23434
167 W. 28th Avenue,  Oshkosh, WI
54901
2401 Cooper Street,  P.O.  Box 938,
Fort Scott, Kansas  66701
1220 Hound Avenue, Racine, WI
53404
2001 Fulford, Kalamazoo,  MI   49001
N143 W6049 Pioneer Road,  Cedarburg,
WI  53012
Springfield Plant, 315 Industry
Avenue, Springfield, MA
01104-3246
Williamsburg Plant,  Route 866,  P.O.
Box C, Williamsburg, PA  16693
Atlanta Plant, 5625 New Peachtree
Road, Chamblee, GA  30341
North Chicago Plant, 1001 South
Sheridan, North Chicago,  IL   60064
Indianapolis Plant,  6302  Churchman
Bypass, Indianapolis, IN  46203
Dallas Plant, 10700 Harry Mines
Blvd., Dallas, TX  75220
Los Angeles Plant,2828 East  12th
Street, Los Angeles, CA  90023
San Francisco Plant, 5650 Hollis
Street, Emeryville,  CA  94608
311 Industry Avenue, Springfield,
MA  01101
3400 East Biddle Street,  Baltimore,
MD  21213
85 Dorothy Street, Buffalo,  NY
14206
4400 West 45th Street, Chicago, IL
60632
2110 West 110th Street, Cleveland,
OH  44102
Blue Springs Road, Cleveland, TN
37311
4847 Cargo Drive,  Columbus,  GA
31907
RR 2, Hwy 35, Eaton, OH  45320
601 North Modena Street,  Gastonia,
NC  28053
Empire Avenue, Meriden, CT  06453
                                   2-38
-------
      Table 2-10,
Wide-Web Flexographic Printing Responses
          (concluded).
Westvaco Container Division

Westvaco container Division

Westvaco, Liquid Packaging Division

Weyerhaeuser Paper Company

Weyerhaeuser Paper Company

Weyerhaeuser Paper Company

Weyerhaeuser Paper Company

Weyerhaeuser Company/IMPAK

Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Willamette Industries, Inc.
Zim's Bagging Co.,  Inc.
                   2300  Jefferson Davis Hwy, Richmond,
                   VA 23234
                   Flexpak  Plant 2910, Cofer Road,
                   Richmond, VA  23224
                   2828  Cofer Road, Richmond, VA
                   23224
                   100 Hawkes Street, Westbrook, ME
                   04092
                   950 Shaver Road NE, Cedar Rapids,
                   IA 52402
                   6706  N.  23rd Street, Tampa, FL
                   33610
                   261 Broadway, P.O. Box 509,
                   Franklin, KY  42134
                   5099  North Royal Atlanta Drive,
                   Tucker,  GA  30084
                   Beaverton, OR;P. O. Box G
                   Buena Park, CA
                   Dallas,  TX
                   Kansas City, MO
                   Tacoma,  WA
                   Aurora,  IL
                   Beaverton, OR; P. O. Box 666
                   Bellvue, Wa
                   Bellmawr, NJ
                   Bowling  Green, KY
                   Cerritos, CA
                   Compton, CA
                   Dallas,  TX
                   Delaware, OH
                   Elk Grove, IL
                   Fort  Smith, AR
                   Golden,  CO
                   Griffin, GA
                   Indianapolis, IN
                   Kansas City, KS
                   Lincoln, IL
                   Louisville, KY
                   Lumberton, NC
                   Matthews, NC
                   Memphis, TN
                   Moses Lake, WA
                   Newton,  NC
                   Sacramento, CA
                   San Leandro, CA
                   Sanger,  CA
                   Sealy, TX
                   St. Paul, MN
                   West  Memphis, AR
                   Tigard,  OR
                   4200  Big Sandy Rd., Prichard, WV
                   25555
                                   2-39
-------
waterborne inks.  Waterborne inks are available for some
applications which contain no HAP.  Some waterborne inks
contain relatively low proportions of HAP, principally
ethylene glycol and glycol ethers.  Most solvent based
flexographic inks contain little or no HAP.  Capture and
control devices used with solvent based inks are usually
designed, permitted and operated for VOC control.
2.3.1.4 Baseline Emissions from Wide Web Flexoqraphic Segment.
HAP emissions data are available for most of the facilities
submitting data in response to the ICR.  In some cases,
responses were received, however the HAP emissions data were
not usable.  This resulted from missing or ambiguous answers
to questions relating to HAP usage and control efficiency.
Nospecific control efficiency relative to HAP was requested.
Data have been analyzed on the assumption that overall HAP
control efficiency is equivalent to reported overall
efficiency.  These data are most often based on tests or
vendor guarantees relating to VOC.  In many cases, HAP makes
up only a minor proportion of the VOC used on press.
     HAP emissions were calculated from wide-web flexographic
press operations at 475 facilities.  Most facilities reported
data for calendar year 1992; in some cases data for more
recent twelve month periods were reported.  A total of 10
facilities were determined to be major sources on the basis of
emissions of 25 tons of HAP per year, or 10 tons of any
individual HAP per year.  If major source status is determined
by potential-to-emit, there will be a greater number of major
sources.  Baseline emissions are given in Table 2-11.
2.3.2 Narrow Web Flexooraphic Printing
     Narrow web flexographic presses are used principally for
printing and adhesive application on tags and labels.  The
presses can be used to print on paper, foil, film or other
substrates.  Ink systems for narrow web flexographic printing
can be similar to those for wide web; in addition, ultraviolet
cure inks are used with some narrow web presses.
                             2-40
-------
 Table 2-11.  Baseline Emissions from Flexographic Printing.

Number of Facilities
Material Applied
(Ib/yr)
HAP Used (Ib/yr)
HAP Emitted
All Responses
485
176,000,000
2,350,000
1,680,000
Major Sources
10
10,200,000
827,000
706,000
     Narrow web presses have the potential to emit relatively
small quantities of HAP.  These presses are sometimes operated
with no capture or control systems.
2.4 LITHOGRAPHY
      Lithography is a planographic method of printing  (in
contrast to gravure, in which the image is etched into  the
plate or flexography, in which the image is raised above the
surface of the plate).  The plate surface is divided between
water repellent (ink receptive) and water receptive (ink
repellent).  In offset lithographic printing, ink is
transferred from the plate to a rubber blanket cylinder.  The
blanket cylinder is used to print the substrate38.  An
extensive discussion of the processes, equipment, inks, and
other substances with the potential to result in HAP emissions
is given in the Control Techniques Guideline for Offset
Lithographic Printing39.  There are over 54,000 lithographic
printing plants in the US, which supply about 50 percent of
the market for printing.  About 91 percent of printing
facilities have lithographic presses40.
     The lithographic printing industry is divided on the
basis of press equipment between sheet-fed, non-heatset web
and heatset web printing.   The CTG41 makes a further
distinction between newspaper non-heatset web and non-
newspaper non-heatset web printing.
                             2-41
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2.4.1 Sheet-fed Lithography
     About 92 percent of the facilities with lithographic
presses have sheetfed lithographic presses.  Sheetfed presses
are used to print on metal, paper, cardboard, foil and film.
Commercial printing (e. g. advertising, brochures, annual
reports, business forms, etc.) is usually done by sheetfed
lithography42.
     Organic emissions can arise from inks, fountain solutions
and cleaning chemicals, although potential HAP emissions come
primarily from fountain solutions.  Sheet-fed lithographic
inks contain phenolic, maleic-modified or rosin-ester resins
dissolved in vegetable drying oils (e. g. linseed and soya)
and diluted with hydrocarbon solvents43.  Most inks used in
sheetfed printing contain less than 25 percent VOC44, and no
HAP.
     Fountain solutions are used to dampen the printing plates
to make the non-image areas repellent to ink.  Traditionally,
these solutions were primarily isopropanol and water with some
added resins and buffering salts.  These solutions contain no
HAP.  In an attempt to reduce VOC emissions, alcohol
substitutes which often contain glycols and glycol ethers,
which are HAP, are now in use.  Generally, no attempt has been
made to capture glycol ethers emitted from sheetfed
lithographic printing.  Refrigeration of the fountain
solutions is a practical means to control emissions of VOC
from this source, but lower VOC, HAP containing alternatives
have been adopted in some cases as an alternative to
refrigeration of higher VOC, no HAP solutions.
     Solvents used for press clean-up are usually kerosene
type high boiling point hydrocarbons, sometimes mixed with
detergents45.  These materials can contain up to 100 percent
VOC but are generally free of HAP.
2.4.2 Non-Heatset Web Lithographic Printing
     Non-heatset web lithography is used to print newspapers,
journals, directories and forms.  It is estimated that there
                              2-42
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are 4950 plants with non-heatset web lithographic presses46.
The ink used  is similar to that used in sheetfed lithography
and generally contains less than 35 percent VOC47.  Fountain
solutions and clean-up solvents are similar to those used in
sheet-fed lithography.  The main source of HAP from this
process is  low VOC fountain solutions which contain glycols
and glycol  ethers.  Typically no controls for HAP are used.
Refrigeration of the fountain solutions is a practical means
to control  emissions of VOC from this source, but lower VOC
HAP-containing alternatives have been adopted in some cases as
an alternative to refrigeration of higher VOC, no HAP
solutions.
2.4.3 Heatset Web Lithographic Printing
     Heatset  web lithography is used to print magazines,
periodicals and catalogs.  It is estimated that there are 1376
plants with heatset web lithographic presses48.  The inks are
about 40 percent VOC and contain high boiling petroleum
distillates,  resins and pigments.  In general, there are no
HAP in the  ink.  Fountain solutions and clean-up solvents are
similar to those used in sheet-fed lithography.  The main
source of HAP from this process is low VOC fountain solutions
which contain glycols and glycol ethers.
     Capture  systems for heatset lithographic presses are used
to collect drier exhaust gases, which contain about 20 percent
of the VOC in the ink.  Control system options include thermal
incinerators, catalytic incinerators, condenser filters with
activated carbon and condenser filters without activated
carbon.  VOC  control efficiencies are estimated at 98 percent
for incinerators, 95 percent for condenser filters with
activated carbon and 90 percent for condenser filters without
activated carbon49.   It should be noted that there are no
performance test data relating to HAP control efficiencies.
     Refrigeration of the fountain solution is a practical
means to control emissions of VOC from this source, but lower
VOC HAP-containing alternatives have been adopted in some
                             2-43
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cases as an alternative to refrigeration of higher VOC, no HAP
solutions.  Clean-up solvents which contain no HAP, or only
very low levels of HAP are available.
2.5 LETTERPRESS
     Letterpress printing uses a relief printing plate as does
flexography and viscous inks similar to lithographic inks.
Various types of letterpress plates are available.  These
plates differ from flexographic plates in that they have a
metal backing.  Both sheetfed and web presses are in use.  Web
letterpress equipment using heatset and non-heatset inks is in
use.  Newspapers were traditionally printed by web non-heatset
letterpress, however these are gradually being replaced by
flexographic and lithographic presses.  Letterpress is used to
print newspapers, magazines, books, stationery and
advertising.  It is estimated that there are about 21,000
plants with letterpress equipment of which about 19,000 have
sheetfed letterpress equipment50.
2.5.1 Non-heatset Letterpress
     Non-heatset web letterpress ink is similar to non-heatset
lithographic ink differing mainly in that it contains less low
viscosity mineral oils and more vegetable oils and high
viscosity mineral oils51.  No fountain solutions are required.
Cleaning solvents are similar to those used in lithography.
This process can be almost entirely HAP free.  Non-heatset
letterpress equipment typically has no emissions control
systems.
      Non-heatset sheetfed letterpress ink varies depending
upon factors including the substrate printed, the type of
plate and press, and the press speed.  In most applications,
this process can be almost entirely HAP free and is typically
conducted with no control system.  No fountain solutions are
required.  Cleaning solvents are similar to those used in
lithography.  "Moisture set" inks used in some packaging
applications contain triethylene glycol, which is a HAP.
"Water washable" letterpress inks are sometimes used for
                             2-44
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printing kraft paper and corrugated boxes.  These inks contain
glycol based solvents which may contain HAP.
2.5.2 Heatset Letterpress
     Heatset letterpress is used for publication printing on
coated papers.  Heatset letterpress ink is similar to heatset
lithographic ink.  These inks contain resins dissolved in
aliphatic hydrocarbons.  These inks are dried in hot air
ovens; drier exhausts can be ducted to VOC control systems.
The inks can be entirely HAP free.  No fountain solutions are
required.  Cleaning solvents are similar to those used in
lithography.
2.6 SCREEN PRINTING
     Screen printing processes involve forcing ink through a
stencil in which the image areas are porous.  The screens are
generally made of silk, nylon or metal mesh.  Screen printing
is used for signs, displays, electronics, wall paper, greeting
cards, ceramics, decals, banners and textiles.  It has been
estimated that there are more than 40,000 screen printing
plants in the U. S., nearly half of which print textiles52.
     Ink systems used in screen printing include ultraviolet
cure, waterborne, solvent borne and plastisol with plastisol
(polyvinyl chloride) being mainly used in textile printing.
Solvent based ink systems contain aliphatic, aromatic and
oxygenated organic solvents.
     Both sheetfed and web presses are used.  Depending on the
substrate printed, the substrate can be dried after each
station or, for absorbent substrates,  after all colors are
printed.  Solvent and waterborne inks are dried in hot air or
infrared drying ovens.  Dryer gases are partially recycled and
partially vented (either to the atmosphere or to a control
system).  Both thermal and catalytic oxidizers are in use on
screen printing dryer exhausts for solvent borne ink systems.
Overall control efficiencies of 70 to 80 percent are
achievable53.
                             2-45
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   2.7 OTHER PRINTING PROCESSES
        Plateless printing technologies are relatively new
   processes used primarily for short runs on paper substrates.
   These processes  include electronic  (e.g., laser printers),
   electrostatic  (e.g., xerographic copiers), magnetic, thermal
   (e.g.,  facsimile machines) and  ink jet printing.  In 1991,
   plateless printing processes accounted for 3 percent of the
   total value of printing54.  Electrostatic toners and ink jet
   printer inks may contain HAP, however the quantities emitted
   at any  location  are small.
   2.7 REFERENCES
1.   U. S. Environmental Protection Agency.  Use Cluster Analysis
     of the Printing Industry, Draft Final Report.  Washington,
     DC.  May 26, 1992.  p. 8.

2.   Documentation for Developing the Initial Source Category
     List.  U. S. Environmental Protection Agency, Research
     Triangle Park, NC. EPA-450/3-91-030.   December, 1991.

3.   Publication Rotogravure Printing - Background Information
     for Proposed Standards. U. S. EPA. Research Triangle Park,
     NC. EPA-450/3-80-031a. October, 1980. pp2-l to 4-40.

4.   Edgerton, Stephen, Joanne Kempen and Thomas W. Lapp. The
     Measurement Solution: Using a Temporary Total Enclosure
     Method for Capture Efficiency Testing. EPA-450/4-91-020.
     August 1991.

5.   Reference 3, p. 3-7.

6.   Profile Survey of the U. S. Gravure Industry; A Market Study
     of Industries Using Gravure and a Profile of Equipment,
     Cylinders, Ink and Substrates.  Gravure Association of
     America.  1989.  p. PRESS-18.

7.   Reference 6,  p. SUM-10.

8.   Memorandum from Green, D., RTI, to D. Salman, EPA/ESD.
     April 6, 1993.  Summary of meeting with EPA, RTI, and
     representatives of the  Flexible Packaging Association,
     Research Triangle Park, NC.

9.   Reference 6,  p. MAR-56.

10.  Reference 6,  p. MAR-67.

                                2-46
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11.  Reference 6,  p. MAR-72.

12.  Reference 6,  p. SUM-12.

13.  Reference 6,  p. MAR-79.

14.  Reference 6,  p. MAR-86.

15.  Reference 6,  p. MAR-87.

16.  Reference 6,  p. SUM-14.

17.  Reference 6,  p. MAR-97.

18.  Reference 6,  p. SUM-16.

19.  Reference 6,  p. SUM-18.

20.  Reference 6,  p. SUM-21.

21.  Memorandum from Green, D.,  RTI, to D. Salman, EPA/ESD.
     September 12, 1994.  Summary of Meeting with Representatives
     of the Gravure Association of America.

22.  Reference 6,  p. INK-5.

23.  Reference 6,  p. INK-11.

24.  Reference 6,  p. INK-6.

25.  Reference 6,  p. INK-8.

26.  Memorandum from Green, D.,  RTI, to Salman, D., EPA/CPB.
     July 30, 1993.  Summary of meeting with Representatives of
     the Flexible Packaging Association.

27.  Reference 26.

28.  Reference 6,  p. INK-9.

29.  Reference 6,  p. MAR-126.

30.  Reference 2.

31.  Reference 1,  p. 15.

32.  Mulvihill, Donna C. Flexography Primer, Graphic Arts
     Technical Foundation, Pittsburgh, PA. 1985.  p. 57.

33.  Printing Ink Handbook, Fifth edition.  National Association
     of Printing Ink Manufacturers, Inc. Harrison, NY. 1988. p.
     38.

                                2-47
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34.  Reference 32,  p. 60.
35.  Reference 32,  p. 60-64.
36.  Reference 32,  p. 49-50.
37.  Cunningham, Elizabeth. Flexo in Flux.  American Ink Maker.
     June 1992. pp. 52.
38.  U. S. Environmental Protection Agency. , Control of Volatile
     Organic Compound Emissions from Offset Lithographic Printing
     -Draft.  Research Triangle Park, NC. September, 1983.  p. 2-
     1.
39.  Reference 38,  235 pp.
40.  Reference 1, p. 63.
41.  Reference 38, p. 2-4
42.  Reference 33,  p. 34.
43.  Kirk-Othmer Encyclopedia of Chemical Technology, Third
     Edition.  "Inks".  New York, NY. 1982. p. 374.
44.  Reference 38, p. 2-8.
45.  Reference 38,  p.2-4.

46.  Reference 1,  p. 63.

47.  Reference 38, p. 3-37.

48.  Reference 1,  p. B-28.
49.  Reference 38, p.4-1 to 4-14.
50.  Reference 1,  p. 101.
51.  Cunningham, H. W. Nonheatset Web Printing, in Bunicore, A.
     and W. T. Davis.  Air Pollution Engineering Manual.  New
     York, NY. 1992.

52.  Kinter, Marcia. Screen Printing, in Bunicore, A. and W. T.
     Davis. Air Pollution Engineering Manual.  New York. NY.
     1992.
                                2-48
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53.  Reference 52.





54.  Reference 1, p. 40.
                               2-49
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       3.0  CONTROL TECHNOLOGY AND PERFORMANCE OF CONTROLS

3.1 INTRODUCTION
     There are two approaches to limitation of HAP in the
printing and publishing industry.  The first approach is to
improve capture and control systems or to add control devices
where none are in use.  Capture and control can be addressed
separately, although in many cases, improved capture is achieved
through an increase in the amount of air handled.  This can
necessitate upgrades to existing control devices.  The second
approach, focusing on pollution prevention, is to substitute low
HAP or HAP-free materials for materials (inks, coatings,
varnishes, adhesives, primers, etc.) presently in use.
3.2 CAPTURE SYSTEMS
     Capture systems are designed to collect solvent laden air
and direct it to a control device.  In heatset printing
processes, solvent is removed from the printed substrate by
evaporation in a dryer.  The exhaust from the dryer can be ducted
to a control device.  Additional systems are often used to
collect solvents which evaporate from other parts of the printing
press, as well as those which escape from the dryer.  In
addition, pressroom ventilation air can be exhausted to a control
device.
     Differences in capture efficiency contribute much more to
the variation in overall efficiencies than the choice of control
device.  Reported capture efficiencies ranged from estimates of
less than 50 percent to the 100 percent capture which is assumed
for systems meeting the requirements of permanent total
enclosures.  Test procedures have been established for
determining capture efficiency1 and  for confirming the presence
                               3-1
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of permanent total enclosures.2  Capture  systems can be  improved
through collection of additional solvent laden air from the press
area and through construction of additional hooding and press
enclosures.  In theory, capture can be improved to (nearly) 100
percent for any press or pressroom by retrofitting walls and
increasing ventilation to meet the requirements of permanent
total enclosures.  In practice, it may be prohibitively expensive
to retrofit some existing facilities.
3.2.1 Publication Rotogravure.
     Within the publication rotogravure industry,  all presses
have dryer exhaust gases routed to the solvent recovery system.
Based on responses to the voluntary question list developed by
the EPA and the GAA, additional capture systems in place were
described as dryer hood systems, partial upper deck enclosures,
full upper deck enclosures, enclosed presses, permanent total
enclosures, room enclosures, rooms operated under negative
pressure and floor sweeps.  It is not known whether the capture
systems described as enclosed presses and room enclosures meet
the EPA definition of permanent total enclosure3.   Typically,
solvent laden air captured from several presses is combined and
treated with a common solvent recovery system.  The individual
presses may have different capture devices, and different capture
efficiencies.
3.2.2 Product and Package Gravure.
     In the product and package gravure industry,  many facilities
use low VOC (and low-HAP) inks and coatings.  Dryer exhausts from
these facilities may be captured and vented to the atmosphere
without the use of a control device.  Where solvent based inks
are in use, more elaborate capture and control systems may be
required.  Capture systems in use at product and packaging
gravure facilities include combinations of dryer exhausts, floor
sweeps, collection ducting, hoods, press enclosures,  total
enclosures, room enclosures, negative pressure pressrooms,
partial enclosures and ink pan covers.  With the exception of
total enclosures, none of these technologies has a precise
                               3-2
-------
 definition with regard to capture efficiency.  In many cases
 terms are used interchangeably.  Where control devices are in
 use, solvent laden air from several presses may be combined and
 ducted to a common control device.
 3.2.3 Wide-web Flexoaraphic Printing.
      Capture systems in use at flexographic printing facilities
 include combinations of dryer exhausts, floor sweeps, hoods, and
 total enclosures.  Capture efficiencies of between 50 and 100
 percent were reported, although many respondents did not report
 capture efficiencies.Many facilities, including most sheetfed
 corrugated box facilities have no capture systems and rely on
 pressroom exhaust to the atmosphere to dilute the small amount of
 HAP present in the ink.
 3.3 CONTROL DEVICES
      The control devices in use in rotogravure and flexographic
 printing processes include carbon adsorption, thermal
 incineration and catalytic incineration.  The selection of a
 control device is influenced by the type of inks (and other
 materials) applied on the press, the volume of solvent laden air
 to be treated and the operating schedule of facility.  Design
 procedures and limitations for these control devices are given in
! the EPA Control Technologies Handbook4.
 3.3.1 Carbon Adsorption.
      Activated carbon is a material with a high surface area
 which adsorbs many organics from air streams.  Typically, solvent
 laden air is passed through two or more fixed beds of granular
 activated carbon.  Organic HAP in the air is adsorbed on active
 sites on the carbon,  until, at some point the capacity of the
 carbon is exhausted,  and the organics pass through unadsorbed.
 Adsorbers are operated in parallel so that when the capacity of
 one unit is exhausted, it can be removed from service and a
 second adsorber can be put into service.  The exhausted carbon in
 the first adsorber is then regenerated5.
      In contrast to incineration techniques, carbon adsorption
 does not destroy the  HAP in the treated air.  Carbon adsorbers in
                                3-3
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the printing industry are regenerated by passing steam through
the carbon beds.  The HAP is removed from the carbon,  and
transferred to the steam.  The steam-HAP mixture is then
condensed, and the solvent separates from the water.  The solvent
can then be decanted for sale or reuse.
     Carbon adsorption systems can achieve control device
efficiencies of 95 to 99 percent for some organic HAP6.   These
systems are most suitable for solvent systems which are
immiscible with water, such as toluene and xylene.  They are not
recommended for ketones such as methyl ethyl ketone and methyl
isobutyl ketone.
3.3.2 Thermal Incineration
     Thermal incinerators are control devices in which the
solvent laden air is preheated and the organic HAP are ignited
and combusted to carbon dioxide and water.  Dilute gas streams
require auxiliary fuel (generally natural gas) to sustain
combustion.  Various incinerator designs are used by different
manufactures.  The combustion chamber designs must provide high
turbulence to mix the fuel and solvent laden air.  The other
requirements are a high enough temperature and a long enough
residence time to insure essentially complete combustion.
Thermal incinerators can be operated to achieve a wide range of
control device efficiencies7.   Efficiencies  of 98  percent* to
greater than 99 percent are possible9.
     Because the incinerator must be in operation at times when
HAP emissions are very low (e. g. when presses are on standby
between jobs)  supplemental fuel requirements will vary.
Incinerators are supplied with controls to start-up and bring the
combustion chamber to the proper temperature.  These controls can
provide an interlock to prevent operation of the press until the
incinerator temperature is adequate to insure destruction of HAP.
3.3.3 Catalytic Incineration
     Catalytic incinerators are control devices in which the
solvent laden air is preheated and the organic HAP are ignited
and combusted to carbon dioxide and water.  In the presence of a
                               3-4
-------
catalyst, this reaction will take place at lower temperatures
than those required for thermal incineration.   Temperatures
between 350 and 500 degrees Celsius are common.  The catalysts
are metal oxides or precious metals where are supported on
ceramic or metallic substrates.  Catalytic incinerators can
achieve control device efficiencies of 95 to 99 percent10.
     From an operational standpoint, the lower reaction
temperature means that the requirement for supplemental fuel is
reduced or eliminated during normal operation.  The lower
operating temperatures will also decease the formation of oxides
of nitrogen.
     The use of a catalyst is inconsistent with certain ink
formulations.  Chlorinated solvents and some silicone ink
additives can poison or deactivate catalysts.  Design of
catalytic incinerators varies from manufacturer to manufacturer.
The major differences involve the geometry of the combustion
chamber, the type of catalyst and support material, and the type
of contact between the gas and the catalyst.
3.4 PERFORMANCE OF CONTROLS
3.4.1 Publication Gravure
     The 27 plants currently operating in the U. S. all use
toluene based ink systems, and operate solvent recovery systems
which include fixed bed activated carbon adsorption units which
are regenerated with steam.  Recovered solvent is added to the
as-purchased ink to adjust the viscosity as necessary.  Excess
recovered solvent is sold back to the ink manufacturers.  Press
capture systems vary depending on the age of the press, however
the majority of the solvent is captured through the dryer
exhausts.
     A total of 31 separate solvent recovery systems are in
service at the 27 publication gravure plants.  In addition, some
plants have substituted non-HAP solvents for a portion of the
toluene based solvent in publication gravure ink.
Catalytic and thermal oxidation systems are technically feasible
for control of publication gravure emissions. These technologies
                               3-5
-------
offer little or no potential improvement in control and have
economic disadvantages as they destroy rather than recover the
solvent.
     The control devices in use at all publication gravure
facilities are similar in design and operation.  Capture
efficiencies of between 85 and 100 percent were reported, however
this information was not available for the majority of the
presses.  Control device efficiencies of 95 to 99.9 percent were
reported, however, these data were not reported for all control
systems.  The median control efficiency reported was 98 percent.
One solvent recovery system manufacturer estimates control device
efficiencies for publication gravure systems at 97 to 99 percent.
This estimate excludes solvent retained in the web equal to
between 1 and 5 percent of that applied11.  This indicates a
maximum expected overall efficiency of 98 percent (i.e. 99
percent control of the 99 percent of the HAP which is not
retained).
     Excluding that portion of the HAP which is retained in the
web and emitted after it leaves the press, control device
efficiencies can theoretically be improved with thicker carbon
beds.  Improvement in capture efficiency is expected to be more
cost effective in many cases, as capture efficiencies of close to
100 percent have been achieved using total enclosures.
     Overall efficiencies, based on liquid-liquid mass balances
were reported for all control systems.  Overall efficiency
represents the product of capture efficiency and control device
efficiency.  These involve determinations of total VOC present in
purchased ink and other VOC containing materials, inventories of
solvent recovery and use through tank level measurements, and
flow meters on ink distribution and recovered solvent purchases.
These balances are conducted frequently by all facilities, and
are typically reported as monthly averages.
     Long term averages are highly accurate as noise from
measurement errors is averaged out.  The nature of the testing,
i. e. material balance, eliminates much of the error associated
                               3-6
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with sampling and analysis of stack emissions.  Analyses of VOC
and HAP content of inks and other materials are, however, subject
to chemical analysis errors.
     On an annual basis, overall efficiencies were reported in
the range of 83 to 109 percent.  It should be noted that the
system reporting 109 percent overall efficiency is able to
achieve a solvent recovery of over 100% by drawing air from a
pressroom controlled by a separate control system, containing
presses with a lower capture efficiency.  Thus, this control
system actually recovers fugitive emissions from a separate
source, in addition to the emissions from the presses that it
controls.
     All facilities reported overall efficiencies achieved in
1992, and provided the range of overall efficiencies achieved
determined on a monthly basis for 1992.  Since some facilities
operate more than one control system, data from 33 control
systems were reported by the 27 facilities.  The range of overall
control data reported for these control systems in the voluntary
responses provided to EPA is given in Table 3-1.

Table 3-1.  Overall Control Efficiencies Reported for Publication
                         Gravure Plants.
Basis of Ranking
Overall Control
Best System
Median System
Worst System
Best Month
%
115
94
85
Annual Average
%
109
91.8
83
Worst Month
%
96
88
78
3.4.2 Product and Packaging Gravure
     Product and packaging gravure facilities use a variety of
ink systems.  Inks in use include toluene based inks which are
similar or identical to those used in publication gravure (See
                               3-7
-------
section 3.4.1), high VOC solvent based inks with very low or no
HAP content, waterborne ink with low VOC and low HAP content and
waterborne ink with low VOC and no HAP content.
     The type of ink used is influenced by factors including the
nature of the substrate printed, the type of product or package
printed, the age of the press and existing air pollution
regulations and permit requirements related to VOC emissions.
Product and packaging rotogravure ink can contain HAP such as
toluene, hexane, methyl ethyl ketone, methyl isobutyl ketone,
methanol and glycol ethers as well as non-HAP VOC such as ethyl
acetate propyl acetate and butyl acetate.  The control
technologies employed are influenced by the type of ink used.
     Existing control technologies for product and packaging
rotogravure are directed to control of VOC.  In most cases, the
HAP and non-HAP portion of the VOC present in the ink are equally
difficult to control.
     Based on data submitted in response to the ICR, control
devices in use at product and packaging gravure facilities
include carbon adsorption, catalytic incineration, fume
incineration, fume/vapor incineration, (unspecified)
incineration, fumes burned in boiler, periodic recuperative
thermal oxidation, recuperative incineration, regenerative
thermal oxidation and regenerative thermal incineration.  These
terms refer to devices which can be divided into three groups:
carbon adsorption, thermal incineration and catalytic
incineration.
     Emissions data submitted in response to the ICR are based on
emissions tests, equipment vendors guarantees and various types
of engineering estimates.  In all cases,  emissions test data
refer to VOC emissions.  It is assumed that recovery or
destruction of VOC is equivalent to that for HAP.  Capture
efficiencies of between 30 and 100 percent were reported,
although many respondents did not report capture efficiencies.
Control device efficiencies of between 89 and 100 percent were
reported by respondents reporting non-zero control device
                               3-8
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efficiencies.  Control device efficiencies were not reported by
all facilities which operate control devices.
     Data on overall efficiency were reported for 87 control
systems.  Some facilities responding to the ICR did not operate
control systems.  The 87 systems for which usable data were
available claimed overall efficiencies of between 45 and 100
percent.  The basis for the estimates vary.  Where solvent
recovery systems are in place the overall efficiencies are
typically determined by liquid-liquid mass balances (as described
in Section 3.4.2).  If total enclosures are in place capture
efficiency is assumed to be 100 percent; control device
efficiency is calculated.
     For catalytic and thermal incineration control devices test
data is available for overall efficiency in some cases and for
control device efficiency in others.  Where test data is
available for destruction across the control device, capture
efficiencies are often estimated using engineering judgment.
Overall efficiencies incorporate these judgments.  In many cases,
either the control device efficiency or the capture efficiency
was based on vender guarantees and the overall efficiency was
estimated.  In general, when operated as designed, control
devices will out-perform vender guarantees on an average basis.
     It should be noted that the accuracy of the reported overall
efficiencies varies.  In addition to the (presumably biased low)
data based on vendor guarantees,  estimates made by operating
personnel of capture efficiency may not be realistic.   There is,
however, less likelihood of a consistent bias (high or low) in
these estimates.
     Overall efficiency data were reported for 87 control
systems.  Other facilities had no control devices in place.
These data are of variable reliability, as described above.  In
addition it should be recalled that reported efficiency data
pertain to VOC control and that the applicability of these data
to the HAP portion of the VOC has not been determined.   The range
of overall efficiencies for carbon adsorption, catalytic
                               3-9
-------
incineration and all other types of incineration are given in
Table 3-2.

     Table 3-2.  Overall  Efficiencies Reported for Product  and
        Packaging Gravure  Facilities with Control Systems.
Control
Device
Carbon
Adsorption
Catalytic
Incineration
Thermal
Incineration
Number of
Systems
22
24
41
Minimum
Efficiency
45
65
47.5
Average
Efficiency
79.8
85.4
83.6
Maximum
Efficiency
100
99.2
99.2
     The range of control device efficiencies for the systems
where these data are reported is given in Table 3-3. Overall
efficiencies reported for three specific industry segments are
given in Table 3-4.  These data are also given for the major
sources (as determined by actual HAP emissions) in the industry
segments.
3.4.3 Wide-web Flexoaraphic Printing
     Flexographic printing facilities use a variety of ink
systems.  Solvent based inks are primarily formulated with non-
HAP solvents which may contain small proportions of ethylene
glycol, glycol ethers and methanol which are HAP.  Solvent based
inks are available for some applications which are completely HAP
free.  Capture and control systems used with these systems are
designed and operated for control of VOC. In the absence of
compound specific performance data it is assumed that individual
HAP are controlled to the same extent as VOC.
     The type of ink used is influenced by factors including the
nature of the substrate printed, the type of product or package
                               3-10
-------
Table 3-3. Control Device Efficiencies Reported for Packaging and
        Product  Gravure  Facilities with Control Systems.
Control Device
Carbon
Adsorption
Catalytic
Incineration
Thermal
Incineration
Minimum Efficiency (%)
89
88.8
88.8
Maximum Eff iciency(%)
100
99.7
99.3
    Table 3-4.  Overall Efficiencies by Industry Segment for
  Packaging and Product Gravure Facilities with Control Systems
             (Data for Major sources in Parentheses).
Industry Segment
Paper/Cardboard Only
Foil/Film Only
Vinyl Product
Overall Efficiency (%)
45-98.6 (65-95.3)
65-95 (65-95)
80-97.7 (80-93)
                              3-11
-------
printed, the age of the press and existing air pollution
regulations and permit requirements related to VOC emissions.
Packaging ink is subject to additional requirements depending on
the intended contents of the package.
     Many wide web flexographic printing facilities use
waterborne inks with either no HAP or low HAP content.  The
majority of these facilities have no control devices,  and may
have converted from solvent based to waterborne materials to
avoid the need to install control devices to comply with VOC
regulations.  Existing control devices for flexography are
directed to control of VOC.  In most cases, the HAP and non-HAP
portion of the VOC present in the ink are equally difficult to
control.
     Where control devices are in use, solvent laden air from
several presses may be combined and ducted to a common control
device.  In addition, HAP from flexographic printing may be
ducted to control devices designed and operated for control of
HAP from other processes (such as rotogravure) operated at the
same plant.
     Based on data submitted in response to the ICR, control
devices in use at flexographic facilities include carbon
adsorption, catalytic incinerators, and thermal incinerators
(including, but not limited to regenerative and recuperative).
Usable ICR data are reported by industry segment and control
device in Table 3-5.
     Emissions data submitted in response to the ICR is based on
emissions tests, equipment vendors guarantees and various types
of engineering estimates.  In all cases, emissions test data
refer to VOC emissions.  It is assumed that recovery or
destruction of VOC is equivalent to that for HAP.  Control device
efficiencies of between 90 and 99 percent were reported by
respondents reporting non-zero control device efficiencies.
     A total of 53 facilities operated control devices.  Those
facilities which do not operate control devices were assumed to
emit 100% of the HAP used.  Not all of the facilities which
                               3-12
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-------
reported overall efficiencies provided separate data on capture
and control efficiencies.  The basis for the estimates vary.
Solvent recovery systems are in place at two facilities; overall
efficiency data for these control systems are typically
determined by liquid-liquid mass balances (as described in
Section 3.4.1).
     For catalytic and thermal incineration control devices test
data is available for overall efficiency in some cases and for
control device efficiency in others.  Where test data is
available for destruction across the control device, capture
efficiencies are often estimated using engineering judgment.
Overall efficiencies incorporate these judgments.  In many cases,
either the control device efficiency or the capture efficiency
was based on vender guarantees and the overall efficiency was
estimated.
     It should be noted that the accuracy of the reported overall
efficiencies varies.  In addition to the (presumably biased low)
data based on vendor guarantees,  estimates made by operating
personnel of capture efficiency may not be realistic.  There is,
however, less likelihood of a consistent bias (high or low) in
these estimates.
     Based on approximately 500 usable responses to the ICR, 125
facilities reported using no HAP whatsoever for flexographic
printing.  Overall efficiency data was reported for 53 control
systems.  It should be noted that none of the facilities
operating control devices had HAP emissions in excess of 25 tons
per year of HAP of 10 tons per year of any specific HAP.
Reported efficiency data pertain to VOC control and the
applicability of these data to the HAP portion of the VOC has not
been determined.  The range of overall efficiencies for carbon
adsorption, catalytic incineration and all other types of
incineration are given in Table 3-6.
     Most of the variation in overall efficiencies is due to
variation in capture efficiencies.  All of the reported control
device efficiencies were greater than 91 percent, although not
                               3-14
-------
     Table  3-6. Overall  Efficiencies Reported for Flexographic
                 Facilities with Control Systems.
Control
Device
Carbon
Adsorption
Catalytic
Incineration
Thermal
Incineration
Number of
Systems
2
42
9
Minimum
Efficiency
91
48
48
Average
Efficiency
93
77
76
Maximum
Efficiency
95
98
95
all facilities reporting overall efficiencies provided data on
control device efficiencies.
     Control device capabilities applicable to flexographic
printing are comparable to those for packaging and product
rotogravure (see Section 3.4.2).  Capture systems for in-line
presses are comparable to those for gravure presses.  Capture
systems for dryer exhausts from common impression and stack
presses may be less efficient than those for in-line presses.
The technology and capabilities of total enclosures and press
room ventilation described in Section 3.2 are applicable to
flexographic printing.
3.5 LOW HAP AND HAP-FREE INKS (AND OTHER MATERIALS)
     Most facilities have adopted air pollution control
strategies directed towards elimination or control of VOC.  Many
low HAP inks contain high proportions of VOC.  VOC control
devices also control organic HAP.  Some existing regulations have
resulted in lower VOC emissions as sources converted from solvent
based to waterborne inks.  In some cases, conversion to
waterborne inks,  which could result in significant reduction in
VOC use, will be inhibited if HAP standards are formulated in
terms of percentage reduction.
                               3-15
-------
     The types of control devices used by facilities using
solvent based inks, are not likely to adequately function as HAP
control devices when waterborne inks are used, because the dryer
exhaust streams will contain relatively large amounts of water
and relatively low heat content.  In cases where low HAP (as
opposed to no HAP) inks are necessary for particular products or
packaging, the feasibilty of conversion to waterborne inks may
form the basis for segmentation of the industry for HAP
regulation.  Conversion from solvent based inks to waterborne
inks may in some cases increase the amount of HAP in the press
exhaust.
3.5.1 Publication Rotogravure
     At present all publication gravure facilities use solvent
systems based on HAP.  The solvent in use is principally toluene;
other aromatic HAP (xylenes and ethylbenzene) are sometimes
present in the solvent blend.  Eleven of the 33 control systems
use solvents which are 100 percent HAP.  Some facilities have
been able to print with acceptable speed and quality using a
solvent which contains a lower proportion of HAP.  While the
solvent in use is still 100 percent VOC, the substitution of non-
HAP solvent represents a HAP pollution prevention opportunity of
demonstrated feasibility.
     As of yet, water-borne publication gravure inks have not
been developed which offer the production speed and print quality
of solvent based inks12.  The development of acceptable
waterborne inks may represent a future pollution prevention
opportunity.
3.5.2 Product and Packaging Rotogravure
     Pollution prevention, in terms of HAP elimination has been
achieved by many facilities in the packaging and product
rotogravure industry.  Inks with zero HAP content are available
and in use at some facilities in all industry segments.  In
addition, many facilities, particularly those printing on paper
and cardboard packaging, use waterborne inks which contain only a
very low percentage of HAP.  These inks typically contain a small
                               3-16
-------
proportion of glycol ethers which function to reduce surface
tension and improve flow characteristics.  The adoption of these
inks by additional existing sources is a likely consequence of
increased regulation of HAP emissions.  It should also be noted
that some solvent based inks are completely HAP free.
     Packaging and product rotogravure facilities produce a wide
variety of products.  Flexible packaging producers, in
particular, print on many different substrates within the same
facility.  Low HAP inks may not be available to meet all of the
performance requirements of these facilities.  In addition, many
facilities use hundreds of different inks to print various custom
colors required by their packaging customers.  Low HAP inks may
not be available for all substrates in all of the colors required
by some facilities.  Existing facilities with well performing
control systems may have little incentive to make additional
investments to adapt to inks with no HAP.
     Some sources currently use carbon adsorption steam
regeneration solvent recovery systems.  These systems have
important pollution prevention benefits, in that they recover
solvent for reuse as opposed to thermal or catalytic destruction.
At present, solvent recovery systems work best with HAP solvents,
particularly toluene.   Conversion to no HAP or low HAP acetate
based solvent systems would complicate or eliminate the utility
of these systems and increase VOC use.  In cases where existing
solvent recovery systems are performing well, they may represent
an overall pollution prevention benefit.  One possibility would
be to regulate product and packaging rotogravure facilities with
solvent recovery systems under the same standards which are
applied to publication rotogravure facilities.
3.5.3 Wide~web Flexographic Printing
     Pollution prevention,  in terms of HAP elimination has been
achieved by many facilities in the flexographic printing
industry.   Inks with zero HAP content are available and in use at
some facilities in all industry segments.   In addition,  many
facilities use inks which contain only a very low percentage of
                              3-17
-------
HAP.  These inks typically contain a small proportion of glycol
ethers which function to reduce surface tension and improve flow
characteristics.  The adoption of these inks by additional
existing sources is a likely consequence of increased regulation
of HAP emissions.
     Flexographic printing facilities produce a wide variety of
products.  Flexible packaging producers, in particular, print on
many different substrates within the same facility.  Low HAP inks
may not be available to meet all of the performance requirements
of these facilities.  In addition, many facilities use hundreds
of different inks to print various custom colors required by
their packaging customers.  Low HAP inks may not be available for
all substrates in all of the colors required by some facilities.
Replacement of existing inks with inks containing less HAP (for
those applications for which satisfactory replacements are
available) is likely to occur.
     Two specific examples where pollution prevention strategies
are promising are corrugated box and newspaper production.  In
both cases facilities using zero HAP inks can produce nearly
identical products to those using low HAP inks.  Increased
awareness of the options available will cause some flexographic
printers to eliminate HAP.
     Based on approximately 500 usable responses to the ICR,  125
facilities reported using no HAP whatsoever for flexographic
printing.  These facilities included 49 corrugated box
manufacturers, 22 paper product manufacturers, 2 product
manufacturers that made at least some plastic products, one book
manufacturer, and 51 flexible packaging manufacturers.  Of the
flexible packaging manufacturers, 15 printed on paper substrates,
19 printed on foil or film substrates.  The remaining 17 flexible
packaging manufacturers either indicated that they printed on
both paper and film or did not provide specific information about
substrate.  It should be noted that 9 of these facilities
operated catalytic incinerators for VOC control.  Some unknown
fraction of the facilities which reported no HAP use on press may
                               3-18
-------
have been unaware of the HAP content.  It is clear, however, that
HAP free formulations are available for printing on both porous
and non-porous substrates.  Many other facilities applied
materials on their flexographic presses which contained very low
proportions of HAP on an average annual basis.
     The types of control devices used by facilities applying
solvent based materials are not likely to adequately function as
HAP control devices when waterborne inks are used, because the
dryer exhaust streams will contain relatively large amounts of
water and relatively low heat content.  In cases where low HAP
(as opposed to no HAP) inks are necessary for particular products
or packaging, the feasibility of conversion to waterborne inks
may be a basis for segmentation of the industry for HAP
regulation.  Conversion from solvent based inks to waterborne
inks may in some cases increase the amount of HAP in the dryer
exhaust.
3.6 REFERENCES
1.   Edgerton, Stephen, Joanne Kempen and Thomas W. Lapp.  The
     Measurement Solution:  Using a temporary Total Enclosure
     Method for Capture Efficiency Testing.  EPA-450/4-91-020.
     August 1991.  p.39-42.
2.   Reference 1,  p. B-l through B-4.
3.   Standards of Performance for Magnetic Tape Coating
     Facilities. 40 CFR 60, Subpart SS, July 1990. pp.438-444.
4.   U. S. Environmental Protection Agency.  Handbook: Control
     Technologies for Hazardous Air Pollutants.  Publication No.
     EPA/625/6-91/014.  Cincinnati, OH. June 1991. 168 pp.
5.   U. S. Environmental Protection Agency.  Internal Instruction
     Manual for ESD Regulation Development: Combustion Controls
     for Organic Emissions from Process Vents, Second Printing.
     Research Triangle Park, North Carolina.   August 31,  1994.
     p. 3-39 through 3-43.
6.   Reference 4,  p.3-4.
7.   Reference 6, p.  3-16 through 3-21.
8.   Reference 6, p.  3-16.
                              3-19
-------
9.   Handbook: Control Technologies for Hazardous Air Pollutants.
     (Ref. 2)  p.4-2.

10.  Reference 4, p. 4-10.

11.  Worrall,  M. J.  VOC Capture for High Speed Publication
     Rotogravure Printing.  Paper 93-TA-33.02, presented at AWMA
     Meeting.   June 1993.

12.  Reference 11.
                               3-20
-------
   4.0 MODEL PLANTS, CONTROL OPTIONS, AND ENHANCED MONITORING
4.1 INTRODUCTION
     This chapter describes model plants, control options and
enhanced monitoring options for specific segments of the printing
and publishing industry.  Model plants were developed to evaluate
the effects of various control options on the source category.
Control options were selected based on the application of
presently available control devices and varying levels of capture
consistent with different levels of overall control.  Enhanced
monitoring options are specified to insure the consistent
performance of control devices.
4.2 MODEL PLANTS
     Model plants have been specified for three segments of the
printing industry.  Model plants have been selected to represent
the range of capacity and overall control efficiency existing in
these industry segments as determined by responses to the
information collection requests.
4.2.1 Publication Rotogravure Model Plants
     Model plants have been selected to represent a total
industry population of 33 separate control systems at 27
publication rotogravure plants.  Specifications for these plants
are given in Table 4-1.  Information on HAP usage and overall
control efficiencies are available for the entire population.
Four model plants are based on size (based on ink usage) and
control efficiencies reported in voluntary responses to EPA
question lists.  The large plants (Model Plants 1 and 2) were
specified based on the 80th percentile of ink usage.  The small
plants (Model Plants 3 and 4)  were specified based on the 20th
percentile of ink usage.
                               4-1
-------
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     Plants with a high  level of control  (Model Plants i and 3)
were selected based on the 80th percentile of overall control
efficiencies.  Plants with a low level of control  (Model Plants 2
and 4) were specified based on the 20th percentile of overall
control efficiency.  One additional model plant (Model Plant 5)
was selected based on the lowest reported monthly overall control
efficiency.  The size of this plant was specified based on the
approximate size of the  actual plant reporting this efficiency.
     Presses under control at each model plant were specified
based on the approximate equipment in use at plants with this
level of ink usage.  Pressroom dimensions were assumed based on
equipment size.  Actual  facilities may have multiple pressrooms
under control by common  systems, or more widely spaced presses
separated by other equipment.  All plants in this segment of the
industry have similar solvent recovery systems;  most of the
difference in overall control is due to variations in capture.
All or nearly all of the HAP in use at the plants is accounted
for by overall liquid-liquid mass balances.  Unrecovered HAP may
be due to fugitive emissions, stack emissions or residual solvent
shipped out in the product (this is assumed to be emitted at some
stage in the life cycle  of the product).
4.2.2 Product and Packaging Gravure Model Plants
     Data provided by packaging and product rotogravure
facilities in response to the ICR were used to subcategorize this
part of the printing industry on the basis of substrate and end
use.  The list of facilities for which usable information was
received and the subcategories into which these facilities were
placed is described in Chapter 2.
     HAP usage varied widely among the facilities.  In addition,
HAP usage as a proportion of total material applied on
rotogravure presses varied widely.   At least twelve facilities
reported zero HAP usage,  including one facility which applied
over 7 million pounds per year of inks and coatings.   The
availability of suitable low HAP or no HAP ink may be dependent
upon the substrate and specific end product.   In addition,
                               4-3
-------
existing control devices, which in most cases are designed and
operated for VOC control, may not be compatible with low HAP
formulations.  Substitution of inks with lower HAP content may be
an important pollution prevention option at some facilities.
Other facilities, which are operating efficient VOC control
systems may have little incentive to reduce the HAP content of
their inks.
     Facilities printing on paper and cardboard packaging only,
film and foil packaging only and vinyl products have been listed
in Tables 4-2 through 4-4.  Based on data submitted in response
to the ICR, total ink (including coatings, adhesives, varnishes
and primers) use, HAP use associated with this ink use, estimated
overall control and probable major source status have been listed
in these tables.  In some cases, data were incomplete or
ambiguous.  These tables exclude facilities which print on both
paper or cardboard and foil or film, and other miscellaneous
products.  Lists of these facilities are given in Chapter 2.
     Model plants were selected from the mid-range of the
identifiable manor sources within each subcategory.  It should be
noted that while this is representative of the sources which will
be regulated, it is not necessarily representative of the
subcategory as a whole.   Because of the varying approaches to
emissions control used by the major sources in the packaging
subcategories (relatively high HAP use with extensive control
versus relatively low-HAP use with no control), two model plants
have been selected for paper/cardboard and foil/film packaging.
     Model plant specifications are given in Table 4-5.  Ink, HAP
and VOC use, overall efficiency and numbers of presses and
stations were based on actual responses from representative
facilities in each sub-category.
4.2.3 Wide-web and Sheet Fed Flexography Model Plants
     Data were provided by approximately 500 flexographic
printing facilities in response to the ICR.  The list of
facilities for which usable information was received is included
in Chapter 2.  Responses were obtained from printers of flexible
                               4-4
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packaging, products, corrugated cartons and newspapers.  Flexible
packaging and products  involved both porous and non-porous
substrates.
     HAP usage varied widely among the facilities.  In addition,
HAP usage as a proportion of total material applied on
flexographic presses varied widely.  Over 100 facilities reported
zero HAP usage; many more reported HAP usage well below one
percent of the total material applied.  The availability of
suitable low HAP or no  HAP ink is dependent upon the substrate
and specific end product.  In addition, existing control devices,
which in most cases are designed and operated for VOC control,
may not be compatible with low HAP formulations.  Substitution of
inks with lower HAP content may be an important pollution
prevention option at some facilities.  Other facilities, which
are operating efficient VOC control systems may have little
incentive to reduce the HAP content of their inks.
     A list of facilities for which usable data are available is
given in Table 4-6.  Based on data submitted in response to the
ICR, total ink (including coatings, adhesives, varnishes and
primers) use, HAP use associated with this ink use, estimated
emissions and type of substrate have been listed in this table.
In some cases, data were incomplete or ambiguous.
     Model plants have  been selected to represent those sources
which are likely to be  regulated under the standard.  It should
be noted that while this is representative of the sources which
will be regulated, it is not necessarily representative of the
sub-category as a whole.  Three model plants are specified in
Table 4-7.   Plants 1 and 2 and based on actual responses from
uncontrolled major sources due to flexographic printing.  Model
plant 1 is a large plant using waterborne inks with a low HAP
concentration and no control device.  Model plant 2 is a medium
sized plant using solvent based inks containing a significant
amount of HAP and no control device.
     A number of facilities operate flexographic printing
operations as well as other more HAP intensive operations such as
                              4-11
-------
Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table).
Name
Abbott Box Co. Inc.
Acorn Corrugated Box Co.
Advance Packaging Corporation
Advance Packaging- Jackson
Tennessee Packaging
Koch Container
All-size Corrugated Prods.
Compak, Inc.
Webcor Packaging Corp.
Castle Rock Container Company
Fleetwood Container & Display
Focus Packaging, Inc.
Frank C. Meyer Company, Inc.
GP-Albany Plant
GP-Asheboro Plant
GP-Augusta Plant
GP-Bradford Plant
GP-Buena Park Plant
GP-Canton Plant
GP-Chicago Plant
GP-Cincinnati
GP-circleville Plant
GP-Cleveland Plant
GP-Cleveland Plant
GP-Doraville Plant
GP-Dubuque Plant
GP-Franklin Plant
GP-Huntsville Plant
GP-Kansas City Plant
INK ETC.
APPLIED
(Ib/yr)
15,000
161,000
122,100
13,400
19,454
2,154
11,178
10,295
122,060
231,768
78,660
36,000
333,045
361,893
165,206
225,000
212,664
1,235,300
70,627
135,335
114,342
224,653
134,926
131,708
114,791
216,303
180,000
187,152
219,516
HAP USED
ON PRESS
(Ib/yr)
10
0
1,591
745
72
0
0
193
2,512
10
Not major
0
0
3,619
1,652
4,500
2,127
12,353
706
2,707
1,143
2,247
1,349
13,171
1,148
649
12,600
0
0
HAP
Emissions
(Ib/yr)
10
0
1,591
745
72
0
0
193
2,512
10

0
0
3,619
1,652
4,500
2,127
12,353
706
2,707
1,143
2,247
1,349
13,171
1,148
649
12,600
0
0
PROD.
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
4-12
-------
Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table).
Name
GP-Lake Placid Plant
GP-Madera Container Plant
GP-'Martinsville Plant
GP-Memphis Plant
GP-Milan Plant
Modesto Plant
GP-Monticello Plant
GP-Mt. Olive Plant
GP-Mt. Wolf Plant
GP-Olympia Plant
GP-Ooltewah Plant
GP-Oshkosh Plant
GP-Owosso Plant
GP-Schenectady Plant
GP-Sheboygan Plant
GP-So. San Francisco Plant
GP-Spartanburg Plant
GP-Valdosta Plant
GP-Warren County Plant
GP-West Monroe Plant
GP-Waxahachie Plant
GP-Gulf States Paper Corp.
International Paper— Presque
Isle
International
Paper-Auburndale
International Paper-Carson
International Paper-Chicago
International
Paper-Cincinnati
International Paper-Dallas
International Paper-Detroit
INK ETC.
APPLIED
(Ib/yr)
721,374
213,754
250,000
69,786
190,693
175,052
26,779
212,188
70,586
133,080
1,000
27,077
94,057
57,763
122,629
932,691
141,211
540,000
120,173
140,969
228,934
424,405
101,725
223,525
375,752
226,287
129,055
166,287
146,360
HAP USED
ON PRESS
(Ib/yr)
0
641
0
209
572
525
7,498
664
212
1,198
40
542
1,882
1,329
2,453
2,798
0
0
361
5,639
9,157
0
844
1,182
822
770
523
390
1,020
HAP
Emissions
(Ib/yr)
0
641
0
209
572
525
7,498
664
212
1,198
40
542
1,882
1,329
2,453
2,798
0
0
361
5,639
9,157
0
844
1,182
822
770
523
390
1,020
PROD.
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
4-13
-------
Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table).
Name
International PaperEdinburg
International Paper-El Paso
International Paper-Fond du
Lac
International Paper-Geneva
International
Paper-Georgetown
International
Paper-Minneapolis
International Paper-Mobile
International Paper-Modesto
International Paper-Mt.
Carmel
International Paper-Nashville
International Paper-Putnam
International
Paper-Russellville
International Paper-San Jose
International
Paper-Shreveport
International PaperSpring
Hill
International
Paper-Statesville
International PaperStockton
International Paper-Tallman
International Paper-Wooster
International
Paper-Hopkinsville
James River-Portland
Jefferson Smurfit
Corp-Lexington
Jefferson Smurfit-Renton
Jefferson Smurfit Corp-Muncie
INK ETC.
APPLIED
(Ib/yr)
240,391
197,102
230,990
98,250
59,711
95,542
230,224
347,046
337,500
245,662
228,407
247,201
328,783
417,513
254,985
158,250
2,626
447,392
200,425
308,312
124,655
6,000
103,004
13,100
HAP USED
ON PRESS
(Ib/yr)
856
1,900
683
136
2,846
720
3,039
1,341
4,940
8,685
890
1,198
775
0
3,957
5,315
36
2,139
859
2,312
0
113
483
0
HAP
Emissions
(Ib/yr)
856
1,900
683
136
2,846
720
3,039
1,341
4,940
8,685
890
1,198
775
0
3,957
5,315
36
2,139
859
2,312
0
113
483
0
PROD.
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
4-14
-------
Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table).
Name
Jefferson Smurfit
Corp-Port 1 and
JSC/CCA-Fulton
JSC/CCA-Houston
Jefferson Smurfit
Corp. -Muskogee
Jefferson Smurfit
Corp-Highland
Jefferson Smurfit Corp-New
Brunswick
Jefferson Smurfit
Corp-Chesterf ield
Jefferson Smurfit -Memphis
Jefferson Smurfit -St. Louis
Jefferson Smurfit Milpitas
Jefferson Smurfit-Ft. Smith
Jefferson Smurfit-Ft. Worth
Jefferson Smurfit -Anderson
Jefferson Smurf it-Montgomery
Jefferson Smurfit -Milford
JSC/CCA-Aston
Jefferson Smurfit-New
hartford
Jefferson Smurf it-Louisville
Jefferson Smurf it-Wildwood
Jefferson Smurfit -Wakefield
Jefferson Smurf it-Knoxvi lie
Jefferson Smurf it-Jonesboro
Jefferson Smurfit-Los Angeles
JSC/CCA-Baltimore
Jefferson Smurf it-Corona
Jefferson Smurf it-Dolton
Jefferson Smurf it-Dallas
INK ETC.
APPLIED
(Ib/yr)
111,952
42,672
150,200
94,733
101,000
156,597
68,000
193,043
39,000
210,000
6,500
186,000
102,625
252,000
63,990
312,136
121,488
98,300
183,798
100,300
na
na
179,367
140,170
129,419
151,682
40,300
HAP USED
ON PRESS
(Ib/yr)
0
0
2,148
344
0
815
0
3,455
0
0
49
0
1,840
0
422
1,853
728
1,760
1,060
496
1,320
14
0
894
0
550
22
HAP
Emissions
(Ib/yr)
0
0
2,148
344
0
815
0
3,455
0
0
49
0
1,840
0
422
1,853
728
1,760
1,060
496
1,320
14
0
894
0
550
22
PROD.
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
4-15
-------
Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table).
Name
JSC/CCA-Fresno
JSC/CCA-Cincinnati
JSC/CCA-Ravenna
Jefferson Smurfit -LaPorte
Jefferson
Smurfit-Winston-Salem
Jefferson Smurfit -Humboldt
Jefferson Smurf it-Sioux City
Jefferson Smurfit -Lancaster
Jefferson Smurf it-Galesburg
JSC Preprint-Cincinnati
Jefferson Smurfit
-Murfreeesboro
Jefferson Smurf it-Springfield
Jefferson Smurfit -Shelby
Packaging Unlimited, Inc.
Jefferson Smurfit
-Chattanooga
Lin Pac, Inc.
Mafcote Industries
Mafcote/SWACO
Malnove, Inc.
Massillon Container
Menasha Corporation
Milwaukee Container
PCA/Akron
PCA/Arlington
PCA/Ashland
PCA/Atlanta
PCA/Buffalo
PCA/Burlington
PCA/Colby
INK ETC.
APPLIED
(Ib/yr)
135,093
178,484
75,753
174,297
240,000
11,887
160,536
79,000
46,149
251,500
115,466
15,589
83,773
121,382
120,000
52,289
138,189
96,674
27,606
13,000
197,095
139,571
21,860
198,800
234,000
120,000
62,300
305,000
116,000
HAP USED
ON PRESS
(Ib/yr)
0
3,195
1,356
316
0
270
92
620
0
0
0
0
586
6,386
0
3
9,130
0
0
0
282
2,791
219
1,998
2,340
1,200
623
3,050
1,160
HAP
Emissions
{ Ib/yr)
0
3,195
1,356
316
0
270
92
620
0
0
0
0
586
6,386
0
3
9,130
0
0
0
282
2,791
219
1,998
2,340
1,200
623
3,050
1,160
PROD.
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
4-16
-------


*







1
»


V

Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table).
Name
PCA/Oenver
PCA/Garland
PCA/Gas City
PCA/Goldsboro
PCA/Grafton
PCA/Grandville
PCA/Hanover
PCA/Harrisonburg
PCA/High Point
PCA/Honea Path
PCA/Jackson
PCA/Jacksonville
PCA/Knoxville
PCA/Lancaster
PCA/Los Angeles
PCA/Marshalltown
PCA/Miami
PCA/Middletown
PCA/Milwaukee
PCA/Minneapoolis
PCA/Morganton
PCA/Newark
PCA/Newberry
PCA/Northhampton
PCA/Otnaha
PCA/Opelika
PCA/Phoenix
PCA/Pittsburgh
PCA/Plano
PCA/Plymouth
PCA/Richmond
INK ETC.
APPLIED
(Ib/yr)
119,900
145,800
97,300
11,400
43,000
110,600
28,000
160,000
19,100
45,950
137,000
126,700
3,520
187,800
294,000
129,800
64,300
75,022
38,300
78,000
60,800
76,300
109,500
133,900
90,000
10,600
98,800
193,800
140,600
60,500
49,400
HAP USED
ON PRESS
(Ib/yr)
1,199
1,458
973
114
430
1,106
280
1,200
191
460
1,370
1,267
35
1,878
1,470
1,298
643
750
383
780
1,250
763
1,095
1,339
900
106
988
1,938
1,406
605
494
HAP
Emissions
(Ib/yr)
1,199
1,458
973
114
430
1,106
280
1,200
191
460
1,370
1,267
35
1,878
1,470
1,298
643
750
383
780
1,250
763
1,095
1,339
900
106
988
1,938
1,406
605
494
PROD.
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
4-17
-------
Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table).
Name
PCA/Salisbury
PCA/Syracuse
PCA/Trexlertown
PCA/Vincennes
PCA/Wtnter Haven
Rand -Whitney/Northeast
Container
Rand -Whitney/Southeast
Container Corp.
Rand -Whitney Container Corp.
Rock-Tenn-Harrison
Rock-Tenn -Chattanooga
Rock-Tenn-Stone Mountain
Rock-Tenn-Lebanon
Rock-Tenn-Marshvi 1 le
Rock-Tenn-Eutaw
Rock-Tenn-Conway
Rock-Tenn Greenville
Sealright Packaging Co.
Union Camp Corp. -Tucker
Wabash Pioneer Container
Corp.
Westvaco-Baltimore
Westvaco-Buffalo
Westvaco Chicago
Westvaco-Cleveland OH
Westvaco-Cleveland TN
Westvaco-Columbus
Westvaco-Eaton
Westvaco-Gastonia
Westvaco-Meridian
Westvaco-Richmond
INK ETC.
APPLIED
(Ib/yr)
97,000
141,800
158,332
65,500
238,800
18,087
17,426
91,727
25,000
30,000
117,624
104,400
15,000
200,000
28,719
125,000
326,000
126,000
498,303
305,000
219,000
423,000
205,000
290,000
249,000
292,000
125,000
214,400
128,000
HAP USED
ON PRESS
(Ib/yr)
970
1,418
1,583
655
2,388
158
5
0
0
300
1,340
0
0
500
4
0
0
2,720
2,145
15,410
1,590
290
870
5,300
1,900
4,740
2,630
1,400
560
HAP
Emissions
(Ib/yr)
970
1,418
1,583
655
2,388
158
5
0
0
300
1,340
0
0
500
4
0
0
2,720
2,145
15,410
1,590
290
870
5,300
1,900
4,740
2,630
1,400
560
PROD.
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
4-18
-------
Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table).
Name
Westvaco-Flexpak-Richmond
Weyerhaeuser -Westbrook
Weyerhaeuser-Cedar Rapids
Weyerhaeu ser-Tampa
Weyerhaeuser -Franklin
Weyerhaeuser-Tucker
Willamette -Beaverton
Willamette -Buena Park
Willamette -Dallas
Willamette -Kansas City
Willamette -Tacoma
Willamette -Aurora
Willamette -Beaverton 2
Willamette -Ellvue
Willamette -Bellmawr
Willamette -Bowling Green
Willamette -Cerritos
Willamette -Compton
Willamette -Dallas 2
Willamette -Delaware
Willamette -Elk Grove
Willamette -Ft. Smith
Willamette -Golden
Willamette -Griffen
Willamette -Indianapolis
Willamette -Kansas City
Willamette-Lincoln
Willamette -Louisville
Willamette -Lumberton
Willamette -Matthews
INK ETC.
APPLIED
(Ib/yr)
482,000
145,609
151,270
464,367
540,817
1,674,177
435,581
394,942
383,384
140,814
130,604
435,235
237,772
460,521
265,373
226,528
268,859
403,363
299,787
679,079
223,379
231,814
58,801
380,183
63,083
168,945
41,256
11,924
41,488
90,770
HAP USED
ON PRESS
(Ib/yr)
0
790
1,971
421
3,366
151
0
0
0
0
0
962
311
1,895
355
516
515
685
684
3,334
447
440
90
1,784
159
338
80
16
191
203
HAP
Emissions
(Ib/yr)
0
790
1,971
421
3,366
151
0
0
0
0
0
962
311
1,895
355
516
515
685
684
3,334
447
440
90
1,784
159
338
80
16
191
203
PROD.
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
4-19
-------
Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table).
Name
Willamette -Memphis
Willamette -Moses Lake
Willamette -Newton
Willamette -Sacramento
Willamette -San Leandro
Willamette -Sanger
Willamette -Sealy
Willamette -St. Paul
Willamette -West Memphis
American Greetings Corp
Avery-Dennison
Cadillac Products, Inc. Paris
Cadillac Products, Inc.
Cleo, Inc.
Crystal Tissue
Eisenhart Wallcoverings Co.
Pioneer Balloon Company
Waldan Paper Services, Inc.
American Greetings Corp. Af tan
Deco Paper Products, Inc.
Design Containers, Inc.
GP-LaGrange
GP-Plattsburgh
GP-Crosett
GP-Palatka
GP-Bratt leboro
GP-Be 1 1 ingham
Oilman Converted Products
Hallmark Cards
INK ETC.
APPLIED
(lb/yr)
40,958
302,716
65,621
297,249
423,133
227,039
133,688
81,811
157,355
230,000
15,954
250,633
25,516
20,000
125,333
63,076
113,820
550,000
4,187,556
571,308
11,201
36,941
1,757,500
652,182
329,000
134,810
76,650
913,367
69,900
HAP USED
ON PRESS
(lb/yr)
214
549
475
537
590
496
289
118
177
7,400
0
27,334
3,039
400
170
321
1,484
0
0
4,055
21
843
0
8,424
0
125
0
5,460
14
HAP
Emissions
(lb/yr)
214
549
475
537
590
496
289
118
177
7,400
0
27,334
3,039
400
170
321
1,484
0
0
4,055
21
843
0
8,424
0
125
0
5,460
14
PROD.
b
b
b
b
b
b
b
b
b
d
d
d
d
d
d
d
d
d
e
e
e
e
e
e
e
e
e
e
e
4-20
-------
Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table).
Name
James River Darlington
James River-Easton
James River-Lexington
James River-Indianapolis
John H. Harland Company
Kookaburra USA LTD
Mail-Hell Envelope
Moore, Business Forms and
Systems
NCR Corp.
Procter and Gamble-Albany
Procter/Gamble-Mehoopany
Procter/Gamble-Green Bay
Procter /Gamble-Oxnard
Solo Cup Company-Belan
Solo Cup Company-Chicago
The Standard Register Company
Susan Crane, Inc.
Toph-Osage
Toph-Covington
Ward/Kraft, Inc.
Beach Products
Westvaco-Springf ield
Westvaco-Wil 1 iamsburg
Westvaco-Atlanta
Westvaco-North Chicago
Westvaco-Indianapolis
Westvaco-Dallas
Hestvaco-Los Angeles
Westvaco-San Francisco
Arcata Graphics \Kingsport
INK ETC.
APPLIED
(Ib/yr)
234,017
93,644
88,592
281,088
121,650
55,329
103,150
124
117,290
636,886
949,300
423,400
113,450
38,680
18,870
209,305
136,840
60,000
203,963
37,783
260,000
855,473
929,945
840,289
546,821
890,044
721,007
831,225
460,905
57,117
HAP USED
ON PRESS
(Ib/yr)
5,277
0
0
0
0
0
426
1,101
0
0
0
0
0
0
0
1
0
0
0
5
1,660
0
7,284
0
7,277
4,608
5,662
2,656
0
0
HAP
Emissions
(Ib/yr)
5,277
0
0
0
0
0
426
1,101
0
0
0
0
0
0
0
1
0
0
0
5
1,660
0
7,284
0
7,277
4,608
5,662
2,656
0
0
PROD.
e
e
e
e
e
e
e
e
e
e
e
e
e
e
e
e
e
e
e
e
e
e
e
e
e
e
e
e
e
g
4-21
-------
Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table).
Name
R. R. Donnelley & Sons
Company
Western Publishing Co., Inc.
Interstate Packaging Corp.
American Packaging-Storry
City
American Packaging-Columbus
Avery-Dennison, K & M
Division
Bagcraft Corporation of
America
Bancroft Bag, Inc
Bingo Paper Inc.
Champion-Morristown
Champion-Clinton
Champion-Olmstead Falls
Chamption-Ft. Worth
Champion-Athens
Bemis Company-Crosett
Bemis Company-Memphis
Bemis Company-Minneapolis
Bemis Company-Omaha
Bemis Company-Peoria
Bemis Company-Pepperell
Bemis Company-Seattle
Bemis Company-Vancouver
Bemis Company-Wichita
Graphic Packaging Corp.
Hallmark Cards
International Paper-Camden
International Paper-Mobile
INK ETC.
APPLIED
(Ib/yr)
367,200
57,200
217,277
892,160
1,869,137
28,500
650,000
1,522,877
38,701
294,738
167,415
304,197
192,319
285,554
530,107
323,542
16,000
665,336
318,364
182,063
105,275
437,010
7,138
195,031
72,286
663,359
650,000
HAP USED
ON PRESS
(Ib/yr)
100
5,475
8,361
7,660
3,293
19,950
15,000
350,870
0
23,832
18,728
19,028
14,790
22,213
0
2,070
0
1,728
3,021
0
2,377
0
0
0
846
0
355
HAP
Emissions
(Ib/yr)
100
5,475
2,341
7,660
3,293
19,950
15,000
350,870
0
23,832
18,728
19,028
14,790
22,213
0
2,070
0
1,728
3,021
0
2,377
0
0
0
846
0
355
PROD.
g
g
h
h
h
h
h
h
h
h
h
h
h
h
h
h
h
h
h
h
h
h
h
h
h
h
h
4-22
-------
Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table).
Name
International Paper-Pittsburg
International
Paper-Wi Imington
James River -Ft. Smith
James River - Specialty
Tabletop
James River Corp - Wausau
Plant
Mead Packaging
Percy Kent Bag Co., Inc.
The Robinette Company
Sealright Packaging Co.
Union Camp-Savannah
Union Camp-Spartenburg
Union Camp-Hazleton
Union Camp-Hanford
Union Camp-Sibley
Westvaco, Liquid Packaging
Willamette Industries, Inc.
Alusuisse-Shelbyville
Equitable Bag Co., Inc
Alusuisse-New Hyde Park
Bryce Corporation
BRC, A Division of Bryce
Corporation
Bemis -Terre Haute
Bemis -Oshkosh
INK ETC.
APPLIED
(Ib/yr)
195,000
396,000
41,959
12,500
425,873
2,267,734
665,500
633,000
82,491
320,362
1,476,648
206,000
155,864
435,923
135,900
1,070,078
206,000
1,805,400
2,030,000
2,045,155
294,587
5,114,960
2,619,780
HAP USED
ON PRESS
(Ib/yr)
0
57
2,937
0
291
564
0
0
0
4,416
21,420
0
1,045
13,500
8,524
0
1,000
46,152
76,000
0
34
27,267
108,864
HAP
Emissions
(Ib/yr)
0
57
2,937
0
291
564
0
0
0
4,416
21,420
0
1,045
13,500
8,524
0
282
13,107
15,124
0
14
7,089
14,261
PROD.
h
h
h
h
h
h
h
h
h
h
h
h
h
h
h
h
m
m
m
m
m
m
m
4-23
-------
Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table).
Name
Bemis Milprint Denmark
Bemis Milprint Lancaster
Spec-Fab
Spiralkote, Inc.
Glenroy, Inc.
Smurfit Flexible Packaging
Kleartone, inc.
Packaging Products Corp. ,
Rome, GA Division
Pacquet Oneida, Inc.
Westvaco Envelope Springfield
Fabricon Products
Alusuisse-Bellwood
Union Camp-Asheville
Graphic Packaging Corporation
American Packaging
Philadelphia
American Packaging Rochester
Bell Packaging Corp
Bomarko, Inc
Bryce Corporation
Burrows Paper Corporation -
Ft. Madison Facility
Cello-Wrap Printing Company,
Inc.
Charleston Packaging Company,
Inc.
Bemis Curwood-Murphysboro
Bemis Curwood-New London
Dixico, Inc.
INK ETC.
APPLIED
(Ib/yr)
1,268,300
3,644,494
34,088
844,943
124,809
90,167
118,953
338,780
712,400
453,238
287,616
1,540,000
224,842
120,000
89,756
49,557
27,832
499,260
3,060,900
344,426
170,120
415,057
330,112
2,919,293
734,273
HAP USED
ON PRESS
(Ib/yr)
2,118
1,628
681
19,360
0
7,731
2,271
12,792
1,735
36,470
4,172
8,000
5,193
100,000
243
250
453
0
0
6,180
2,453
350
12,329
38,367
0
HAP
Emissions
(Ib/yr)
593
133
102
6,970
0
951
227
1,254
226
6,565
1,168
2,160
2,700
9,100
243
250
453
0
0
6,180
2,453
350
12,329
38,367
0
PROD.
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
4-24
-------
Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table).
Name
Fabricon Products
fp Hebkote, Inc.
Gateway Packaging
Greif Bros. Corp
H. S. Crocker Co., Inc.
Hargo-Harrisburg
Hargro-Edinburgh
IP-Jackson
IP-Peoria
IP-Menasha
IP-Lancaster
IP-Kaukauna
IP-Knoxville
James River -Camas
James River-Hazelwood
James River-Menasha
James River-San Leandro
Longhorn Packaging, Inc.
Neenah Printing - Wide Web
Flexo Plant
Midwest Film Corp
NCR - B.F.D.
Nichols Paper Products Co.,
Inc.
Phoenix Products Co., Inc.
Solar Press
Standard Packaging & Printing
Corp.
Sunrise Packaging, Inc.
Superpac, Inc.
Teepak, Inc.
Union Camp-Monticello
INK ETC.
APPLIED
(Ib/yr)
104,364
111,606
10,000
279,494
91,823
349,576
200,942
591,966
325,387
100,254
24,124
525,606
127,235
68,000
991,726
64,025
866,000
29,894
364,376
276,679
33,342
86,289
61,040
131,324
305,000
632,789
560,300
816,691
368,000
HAP USED
ON PRESS
(Ib/yr)
1,158
19,800
200
0
0
0
7702
942
33,827
6,490
1,477
3,189
55
0
923
28
0
?
1,924
20
0
418
16,656
0
0
4,579
7,039
0
12,232
HAP
Emissions
(Ib/yr)
1,158
19,800
200
0
0
0
7,702
942
33,827
6,490
1,477
3,189
55
0
923
28
0

1,924
20
0
418
16,656
0
0
4,579
7,039
0
12,232
PROD.
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
4-25
-------
Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table).
Name
Union Camp-Tifton
Vitex Packaging, Inc.
Akron Beacon Journal
Fort Wayne Newspapers
Macon Telegraph
Modesto Bee
The Fresno Bee
Miami Herald Publishing Co.
Press Telegram
Providence Journal Company
Bonar Packaging, Inc.
Georgia-Pacific-Warwick
Paramount Packaging-Longview
Paramount Packaging-Chalfont
Action Packaging
All-Pak, Inc.
Atlanta Film Converting Co,
Inc.
Automated Packaging Systems,
Inc.
Automated Label Systems Co.
Banner Packaging, Inc.
Cryovac-Iowa Park
Cryovac-Cedar Rapids
Cryovac-S impsonvi 1 le
Bemis Company-Hazelton
Cello-Foil Products, Inc.
Excelsior Transparent Bag MFC
Corp.
Flex-Pak, Inc.
INK ETC.
APPLIED
(Ib/yr)
469,967
502,402
308,031
381,022
195,000
394,237
699,367
981,662
236,000
930,300
334,260
721,500
169,577
440,317
120,370
254,199
398,621
344,101
346,955
1,718,688
70,786
248,500
1,060,000
7,622,511
551,055
1,358,606
400,694
HAP USED
ON PRESS
(Ib/yr)
0
5,819
3,018
0
1,053
0
0
22,743
82
2,902
13,401
210
109,200
1,154
602
748
0
2,329
1,461
46,311
350
8,100
1,515
59,472
0
5,300
0
HAP
Emissions
(Ib/yr)
0
5,819
3,018
0
1,053
0
0
22,743
82
2,902
3,886
84
5,460
196
138
187
0
326
136
12,967
182
1,944
348
13,381
0
1,007
0
PROD.
m
m
n
n
n
n
n
n
n
n
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
4-26
-------
Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table).
Name
Hargo-Boyerstown
Huntsman Packaging Products,
Corp
Smurfit Flexible Packaging
Marglo Packaging Corp.
Package Printing Co., Inc.
Package Products Flexible
Corporation
Packaging Materials
Incorporated
Packaging Products Corp.
Plastic Packaging, Inc.
Pi icon Corp.
Poly Plastic Packaging, Inc.
Union Camp-Toman
Union Camp -Griffen
Central States Diversified,
Inc.
Mohawk Northern Plastics,
Inc.
Maine Poly, Inc.
Amko Plastics, Inc.
Anagram International, Inc.
Arcon Coating Mills, Inc.
Arkansas Poly, Inc.
Johnson Bryce Corp.
Bryce Dixico
Buckeye Container
Buckeye Packaging
Cadillac Products, Inc.
Clark Container, Inc.
C. P. C. Packaging, Inc.
INK ETC.
APPLIED
(Ib/yr)
605,047
409,000
392,612
13,506
108,896
2,360,000
7686
397,000
1,002,196
216,717
55,229
305,483
383,193
200,288
101,214
312,000
370,630
254,542
261,812
145,796
230,390
505,943
37,775
115,737
158,021
81,660
9,725
HAP USED
ON PRESS
(Ib/yr)
1,876
10,205
???
333
0
0
0
5,904
126
11,740
506
117,815
2,180
1,973
3,684
4,996
21,354
3,436
787
2,134
0
52
0
0
0
5,216
1,945
HAP
Emissions
(Ib/yr)
413
1,765

130

0
0
1,830
41
3,992
104
16,494
109
322
280
999
21,354
3,436
787
2,134
0
52
0
0
0
5,216
1,945
PROD.
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
4-27
-------
Table 4-6. HAP Use on Flexographic Presses (See Notes Following Table).
Name
Bemis -Flemington
Custom Poly Bag, Inc.
Dart Container Corporation
Dynamic Packaging, Inc.
Eskimo Pie Corporation
Flexo Transparent, Inc.
Gentry Poly Specialties, Inc.
Gulf Coast Plastics Div.
Dairy-Mix, Inc.
Hargro Health Care Packaging
Home Plastics, Inc.
Carolina Printing &
Converting A Division of
Interf lex
James River-Greensburg
James River-New Castle
James River-Parchment
James River-Portland
James River-Shreveport
Lin Pac
Mid-West Poly Pak, Inc.
M.T.P. Industries, Inc.
(Mason Transparent Pkg)
Owens-Illinois, Inc.
Packaging Industries, Inc.
Packaging Products
Corporation
Packaging Specialties, Inc.
Paramount
Packaging-Shelbyville
Paramount Packaging
-Murfreesboro
INK ETC.
APPLIED
(Ib/yr)
53,139
71,417
26,149
189,489
41,767
107,033
38,192
9,702
24,335
35,000
162,739
4,756,127
874,312
150,000
407,858
2,088,304
317,468
25,015
125855
1,438,000
836,972
188,780
598,431
320,770
566,370
HAP USED
ON PRESS
(Ib/yr)
56
0
0
1,591
0
11,094
0
0
0
700
10,694
0
31
0
292
0
298
112
0
42,086
12,117
7,693
14,425
1,169
96,821
HAP
Emissions
(Ib/yr)
56
0
0
1,591
0
11,094
0
0
0
700
10,694
0
31
0
292
0
298
112
0
42,086
12,117
7,693
14,425
1,169
96,821
PROD.
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
4-28
-------
Table 4-6. HAP Use on Flexographic Presses (See Motes Following Table).
Name
Phoenix Packaging
Viakase Corp.
Plastic Packaging Corp
Poly Plastic Packaging, Inc.
Polyflex Film & Converting,
Inc.
Rex-Rosenlew International,
Inc.
Sealright Packaging Company
Packaging Industries, Inc.
Selig Sealing Products, Inc.
Southern Colortype Co., Inc.
Specialty Container
Corporation
Tennessee Press, Inc.
Uniflex, Inc.
Union Camp-Shelbyville
Union Camp-Denton
Union Camp-Freeman Field
Union Camp Corp., Richmond
Viskase Corp.
Zim's Bagging Co., Inc.
INK ETC.
APPLIED
(Ib/yr)
8,170,551
103,718
65,560
26,800
566,106
494,445
429,758
836,972
16,950
65,176
60,819
1,546,762
208617
256,216
269,994
332,087
217,253
103,718
1,400
HAP USED
ON PRESS
(Ib/yr)
19,784
5,924
0
226
0
1
12,729
12,117
26
332
45,790
0
208,617
0
13,499
558
0
5,924
25
HAP
Emissions
(Ib/yr)
19,784
5,924
0
226
0
1
12,729
12,117
26
332
45,790
0
50,068
0
13,499
558
0
5,924
25
PROD.
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
p
P
Notes: b=corrugated box, d=paper/plastic products, e=paper products, g=books,
hspaper packaging, m=mixed packaging, n=newspaper s , p=plastic packaging
4-29
-------
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                                                  4-30
-------
 rotogravure.  Model plant  3 represents a flexographic printing
 operation which  is not a major source when considered alone.
 Some  flexographic operations of this nature will come under the
 NESHAP regulations because of other HAP emitting operations at
 the facility.  It is possible that more flexographic facilities
 will  be regulated because  of non-flexographic printing emissions
 than  because of  the HAP which results from flexographic
 operations by themselves.
 4.3 CONTROL OPTIONS
 4.3.1 Control Options for  Publication Rotogravure
      All publication rotogravure plants in the United States
 presently use solvent recovery systems incorporating activated
 carbon adsorption and steam regeneration.  Control device
 efficiencies of  95 percent to greater than 99 percent were
 reported.  The recovered solvent is blended with purchased ink to
 maintain the proper viscosity for printing.  Excess solvent is
 resold to the ink manufacturers.
      Most of the variation in overall efficiencies reported by
 publication gravure facilities is due to variations in capture
 systems.  In all cases, dryer exhausts, containing relatively
 concentrated solvent laden air, are ducted to the solvent
 recovery system.  Additional solvent losses during the printing
 process result from evaporation from ink fountains, escape of
 solvent laden air from driers (e. g. carried out with web between
 stages)  and residual solvent left in substrate after the final
 press station.  Non-production solvent losses occur from
 uncontrolled proof presses, off-press cylinder cleaning, and the
 storage, mixing, shipping  and receiving of ink and solvent.
     Control options include varying degrees of improvement in
 capture and reduction in HAP content of ink.   Improved capture
 involves containment of additional solvent laden air.  Capture
technologies, beyond collection and ducting of dryer exhausts,
presently in use include floor sweeps,  partial and full upper
deck hooding of the presses,  and total enclosures.   Total
enclosures are used in conjunction with collection and treatment
                              4-31
-------
of all pressroom ventilation air.  Control options involving air
handling can be specified in terms of varying degrees of air
collection, up to and including construction of (or conversion of
existing pressrooms to) permanent total enclosures.  Improvements
to press capture systems, including "close-in" hooding, will
result in less HAP escaping to the pressroom.  Reduced flows of
HAP to the pressroom will decrease the overall air treatment
requirements (with or without a total enclosure) if pressroom
ventilation air must be treated to improve overall efficiency.
     All improved capture and control options, costed in Chapter
6, require the handling and treatment of additional volumes of
air.  The incremental solvent captured will be present at lower
concentrations than the solvent laden air presently ducted to the
solvent recovery systems.  In the case of total enclosure
systems, the HAP concentration in the additional air will
approximate that of the pressroom.  Pressroom concentrations of
toluene, the HAP present in highest concentration in the ink (and
the pressroom air), are limited by occupational health
considerations to 100 ppmv.
     It may be economically advantageous to pretreat the
additional air resulting from improvements in capture efficiency
using solvent concentrator systems.  It should be noted that
systems of this type are not presently in use in the publication
gravure industry segment; they are, however, in use in related
applications including control of paint spray booth emissions.
Concentrator systems are designed to adsorb solvents from dilute
air streams.  The sorbent (activated carbon or zeolite) is
regenerated with hot air.  The regeneration air requirement is
only about ten percent of the volume of air treated.  Thus the
dilute solvent laden air stream is converted to a concentrated
regeneration air stream which is exhausted to another control
device.  In this case, the exhaust from the concentrator system
may be ducted to the existing solvent recovery system.  Some
increase in capacity of the existing solvent recovery systems may
be required.
                               4-32
-------
     The substitution of non-HAP solvents for a portion of the
HAP solvents in the ink is a control option which may be used to
decrease HAP emissions without increasing either the capture
efficiency or the control device efficiency.  This control option
may not be available to all facilities.  No information is
available on the cost and effects on output quality resulting
from substitution of non-HAP solvents for HAP such as toluene.
It should be noted that while substitution of non-HAP solvents
for HAP could be encouraged as a pollution prevention option, it
does not significantly affect VOC emissions.
     All demonstrated control options include the use of solvent
recovery systems as the control device.  The systems of
demonstrated effectiveness are composed of fixed bed activated
carbon adsorption units which are cyclically regenerated with
steam.  These systems include regeneration gas condensers and
solvent/water decanters.
     The distinction among the control options is the capture
system employed.  The specification of ventilation, hooding and
ducting for incremental improvements to existing systems is site
specific.  There are an infinite number of gradations between
existing capture systems and permanent total enclosures.  Table
4-8 lists control options which represent discrete levels of
capture.
     In all cases pollution prevention could be encouraged by
allowing credit for elimination of HAP emissions through
substitution of non-HAP solvent for HAP.  A reduction in HAP
emissions through substitution,  combined with some degree of
improvement in capture can achieve the same reduction in HAP
emissions as that of the specified control option.
4.3.2 Control Options for Product and Packaging Rotogravure
     Packaging and product rotogravure plants in the United
States use a variety of control  technologies.  Control strategies
are influenced by the composition of inks and other materials
applied on the press,  and regulatory requirements.  In most
cases,  regulations presently in  effect limit emissions of VOC.
                              4-33
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 Control devices presently  in operation were, for the most part,
 specified and operated to  meet VOC emissions requirements.  Where
 ink systems are primarily  based on non-HAP solvents, no data have
 been collected to demonstrate the effectiveness of existing
 control devices with respect to individual HAP.  Where HAP (e. g.
 toluene) based inks are used, control device efficiencies are
 directly relevant to HAP control.
     The selection of ink  is influenced by the substrate printed
 and the performance requirements of the packaging or product.
 Air pollution regulations  in force at the time of construction of
 the facility or specification of the control device also
 influence the type of ink  system.
     Control technologies  presently in use among major sources
 include activated carbon solvent recovery systems, catalytic
 incinerators and oxidizers, and thermal incinerators and
 oxidizers.  These devices  are capable of controlling greater than
 95 percent of most volatile organic compounds when properly
 designed and operated.  Much of the variation in overall control
 efficiencies achieved with any of these control devices is due to
 variation in capture efficiency.  Where presses are located
 within permanent total enclosures capture efficiencies are
 assumed to be 100 percent.  In other cases, capture efficiencies
 depend on the type of capture devices and pressroom ventilation
 systems in use.
     Some plants have adopted waterborne ink technologies to
 reduce VOC emissions.  In  many cases, low VOC ink formulations
 are used with no control devices.  Capture systems at these
 facilities serve to collect dryer exhausts and vent them to the
 atmosphere.   Some formulations are HAP free; many low VOC
waterborne ink systems do  contain small percentages of HAP
 (typically glycols,  glycol ethers or alcohols).
     Control options for packaging and product rotogravure plants
are given in Table 4-9.   In options A and B, a control device is
used with different levels of capture efficiency.   The control
device can be selected based on the ink system in use,  or if more
                              4-35
-------
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than one type of device is potentially suitable, on the basis of
cost.  As described above, all control devices presently in use
in this segment of the industry can achieve efficiencies of more
than 95 percent.  Option C provides for the use of low HAP ink
with no control, provided that emissions do not exceed those of
plants using solvent based inks with a high HAP content using an
efficient capture and control system.
4.3.3 Control Options for Wide-web and Sheet Fed Flexography
     Most flexographic printing facilities, and all flexographic
printing facilities outside of the flexible packaging industry,
operate without control devices.  Control strategies are
influenced by the composition of inks and other materials applied
on the press, and regulatory requirements.  Control devices
presently in operation were, for the most part, designed and
operated to meet VOC emissions requirements.  Where ink systems
are primarily based on non-HAP solvents, no data have been
collected to demonstrate the effectiveness of existing control
devices with respect to individual HAP.
     The selection of ink (and other materials such as adhesives,
primers and varnishes) is influenced by the substrate printed and
the performance requirements of the packaging or product.  Air
pollution regulations in force at the time of construction of the
facility or specification of the control device also influence
the type of ink system.
     Some plants have adopted waterborne ink technologies to
reduce VOC emissions.   In many cases, low VOC ink formulations
are used with no control devices.  Capture systems at these
facilities serve to collect dryer exhausts and vent them to the
atmosphere.   Some formulations are HAP free; many low VOC
waterborne ink systems contain small percentages of HAP
(typically glycols,  glycol ethers or alcohols).  Many
flexographic printers use solvent based formulations which are
completely HAP free.   In some cases,  solvent based inks contain
small percentages of the same HAP used in waterborne materials.
Some of these facilities operate VOC control devices.   In the
                              4-37
-------
absence of compound specific data on HAP control, HAP removal
efficiencies are estimated on the basis of VOC removal
efficiencies.
     Control technologies presently in use include activated
carbon solvent recovery systems, catalytic incinerators and
oxidizers, and thermal incinerators and oxidizers.  These devices
are capable of controlling greater than 95 percent of most
volatile organic compounds when properly designed and operated.
Much of the variation in overall control efficiencies achieved
with any of these control devices is due to variation in capture
efficiency.  Where presses are located within permanent total
enclosures capture efficiencies are assumed to be 100 percent.
In other cases, capture efficiencies depend on the type of
capture devices and pressroom ventilation systems in use.  None
of the flexographic facilities using control devices for
materials applied on flexographic presses are major sources on
the basis of reported HAP emissions.
     Control options for flexographic printing facilities are
given in Table 4-10.  In options A and B, a control device is
used with different levels of capture efficiency.  The control
device can be selected based on the ink system in use, or if more
than one type of device is potentially suitable,  on the basis of
cost.  As described above, all control devices presently in use
in this segment of the industry can achieve efficiencies of more
than 95 percent, at high concentrations of HAP in the solvent
laden air.  (It may be difficult to reach this level of control
device efficiency at lower HAP concentrations.)  Option C
provides for the use of low HAP ink with no control, provided
that emissions do not exceed those of plants using solvent based
inks with a high HAP content using an efficient capture and
control system.
4.4 ENHANCED MONITORING
4.4.1 Enhanced Monitoring for Publication Gravure
     All existing publication rotogravure facilities monitor
control system performance using liquid-liquid mass balances.
                               4-38
-------
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These mass balances provide average recovery data averaged over
the reporting period.  Because the HAP emissions are recovered,
rather than destroyed, any intermittent system failures,
decreases in control device efficiency or increases in fugitive
emissions will be reflected in the overall mass balance.  This
method provides an average of continuous overall efficiency
(rather than an average of discrete measurements of control
device efficiency).
4.4.2 Enhanced Monitoring for Product and Packaging Rotogravure
     Facilities operating solvent recovery systems monitor
control system performance using liquid-liquid mass balances.
These mass balances provide recovery data averaged over the
reporting period.  Because the HAP emissions are recovered,
rather than destroyed, any intermittent system failures,
decreases in control device efficiency or increases in fugitive
emissions will be reflected in the overall mass balance.  Since
this method provides an average of continuous overall efficiency
(rather than an average of discrete measurements of control
device efficiency) enhanced monitoring is not recommended for
this industry segment.
     Facilities operating thermal incinerators or catalytic
incinerators must monitor control device performance.  Continuous
emission monitoring may not be reliable for emission streams in
which the HAP present makes up a small percentage of the VOC
present, as is the case in many emission streams from packaging
and product rotogravure printing.  The output of continuous
emissions monitors may not reflect the HAP concentration of the
emissions stream due to differences in response among the HAP,
non-HAP VOC, and products of incomplete combustion.
     Continuous control device measurement should be required for
facilities operating thermal incinerators or catalytic
incinerators.  Variations in combustion temperature affect the
performance of these devices.  The operators of thermal and
catalytic incinerators should install, calibrate, maintain, and
                               4-40
-------
operate a temperature monitoring device in accordance with the
manufacturer's specifications.   The temperature should be
maintained at a temperature equal to or higher than the
temperature at which compliance was demonstrated.
4.4.3 Enhanced Monitoring for Wide-web and Sheet Fed Flexography
     Based on responses to the ICR, none of the flexographic
printing facilities operating control devices had HAP emissions
in excess of 25 tons per year of HAP or 10 tons per year of any
specific HAP.  Facilities affected by a MACT standard regulating
HAP emissions which operate control devices should be subject to
the same enhanced monitoring requirements as product and
packaging gravure facilities (see Section 4.4.2).
     Facilities controlling HAP emissions through the use of low
HAP ink formulations should maintain documentation confirming the
HAP content of the materials applied on flexographic presses.  In
the event that specifications provided by ink suppliers are
inadequate to establish the HAP content, additional compositional
analyses should be conducted by the facility.
                              4-41
-------
     5.0 ENVIRONMENTAL AND ENERGY IMPACTS OF CONTROL OPTIONS

5.1 ENERGY IMPACT
5.1.1 Publication Rotogravure
     Energy requirements for implementation of the control
options for publication gravure plants include electricity to
collect and treat additional ventilation air, natural gas to heat
air for desorption of HAP recovered by the concentrators, and
additional steam required for regeneration of the incremental
activated carbon and recovery of the incremental HAP.  The
control options will recover incremental amounts of toluene,
which has a heating value but is not used as a fuel.  Energy use
has been estimated for each of the 27 publication rotogravure
facilities.  The sum of the increased energy requirements is
given in Table 5-1. Control options B and C have equal energy
requirements.
     Energy impact calculations were based on the assumption of
1.5 percent solvent retention in the substrate.  Uncontrolled and
unretained HAP is assumed to be available in pressroom air at 50
ppmv.  Ventilation requirements are estimated based on the volume
of air necessary to dilute the uncontrolled and unretained HAP to
this level.  Fan power requirements are based on moving 50
percent (Control option A)  or 100% (Control options B and C) of
the pressroom ventilation requirement through concentrator
systems plus the desorption gas.  The desorption gas flow rate is
10 percent of the gas treated.   The concentrator is assumed to be
93 percent efficient (this assumption is subject to change,
should test data become available); the incremental adsorption
capacity devoted to the concentrated stream is assumed to be 98
percent efficient.
                               5-1
-------
   Table 5-1. Energy Impact of Control Options for Publication
                       Rotogravure  Plants.
Energy Impact
Fan Power (kwhr/yr)
Natural Gas
(SCF/yr)
Control Option A
26,100,000
553,000,000
Control Options B & C
52,100,000
1,100,000,000
The concentrator is assumed to be desorbed with 300 degree F air
heated with natural gas at 90 percent efficiency.  Incremental
carbon capacity is desorbed with 2 pounds steam per pound of HAP,
based on model plant calculations.  Table 5-1 gives the energy
impact of the control options, assuming natural gas fired boilers
are used to generate incremental carbon regeneration steam.
5.1.2 Product and Packaging Rotogravure
     Energy requirements for implementation of the control
options A and B for package and product gravure plants include
electricity to collect and treat additional ventilation air and
natural gas for auxiliary fuel required for HAP destruction.
Energy use has been estimated for 36 package and product
rotogravure facilities with large enough emissions to be covered
under the MACT standard.  The sum of the increased energy
requirements for control options A and B have been estimated in
Table 5-2.  These estimates are based on improvements to capture
(with incineration of the recovered fugitive emissions) at 28
facilities, and installation of capture systems and control
devices at 6 presently uncontrolled facilities.  Two facilities
which apply materials which are less than 4 percent HAP, and have
no control devices, are excluded from the estimate.
     Electricity and natural gas requirements have been based on
the model plant calculations.  Model plants with control devices
had average electricity and gas requirements of 16 kwhr and 9000
SCF per pound of incrementally controlled HAP.  Model plants
                               5-2
-------
   Table 5-2. Energy Impact of Control Options for Product and
                    Packaging Gravure Plants.
Energy Impact
Fan Power (kwhr/yr)
Natural Gas
(SCF/yr)
Control Option A
47,000,000
1.8 E 10
Control Option B
70,000,000
3.0 E 10
without control devices had average electricity and gas
requirements of 11 kwhr and 2000 SCF per pound of incrementally
controlled HAP.  Control option B provides overall control
equivalent to 96.5 percent of HAP usage.  This is consistent with
a 98 percent efficient control device, allowing for 1.5 percent
HAP retention in the printed substrate.  Control option A
provides for varying overall efficiencies depending on the
capture efficiency of the existing system.  HAP retention may
vary, but this will have only a small effect on energy
requirements.
     Control option C could represent a decrease in energy
requirements if facilities which presently operate incinerators
converted to ink formulations with lower HAP content.  Under some
circumstances, operation of existing incinerators would no longer
be required.  This would result in the elimination of all
auxiliary fuel requirements.  These energy savings would not be
realized by facilities presently operating control devices for
VOC control unless waterborne (low HAP, low VOC), formulations
were used.  The energy impact of this control option has not been
estimated because it is impossible to predict what formulations
would be used to comply.
5.1.3 Wide-web and Sheet Fed Flexography
     Energy requirements for implementation of the control
options A and B for wide web flexography plants include
electricity to collect and treat additional ventilation air and
                               5-3
-------
natural gas for auxiliary fuel required for HAP destruction.  It
is estimated that 50 facilities may have emissions large enough
to be covered by the standard based on estimated "potential to
emit".  This includes all facilities providing responses to the
ICR with HAP usage of at least 10,000 pounds in 1992.  Some of
these facilities may have permit restrictions or other
limitations which would keep their potential to emit below 25
tons HAP per year (or ten tons of any single HAP).  Of these
facilities, 15 presently operate control devices.   The following
discussion assumes that the 35 flexographic printing facilities
not presently operating control devices will comply with the
standard by reducing their HAP usage and the remaining facilities
will improve capture and control.
     The sum of the increased energy requirements for control
options A and B have been estimated in Table 5-3.   These
estimates are based on improvements to capture (with incineration
of the recovered fugitive emissions) at 15 facilities.  Energy
requirements will increase if facilities which presently have no
control devices install them to meet the standard.  Energy
requirements may decrease somewhat if some of the facilities
considered on the basis of HAP usage are not major sources by
reason of limitations of their potential to emit.
     Electricity and natural gas requirements have been based on
the model plant calculations.  Model plants with control devices
had average electricity and gas requirements of 30 kwhr and 5400
SCF per pound of incrementally controlled HAP.  Control option B
provides overall control equivalent to 93.5 percent of HAP usage.
This is consistent with a 95 percent efficient control device,
allowing for 1.5 percent HAP retention in the printed substrate.
Control option A provides for varying overall efficiencies
depending on the capture efficiency of the existing system.  HAP
retention may vary, but this will have only a small effect on
energy requirements.
                               5-4
-------
   Table 5-3. Energy Impact of Control Options for Wide-web and
                      Sheet Fed Flexography.
Energy Impact
Fan Power (kwhr/yr)
Natural Gas
(SCF/yr)
Control Option A
1,770,000
318,000,000
Control Option B
3,540,000
637,000,000
      Control option C could represent a decrease in energy
 requirements if facilities which presently operate incinerators
 converted to ink formulations  with lower HAP  content.   Under
 somecircumstances,  operation of  existing incinerators  would no
 longer be required.   This would  result in the elimination of all
 auxiliary fuel requirements.   These energy savings would not be
 realized by facilities presently operating control devices for
 VOC control unless  waterborne  (low HAP,  low VOC),  formulations
 were used.   The energy impact  of this control option has not been
 estimated because it is impossible to predict what formulations
.would be used to comply.
 5.2 AIR IMPACTS
 5.2.1 Publication Rotogravure
      The major air  impact of implementing the control  options is
 reduced emissions of HAP to the  atmosphere.   Minor impacts are
 associated  with the production and use of electricity  and fuel
 required for fans,  desorption  gas heaters,  and boilers generating
 steam for incremental carbon regeneration requirements.   Table
 5-4 lists air impacts for the  control options.   Impacts
 associated  with electric utility generation are  assumed to be 3.6
 grams sulfur dioxide and 560 grams carbon dioxide  per  kwhr.
 5.2.2 Product and Packaging Gravure
      The major air  impact of implementing the control  options is
 reduced emissions of HAP to the  atmosphere.   Minor impacts are
 associated  with the  production and use of electricity  required
                               5-5
-------
     Table 5-4.  Air Impact  of  Control  Options  for  Publication
                       Rotogravure Plants.
Air Impact
HAP Eliminated
(Ton/yr)
Sulfur Dioxide
Emitted (Ton/yr)
Carbon Dioxide
Emitted (Ton/yr)
Control Option A
7,000
103
50,000
Control Options B & C
14,000
206
100,000
for fans and auxiliary fuel for incinerators.  Table 5-5 lists
air impacts for the control options.  Estimates for options A and
B are based on upgrades to 28 facilities presently
operatingcontrol devices and installation of capture and control
systems at 6 facilities.  Estimates for option C are based on the
34 facilities considered for options A and B plus two additional
facilities presently applying formulations containing less than 4
percent HAP.  Impacts associated with electric utility generation
are assumed to be 3.6 grams sulfur dioxide and 560 grams carbon
dioxide per kwhr.
5.2.3 Wide-web and Sheet Fed Flexocrraphv
     The major air impact of implementing the control options is
reduced emissions of HAP to the atmosphere.  Minor impacts are
associated with the production and use of electricity required
for fans and auxiliary fuel for incinerators.  Table 5-6 lists
air impacts for the control options.  Estimates for options A and
B are based on upgrades to 15 facilities presently operating
control devices.  Estimates for option C are based on a total of
50 facilities (an additional 35 facilities not presently
considered for options A and B are included).  Impacts associated
with electric utility generation are assumed to be 3.6 grams
sulfur dioxide and 560 grams carbon dioxide per kwhr.
                               5-6
-------
    Table 5-5.  Air Impact of Control Options for Product and
                  Packaging Rotogravure Plants.
Air Impact
HAP Eliminated
(Ton/yr)
Sulfur Dioxide
Emitted (Ton/yr)
Carbon Dioxide
Emitted (Ton/yr)
Option A
1800
1900
31000
Option B
2600
2800
47000
Option C
2400
NA
NA
 4A=Not available.
 Table 5-6. Air Impact of Control Options for Wide-web and Sheet
                         Fed Flexography.
Air Impact
HAP Eliminated
(Ton/yr)
Sulfur Dioxide
Emitted (Ton/yr)
Carbon Dioxide
Emitted (Ton/yr)
Option A
29

7.0

20,000

Option B
59

14

39,000

Option C
830

NA

NA

NA=Not available.
                               5-7
-------
5.3 WATER IMPACTS
5.3.1 Publication Rotogravure
     Water impacts resulting from implementation of the control
options are insignificant.  Small increases in boiler blowdown
may be associated with the incremental increase in steam required
for recovery of incremental HAP.  This water will be of
relatively high quality.
5.3.2 Product and Packaging Rotogravure and Wide-web and Sheet
      Fed Flexography
     Water impacts resulting from implementation of the control
options are insignificant.  Control option C does not assume
conversion to waterborne inks.  If waterborne inks are adopted,
pressroom cleaning will be done with water which may generate an
additional low volume wastewater stream.
5.4. SOLID WASTE IMPACT
5.4.1 Publication Rotogravure
     The impact of the control options on solid waste will be
negligible.  The incremental carbon will require replacement
every five to ten years.  It is expected that most of this
material will be sold for reprocessing into other products and
will not become solid waste.  The concentrators are expected to
last 15 years or longer.
5.4.2 Product and Packaging Rotogravure and Wide-web Flexoaraphy
     The impact of the control options on solid waste will be
negligible.  If catalytic incinerators are used, catalyst
replacement may be necessary every ten years.  Spent catalyst may
require disposal as hazardous waste.
                               5-8
-------
               6.0 MODEL PLANT CONTROL OPTION COST

6.1 INTRODUCTION
     Model plants, and the criteria used to choose them have been
described in Chapter 4.  Control options applicable to specific
segments of the printing and publishing industry have also been
described in Chapter 4.  This chapter describes the estimated
costs of applying the control options to the model plants.
6.2 PUBLICATION ROTOGRAVURE
     Model plant specifications are given in Table 6-1.  These
are based on several assumptions.  HAP retention in the web is
assumed to be 1.5 percent of that used.  This material is not
emitted in the pressroom or dryer. Pressroom ventilation rates
have been proposed based on the volume of air necessary to dilute
the fugitive emissions to acceptable levels for the health and
safety of the operators.  This ventilation may be presently
supplied by doors, windows and leaks to the atmosphere.
Pressroom volumes have been assumed based on the number and size
of the presses in the model plants.  Corresponding air exchange
rates are listed, however, only the assumed ventilation rate
affects the amount of air to be treated.  The pressroom volume
and air exchange rates can vary to provide the assumed
ventilation rate.  The pressroom and control systems are assumed
to operate 120 hours per week.
     The control options apply to incremental capture and control
of fugitive emissions.   The control options involve collecting
and treating pressroom air containing fugitive HAP which escapes
                               6-1
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                                                     6-2
-------
 the  existing  capture system.  Since the pressroom air is at
 relatively  low concentration, cost calculations are based on use
 of a concentrator system.  The assumed concentrator
 specifications are given in Table 6-2.  Control option A has not
 been applied  to model plants 1 and 3, as incremental HAP
 reduction would be negligible for these cases.  The concentrator
 systems are assumed to be 93 percent efficient (this assumption
 is subject to revision if test data become available) and exhaust
 a stream of 10 percent of the volume of the treated pressroom
 air.  This concentrated exhaust stream is assumed to be added to
 the  carbon adsorption/steam regeneration solvent recovery system.
 The  capital costs of these systems for the three control options
 are  given in  Tables 6-3 through 6-5.  Concentrator system costs
 were based on telephone quotes from three vendors.  An upgrade to
 the  existing  solvent recovery system to account for the increased
 capacity required to treat the concentrator exhaust is included
 in Tables 6-3 through 6-5.  These costs are detailed in Tables 6-
 6 and 6-7.  The inclusion of solvent recovery system upgrade
 costs is conservative as existing solvent recovery systems may be
 adequate to treat the incremental concentrator exhaust flows.  In
 this case, increased regeneration frequencies could be required.
 Control option C includes retrofit construction of a permanent
 total enclosure.  These costs are estimated in Table 6-8 and
 included in Table 6-5.  Total enclosure costs are based on the
 construction  of two new walls and the presence of two existing
walls.  Depending on the existing structure, total enclosure
 costs could be higher or lower than those estimated.
Total annual  costs have been estimated for the three control
options in Tables 6-9 through 6-11.   These estimates include
recovery of capital costs based on a 7 percent interest rate and
a 15 year equipment life.  Operating costs include utilities,
 labor, materials,  tax, insurance and administration.  Additional
notes to the cost calculation tables are given in Table 6-12.
Cost effectiveness of the control options applied to the model
plants is given in Table 6-13.   Cost effectiveness varies between
                               6-3
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Table 6-3.  Capital Costs of Concentrator/Solvent Recovery
     Systems for Control Option A at Model Publication
                    Rotogravure Plants.
Model Plant
2
4
5

Intake Rate (SCFM)
Intake rate (ACFM)
Exhaust rate (SCFM)
Installed Cost — Note 1
Site Preparation-Note 2
Duct Length (ft) — Note 12
Duct Diameter (in)
Duct Cost @$126/ft
Solvent Recovery System
upgrade
Cost including duct and
site Prep.
Engineering, supervision,
construction, field
expenses, fee, start-up,
performance test and
contingencies-Note 3
300,000
327,473
30,000
$3,600,000
360,000
180
60
22,680
19,040
4,001,720
1,240,533
100,000
109,158
10,000
$1,200,000
120,000
60
60
7,560
7,955
1,335,515
414,010
300,000
327,473
30,000
$3,600,000
360,000
180
60
22,680
24,536
4,007,216
1,242,237

Total Capital Cost-
Concentrator System
5,242,253
1,749,524
5,249,453

Capital Recovery
factor-Note 4
Annualized Capital Cost
0.1098
$575,571
0.1098
$192,088
0.1098
$576,362

Solvent recovery system upgrade costs are detailed in Table
6-6. See notes to cost calculations in Table 6-12.
                            6-5
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                                           6-7
-------
 Table 6-6. Capital Costs of Required Solvent Recovery System
Upgrades for Control Option A at Model Publication Rotogravure
                            Plants.
Model Plant
2
4
5

Incremental Flow Rate
(SCFM)
Pressroom Concentration
(ppm)
Concentrator Exhaust Cone.
(ppm)
Incremental HAP Loading
(Ib/hr)
Adsorption Time (hr)
Equilibrium Adsorptivity
(Ib toluene/ Ib carbon)
Working Capacity (Ib
HAP/lb carbon)
Carbon Required (Ib)
Adsorber Volume Required
(CF)
Adsorber Length (ft)
Adsorber Diameter (ft)
Adsorber Surface (sf)
Adsorber Cost ($1989)
Adsorber Cost ($1993)
Carbon Cost @$2.50/lb
Adsorber Cost including
carbon
30,000
36.8
342
140.6
2
0.31
0.154
1827
109.59
16
3
164.934
$14,389
$14,474
$4,566
$19,040
10,000
26.2
244
33.3
2
0.30
0.148
449
26.97
9
2
62.832
$6,791
$6,831
$1,124
$7,955
30,000
53.2
495
203.0
2
0.32
0.160
2532
151.95
22
3
221.4828
$18,099
$18,205
$6,331
$24,536

Note: Costs escalated to 1993$ using Marshall and Swift cost
index factor of (394.4/392.1).
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Table 6-12.  Notes to Control Cost Calculations for Model
              Publication Rotogravure  Plants.
Note
Note
Note
Note
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2.
3.
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11.
12.
13.
14.
15.
From telephone quotes; $12/SCFM installed
price — modular: no economies of scale
Arbitrarily assumed 10% of installed cost.
31% of installed cost, per EPA Handbook
(EPA/625/6-91/014)
15 years at 7%
Volume is 110% of intake rate, pressure drop =6 in.
water, fan efficiency is 65%, electricity at
0.06/kwhr
Desorption air at 300 degrees F. Desorption gas
flow rate =10% intake flow rate. Gas at $5/MM Btu.
0.5 hr/shift per concentrator, $25/hr including
overhead .
15% of operating labor
110% of operating labor
Assumed equal to maintenance labor.
4% of total capital cost
30 ft length of 5 ft diameter duct in parallel.
The existing adsorbers can be operated to handle the
small additional loading. A nominal upgrade cost is
given as a upper bound estimate.
0.3 Ib steam/lb carbon. Steam at $6/1000 Ib.
Recovered toluene valued at $0.15/lb.
                           6-14

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$1500 and $14,000 per ton of HAP reduction.  The cost per
incremental ton of HAP reduction is highest at the model plants
with high levels of baseline HAP control, as these plants have
less fugitive emissions available for capture and treatment.  The
annual costs for these plants are lower than the annual costs for
the model plants with low levels of baseline control as less
additional air must be handled at the well controlled plants.
6.3 PRODUCT AND PACKAGING ROTOGRAVURE
     Model plant specifications are given in Table 6-14.  These
are based on several assumptions.  HAP retention in the web is
assumed to be 1.5 percent of that used.  This material is not
emitted in the pressroom or dryer.  Pressroom ventilation rates
have been proposed based on the volume of air necessary to dilute
the fugitive emissions to 50 ppmv VOC.  The concentration of HAP
in the pressroom varies depending on the composition of the
materials applied.  Ventilation air to dilute fugitive emissions
may be presently supplied by doors, windows, and leaks to the
atmosphere.  Pressroom volumes have been assumed based on the
number and size of the presses in the model plants.  The
pressroom and control systems are assumed to operate 80 hours per
week.
     Control options A and B, as described in chapter 4,  apply
to incremental capture and control of fugitive emissions from
existing capture systems at the model plants.  Control options A
and B involve collecting and treating pressroom air containing
fugitive HAP which escapes the existing capture system.  Costs
have been estimated on the basis of thermal incineration of this
pressroom air stream.  Specifications for thermal incinerators
applicable to the model plants are given in Table 6-15.  In many
cases, catalytic incineration would be appropriate for the
solvents in use.  Catalytic incineration systems would have lower
operating costs and might have total annualized costs than the
estimates for thermal incineration systems.  In some cases,
concentrator systems (see Section 6.2) might be used to reduce
the size and capital and operating costs of the incinerator.
                               6-16

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     The capital costs of these systems for control options A and
B are given in Tables 6-16 and 6-17.  These costs are based on
the OAQPS Control Cost Manual1.   The capital  cost for control
option B includes retrofit construction of a permanent total
enclosure.  The basis of this cost estimate is given in Table
6-18, and included in Table 6-17.  Total enclosure costs are
based on the construction of two new walls and the presence of
two existing walls.  Depending on the existing structure, total
enclosure costs could be higher or lower than those estimated.
     Total annual costs have been estimated for control options A
and B in Tables 6-19 and 6-20.  These estimates include recovery
of capital costs based on a 7 percent interest rate and a 15 year
equipment life.  Operating costs include utilities, labor,
materials, tax, insurance and administration.
     Cost effectiveness of the control options applied to the
model plants is given in Table 6-21.  Cost effectiveness varies
between $10,000 and $48,000 per ton of HAP reduction.  The cost
per incremental ton of HAP reduction is highest at the model
plants with high levels of baseline HAP control, as these plants
have less fugitive emissions available for capture and treatment.
The annual costs for these plants are lower than the annual costs
for the model plants with low levels of baseline control as less
additional air must be handled at the well controlled plants.
     Control option C involves the use of low HAP ink.  The
adoption of this control option could, in some cases, represent a
net savings over baseline levels of control.   The applicability
of this option depends to a large extent on the type of printing
and the performance requirements of the product or package.   Some
facilities,  printing on both porous and non-porous substrates
report either zero or very low HAP use as a proportion of total
materials applied on rotogravure presses.   Where feasible,
conversion to low HAP inks could result in substantial reductions
in operating costs.   Cost reductions from conversion to low HAP
inks have not been calculated, because low HAP inks may still
                              6-19

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-------
require operation of a control device to meet VOC emissions
standards established by other regulations.
6.4 WIDE-WEB AND SHEET FED FLEXOGRAPHY
     Model plant specifications are given in Table 6-22.  These
are based on several assumptions.  HAP retention in the web is
assumed to be 1.5 percent of that used.  This material is not
emitted in the pressroom or dryer.  Pressroom ventilation rates
have been proposed based on the volume of air necessary to dilute
the fugitive emissions to 50 ppmv VOC.  The concentration of HAP
in the pressroom varies depending on the composition of the
materials applied.  Ventilation air to dilute fugitive emissions
may be presently supplied by doors, windows, and leaks to the
atmosphere and by exhaust fans discharging directly to the
atmosphere.  Pressroom volumes have been assumed based on the
number and size of the presses in the model plants.  The
pressroom and control systems are assumed to operate 80 hours per
week.
     Control options A and B apply to incremental capture and
control of uncontrolled emissions and fugitive emissions at the
model plants. Control options A and B involve collecting and
treating pressroom air containing uncontrolled HAP (model plants
1 and 2) or fugitive HAP which escapes the existing capture
system (model plant 3).  Costs have been estimated on the basis
of thermal incineration of this pressroom air stream.
Specifications for thermal incinerators applicable to the model
plants are given in Table 6-23.  In many cases, catalytic
incineration would be appropriate for the solvents in use.
Catalytic incineration systems would have lower operating costs
and might have lower total annualized costs than the estimates
for thermal incineration systems.  In some cases, concentrator
systems (see Section 6.2) might be used to reduce the size and
capital and operating costs of the incinerator.
     The capital costs of these systems for control options A and
B are given in Tables 6-24 and 6-25.  These costs are based on
                               6-26
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                                              6-27
-------
Table 6-23. Incinerator Specifications for Flexography
                   Control Options.
Thermal Incinerator — Control Option A

Model Plant
1
2
3

VOC Molecular Weight
Ventilation Rate
Incinerator Intake
VOC to Incinerator
HAP to Incinerator
Incremental HAP
Control
Incremental Control
Efficiency
New Overall Control

SCFM
SCFM
lb/yr
Ib/yr
lb/yr
%
%
35.5
19,899
9,950
12,313
10,343
9,825
46.8
46.8
66.8
232,654
116,327
270,875
49,250
46,788
46.8
46.8
87
92,492
46,246
140,250
1,020
969
12.1
85.1

Thermal Incinerator — Control Option B

Model Plant
1
2
3

VOC Molecular Weight
Ventilation Rate
Incinerator Intake
VOC to Incinerator
HAP to Incinerator
Incremental HAP
Control
Incremental Control
Efficiency
New Overall Control

SCFM
SCFM
lb/yr
lb/yr
lb/yr
%
%
35,5
19,899
19,899
24,625
20,685
19,651
93.6
93.6
66.8
232,654
232,654
541,750
98,500
93,575
93.6
93.6
87
92,492
92,492
280,500
2,040
1,938
24.2
97.2

Assume: HAP is methanol (MW=32) , Non-HAP VOC is ethyl acetate
(MW=88.1) Pressroom ventilation incinerator efficiency = 95%.
                         6-28
-------
Table 6-24.  Capital Costs for Thermal Incinerators at Model
           Flexographic plants - Control Option A.
Model Plant
1
2
3

Incinerator Intake
VOC to Incinerator
HAP to Incinerator
Control Efficiency
Heat Recovery
Costs (1988$)
Incinerator, auxiliary
instrumentation, sales
freight
SCFM
lb/yr
Ib/yr
%
%
9,950
12,313
10,343
95
70
116,327
270,875
49,250
95
70
46,246
140,250
1,020
95
70

equipment
tax, and
Direct Installation Cost
Indirect Installation Cost
Site Preparation
Total Costs (1988$)
Total Costs (1993$)
257,811
77,343
79,921
25,781
440,856
500,311
476,716
143,015
147,782
47,672
815,185
925,120
378,535
113,560
117,346
37,853
647,294
734,588

Capital Recovery Factor
Annualized capital cost
0.1098
$54,934
0.1098
$101,578
0.1098
$80,658

Direct Installation includes foundation, supports, handling,
erection, electrical, piping, insulation for ductwork, and
painting. Indirect installation cost includes engineering,
construction and field expenses, contractor fees, start-up,
performance test, and contingencies. Costs based on OAQPS
Control Cost Manual (EPA 450/3-90-006, January 1990) . Costs
escalated to 1993$ using Marshall and Swift Cost Index
(Factor=966. 9/852.0) .
                            6-29
-------
Table 6-25.  Capital Costs for Thermal Incinerators at Model
           Flexographic plants - Control Option B.
Model Plant
1
2
3

Incinerator Intake SCFM
VOC to Incinerator Ib/yr
HAP to Incinerator Ib/yr
Control Efficiency %
Heat Recovery %
19,899
24,625
20,685
95
70
232,654
541,750
98,500
95
70
92,492
280,500
2,040
95
70
Costs (1988$)
Incinerator, auxiliary
equipment, instrumentation,
sales tax and freight
Direct Installation Cost
Indirect Installation Cost
Site Preparation
Total Equipment Costs (1988$)
Total Equipment Costs (1993$)
Permanent Total Enclosure
(1993$)
Cost including PTE (1993$)
306,588
91,976
95,042
30,659
524,265
594,967
28,284
623,251
566,916
170,075
175,744
56,692
969,427
1,100,162
28,284
1,128,446
450,156
135,047
139,548
45,016
769,767
873,577
28,284
901,861

Capital Recovery Factor
Annualized capital cost
0.1098
$68,433
0.1098
$123,903
0.1098
$99,024

Direct Installation includes foundation, supports, handling,
erection, electrical, piping, insulation for ductwork, and
painting. Indirect installation cost includes engineering,
construction and field expenses, contractor fees, start-up,
performance test, and contingencies. Permanent total
enclosure costs based on assumptions in following table.
Costs based on OAQPS Control Cost Manual (EPA 450/3-90-006,
January 1990) . Costs escalated to 1993$ using Marshall and
Swift Cost Index (Factor=966. 9/852. 0) .
                            6-30
-------
the OAQPS Control Cost Manual2.   The capital cost for control
option B includes retrofit construction of a permanent total
enclosure.  The basis of this cost estimate is given in Table
6-26, and included in Table 6-25.  Total enclosure costs are
based on the construction of two new walls and the presence of
two existing walls.  Depending on the existing structure, total
enclosure costs could be higher or lower than those estimated.
Total annual costs have been estimated for control options A and
B in Tables 6-27 and 6-28.  These estimates include recovery of
capital costs based on a 7 percent interest rate and a 15 year
equipment life.  Operating costs include utilities, labor,
materials, tax, insurance and administration.
     Cost effectiveness of the control options applied to the
model plants is given in Table 6-29.  Cost effectiveness varies
between $30,000 and $60,000 per ton of HAP reduction for model
plants 1 and 2.  For model plant 2, a large part of the cost may
be justified on the basis of non-HAP VOC control.  Costs per ton
of HAP reduction at model plant 3 are extremely high because of
the dilute nature of the fugitive HAP.  This type of plant would
be expected to meet the standard by reducing the HAP content of
its ink, or limiting its potential to emit in some other way.
     Control option C involves the use of low HAP ink.  The
adoption of this control option could, in some cases, represent a
net savings over baseline levels of control.  The applicability
of this option depends to a large extent on the type of printing
and the performance requirements of the product or package.  Some
facilities,  printing on both porous and non-porous substrates
report either zero or very low HAP use as a proportion of total
materials applied on flexographic presses.  Where feasible,
conversion to low HAP inks could result in substantial reductions
in operating costs.   Cost reductions from conversion to low HAP
inks have not been calculated,  because low HAP inks may still
require operation of a control device to meet VOC emissions
standards established by other regulations.
                               6-31
-------
Table 6-26.
Total enclosure Construction Costs for Flexographic
       Plants  -  Control  Option  B.
Wall Dimensions (ft)
Wall Dimensions (ft)
Total Area- Two Walls (SF)
Large Door Dimensions (ft x ft)
Small Door Dimensions (ft x ft)
Wall Cost
Large Door Cost
Small Door Cost
Total Cost
150 x 30
90 X 30
7200
6 X 10
8X4
26274
1850
160
$28,284

Assumptions: Two existing walls, two walls to be
constructed, one large door and one small door to be
added. 8" concrete (sand aggregate) block, 3/8" mortar
joint, tooled one side. Large door-Aluminum door and
frame including hardware and closer. Small door-16
gauge steel, 5" deep.
Costs from Waier, Phillip R. et al.,
Construction Cost Data, 51st Annual
Company, 1992.
Means Building
Edition, R. S. Means
                               6-32
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Table 6-27.  Total Annual Costs for Thermal Incinerators at Model
             Flexographic Plants - Control Option A.
   Model Plant
Electricity Required
Natural Gas Required
Electricity Cost-Note 1
Gas Cost - Note 2
Operating Labor-Note 3.
Maintenance Labor-Note 4
Maintenance Mat'1-Note 5
Overhead-Note 6
Other costs-Note 7
kW
SCFM
$/yr
$/yr
$/yr
$/yr
$/yr
$/yr
$/yr
40.7
123
10,185
92,660
3,886
3,718
3,718
6,793
20,012
475.7
1436
119,069
1,078,176
3,886
3,718
3,718
6,793
37,005
189.1
569
47,334
427,316
3,886
3,718
3,718
6,793
29,384
   Capital Recovery
$/yr| 54,934  |  101,578  |  80,658
   Total Annual  Cost
    |l95,906  |1,353,943|602,807
   Note 1.  Fan power  based on 4  inch pressure  drop  through
   incinerator and 15 inch pressure drop  through  70%
   efficient heat  exchanger.   Fan/motor efficiency  = 60%.
   Operation 4171  hours  per year.  Electricity  cost  =
   0.06/kWhr.

   Note 2.   Operation at 1400 degrees  F,  4171  hours per year.
   Gas  at $0.003/SCF.

   Note 3.  Operator labor 0.5 hr/shift at $12.96/hr.
   Supervisory labor  = 15% of operating labor.

   Note 4.  Maintenance labor  0.5 hr/shift at $14.26/hr.

   Note 5.  Maintenance material assumed equal  to maintenance
   labor.

   Note 6.  Overhead assumed 60% of labor  plus  maintenance
   materials.

   Note 7.  Administrative charges, property taxes and
   insurance assumed  to  be 4% of total capital cost.
                              6-33
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Table 6-28.  Total Annual Costs for Thermal Incinerators at Model
             Flexographic Plants -  Control Option B.
  Model Plant
Electricity Required
Natural Gas Required
Electricity Cost-Note 1
Gas Cost-Note 2.
Operating Labor-Note 3.
Maintenance Labor-Note 4
Maintenance Mat'1-Note 5
Overhead-Note 6
Other costs-Note 7
kW
SCFM
$/yr
$/yr
$/yr
$/yr
$/yr
$/yr
$/yr
81.4
247
20,369
185,311
3,886
3,718
3,718
6,793
24,930
951.5
2872
238,138
2,156,352
3,886
3,718
3,718
6,793
45,138
378.2
1138
94,669
854,631
3,886
3,718
3,718
6,793
36,074
  Capital Recovery
$/yr| 68,433  |   123,903  |    99,024
  Total Annual Cost
    I 317,158  [2,581,646  |  1,102,513
  Note 1.  Fan power based on 4 inch pressure drop through
  incinerator and 15 inch pressure drop through 70% efficient
  heat exchanger.  Fan/motor efficiency = 60%.   Operation 4171
  hours per year.  Electricity cost = 0.06/kWhr.

  Note 2.   Operation at 1400 degrees F, 4171 hours per year.
  Gas at $0.003/SCF.

  Note 3.  Operator labor 0.5 hr/shift at $12.96/hr.
  Supervisory labor = 15% of operating labor.

  Note 4.  Maintenance labor 0.5 hr/shift at $14.26/hr.

  Note 5.  Maintenance material assumed equal to maintenance
  labor.

  Note 6.  Overhead assumed 60% of labor plus maintenance
  materials.

  Note 7.  Administrative charges, property taxes and insurance
  assumed to be 4% of total capital cost.
                              6-34
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 Table 6-29.  Cost Effectiveness of Control Options A and B for
          Control  of Model  Flexographic Printing  Plants.
Model Plant
1
2
3

Control Option
A

HAP Reduction
(lb/yr)
Annual Cost
Cost Effectiveness ($/Ton)
9,825
$195,906
39,879
46,788
$1,353,943
57,876
969
$602,807
1,244,184

Control Option
B

HAP Reduction
(lb/yr)
Annual Cost
Cost Effectiveness ($/Ton)
19,651
$317,158
32,279
93,575
$2,581,646
55,178
1,938
$1,102,513
1,137,784
6.5 REFERENCES
     U.  S.  Environmental Protection Agency.   OAQPS Control Cost
     Manual,  Fourth Edition.   EPA-450/3-90-006,  January,  1990.
     p.  3-42  to 3-58.

     U.  S.  Environmental Protection Agency.   OAQPS Control Cost
     Manual,  Fourth Edition.   EPA-450/3-90-006,  January,  1990.
     p.  3-42  to 3-58.
                              6-35
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TECHNICAL REPORT DATA
(Please read Instructions on reverse before completing)
1 REPORT NO
EPA-453/R-95-002a
2.
4 TITLE AND SUBTITLE
National Emission Standards for Hazardous Air
Pollutants: Printing and Publishing Industry
Background Information for Proposed Standards
7. AUTHOR(S)
9 PERFORMING ORGANIZATION NAME AND ADDRESS
U.S. Environmental Protection Agency
Emission Standards Division (MD-13)
Office of Air Quality Planning and Standards
Research Triangle Park, NC 27711
12 SPONSORING AGENCY NAME AND ADDRESS
Director
Office of Air Quality Planning and Standards
Office of Air and Radiation
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
3. RECIPIENT'S ACCESSION NO.
5. REPORT DATE
February 1995
6. PERFORMING ORGANIZATION CODE
8. PERFORMING ORGANIZATION REPORT NO.
10. PROGRAM ELEMENT NO.
1 1 . CONTRACT/GRANT NO
13. TYPE OF REPORT AND
Final
14. SPONSORING AGENCY
EPA/200/04
PERIOD COVERED
CODE
15. SUPPLEMENTARY NOTES
16. ABSTRACT National emission standards for the control of hazardous air pollutants from the printing and
publishing industry are being proosed under the authority of Section 112 of the Clean Air Act. This
document contains background information and environmental and cost impact assessments of the
regulatory alternatives considered in developing the proposed standards.
17.
KEY WORDS AND DOCUMENT ANALYSIS
a DESCRIPTORS
Air Pollution
Printing
Publishing
Rotogravure
Flexography
Hazardous Air Pollutants
18. DISTRIBUTION STATEMENT
Release Unlimited
b. IDENTIFIERS/OPEN ENDED TERMS
Air Pollution control
19. SECURITY CLASS (Report)
Unclassified
20. SECURITY CLASS (Page)
Unclassified
e. COSATI Field/Group

21. NO. OF PAGES
176
22. PRICE
EPA Form 2220-1 (Rev. 4-77)
                               PREVIOUS EDITION IS OBSOLETE
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