United States
Environmental Protection
Agency
Research and Development
Risk Reduction
Engineering Laboratory
Cincinnati, OH 45268
EPA/600/S-92/041 Oct. 1992
ENVIRONMENTAL
RESEARCH BRIEF
Waste Reduction Activities and Options for a
Manufacturer of Writing Instruments
Patrick Eyraud and Daniel J. Watts*
Abstract
The U.S. Environmental Protection Agency (EPA) funded a project
with the New Jersey Department of Environmental Protection and
Energy (NJDEPE) to assist in conducting waste minimization as-
sessments at 30 small- to medium-sized businesses in the state of
New Jersey. One of the sites selected was a facility that manufac-
tures writing instruments. A site visit was made in 1990 during which
several opportunities for waste minimizatbn were identified. These
opportunities include reformulation of ink, reuse of rinse waters,
changes in scheduling of ink production runs, and changes in
degreasing techniques. Implementation of the identified waste mini-
mization opportunities was not part of the program. Percent waste
reduction, net annual savings, implementation costs and payback
periods were estimated.
This Research Brief was developed by the Principal Investigators
and EPA's Risk Reduction Engineering Laboratory in Cincinnati,
OH, to announce key findings of this completed assessment.
Introduction
The environmental issues facing industry today have expanded
considerably beyond traditional concerns. Wastewater, air
emissions, potential soil and groundwater contamination, solid
waste disposal, and employee health and safety have become
increasingly important concerns. The management and disposal
of hazardous substances, including both process-related wastes
and residues from waste treatment, receive significant attention
because of regulation and economics.
As environmental issues have become more complex, the
strategies for waste management and control have become
more systematic and integrated. The positive role of waste
minimization and pollution prevention within industrial opera-
tions at each stage of product life is recognized throughout the
world. An ideal goal is to manufacture products while generat-
ing the least amount of waste possible.
The Hazardous Waste Advisement Program (HWAP) of the Divi-
sion of Hazardous Waste Management, NJDEPE, is pursuing the
goals of waste minimizatbn awareness and program implementa-
tion in the state. HWAP, with the help of an EPA grant from the Risk
Reduction Engineering Laboratory, conducted an Assessment of
Reduction and Recycling Opportunities for Hazardous Waste (AR-
ROW) project. ARROW was designed to assess waste minimization
potential across a broad range of New Jersey industries. The
project targeted 30 sites to perform waste minimization assess-
ments following the approach outlined in EPA's Waste Minimization
Opportunity Assessment Manual (EPA/625/7-88/003). Under con-
tract to NJDEPE, the Hazardous Substance Management Research
Center at the New Jersey Institute of Technology (NJIT) assisted in
conducting the assessments. This research brief presents an as-
sessment of a writing instruments manufacturer (1 of the 30 as-
sessments performed) and provides recommendations for waste
minimization options resulting from the assessment.
Methodology of Assessments
The assessment process was coordinated by a team of techni-
cal staff from NJIT with experience in process operations,
basic chemistry, and environmental concerns and needs. Be-
cause the EPA waste minimization manual is designed to be
primarily applied by the inhouse staff of the facility, the degree
of involvement of the NJIT team varied according to the ease
with which the facility staff could apply the manual. In some
cases, NJIT's role was to provide advice. In others, NJIT
conducted essentially the entire evaluation.
* New Jersey Institute of Technology, Newark, NJ 07102
Printed on Recycled Paper
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The goal of the project was to encourage participation in the
assessment process by management and staff at the facility.
To do this, the participants were encouraged to proceed through
the organizational steps outlined in the manual. These steps
can be summarized as follows:
• Obtaining corporate commitment to a waste minimization
initiative
• Organizing a task force or similar group to carry out the
assessment
• Developing a policy statement regarding waste minimiza-
tion for issuance by corporate management
• Establishing tentative waste reduction goals to be achieved
by the program
• Identifying waste-generating sites and processes
• Conducting a detailed site inspection
• Developing a list of options which may lead to the waste
reduction goal
• Formally analyzing the feasibility of the various options
• Measuring the effectiveness of the options and continuing
the assessment.
Not every facility was able to follow these steps as presented.
In each case, however, the identification of waste-generating
sites and processes, detailed site inspections, and development
of options was carried out. Frequently, it was necessary for a
high degree of involvement by NJIT to accomplish these steps.
Two common reasons for needing outside participation were a
shortage of technical staff within the company and a need to
develop an agenda for technical action before corporate com-
mitment and policy statements could be obtained.
It was not a goal of the ARROW project to participate in the
feasibility analysis or implementation steps. However, NJIT
offered to provide advice for feasibility analysis if requested.
In each case, the NJIT team made several site visits to the facility.
Initially, visits were made to explain the EPA manual and to encourage
the facility through the organizational stages. If delays and compli-
cations developed, the team offered assistance in the technical
review, inspections, and option development.
The Writing Instruments Manufacturer
The facility is an integrated manufacturer of writing instruments.
The process used involves fabrication of plastic components
usually prepared by injection molding, and assembly of the
components including metal components which are generally
produced offsite. Many of the writing instruments are filled with
ink at the facility prior to shipment to the users.
There are four major production areas at this facility, all of
which play an important role in the production of the final
product. One area consists of an injection molding operation
where the writing instrument bodies are created from melted
plastic pellets. The major waste stream from this operation is
the plastic fragments which are snapped off from the writing
instruments bodies after formation. These materials are usually
picked up by a broker for reuse.
The second area is the assembly area where components of
the writing instruments are assembled. There is very little
waste from this area except for degreasing and acid wastes
which are generated when etching the components. Some
degreasing steps with chlorinated solvents are used to facilitate
connections between the metal and plastic components. Some
of the stainless steel components are pickled and have parts
numbers etched on. This produces an acid waste stream.
The third area is the ink production area where pigments and
additives are mixed with solvent in large tanks according to specifi-
cation to produce the colors and consistencies of ink required. Both
solvent-based and water-based inks are produced. The company is
moving in the direction of more water-based inks.
The fourth area is the ink filling area, where the ink is put into the
writing instruments. Typically this is accomplished with metering
pumps. The pumps and the attendant tubing need to be cleaned
between runs to prevent cross-contamination. The filled writing
instruments are packaged and shipped to customers. Some of the
writing instruments are shipped without ink. Ink is also sold in
containers to previous purchasers of the instruments.
The company has already identified and established some
positive pollution prevention initiatives. The increased use of
water-based inks to replace solvent-based inks is a good
example of this. There is also a research and development
program to find an alternative to heavy metal containing dyes.
This effort is limited by the relatively poor availability of substi-
tute colorants without heavy metal contents.
Waste Streams and Existing Waste
Management
Ten individual waste streams were identified from the manufacturing
operatbns. A rinsing wastewater stream results primarily from rinsing
procedures in the ink manufacturing room. These procedures include
rinsing of mixing tanks and filtration units. In addition, rinses from
cleaning the ink transfer containers and pumps also enter the waste
stream. There is also a contribution from the rinsing of chromium
plated tips used in assembly of the writing instruments. About
30,000 gal of this wastestream are generated annually. The major
component of environmental concern is chromium, although the
formulated inks contain other heavy metals that would also cause
concern. The wastestream is sent to a commercial wastewater
treatment facility.
A water-based waste ink stream consists largely of material
from flushing of ink pumps used in filling operations and from
off-specification materials being scrapped. The stream also
contains residues from laboratory testing. The component of
environmental concern in this stream is chromium, although
other heavy metals used in ink formulation may also be in the
waste stream. The annual volume of this stream is about 800
gal, which is sent to a commercial treatment facility.
A flammable waste ink stream is similar to the water-based
stream described above except that it is composed of organic
solvents. The annual volume of this waste stream is about 200
gal, which is sent to a commercial treatment facility and usually
incinerated. The major component of environmental concern is
acetone and related organic solvents.
An ink spill solids stream has an annual volume of about
12,000 Ib. It consists primarily of residues from cleanup of
manufacturing equipment and ink dispersing equipment as well
as some off-specification product. It also contains residues
from spills including adsorbent materials used to facilitate
cleanups. The major components of environmental concern
are heavy metals, particularly chromium. The stream is sent to
a commercial treatment facility where it undergoes solidifica-
tion, stabilization, or fixation procedures prior to landfilling.
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A solvent-based ink spill solids stream is similar to the preced-
ing stream except that it involves solvent-based inks. Approxi-
mately 1500 Ib of this material are generated annually. It is
sent offsite for treatment or disposal, typically by incineration.
Waste solvent from decreasing operations comes from both
manufacturing and maintenance activities. The solvents are
typically chlorinated materials. About 300 gal of this waste are
generated annually and are disposed of by incineration offsite.
A waste oil stream from equipment maintenance results from
procedures carried out on equipment. The annual volume of
this stream is about 400 gal.
A waste stream composed of oily rags results from mainte-
nance operations. The rags are used primarily for wiping and
cleaning the equipment during maintenance procedures as
well as occasionally being used for spill cleanup. The rags are
disposed of offsite by consolidation and solidification prior to
landfilling. The annual volume of this stream is about 2500 Ib.
A waste acid stream results from pickling activities carried out with
stainless steel components, as well as from etching procedures
used to mark parts numbers on some of these components. The
annual volume of this stream is about 60 gal. It is currently treated
offsite by pH adjustment and subsequent biological treatment.
An acid cleanup solids wastestream results from the same
activities described above but primarily represents the wipers
used on the stainless steel components which have been
pickled, etched, rinsed, or soldered. The annual volume of this
stream is about 80 Ib. It is treated by consolidation and solidifi-
cation prior to landfilling.
Summary of Waste Minimization Opportunities
Table 1 presents the type of waste currently generated by the plant,
the sources of waste, the quantity of waste, and the annual treatment
and disposal costs (where known and available).
Table 2 presents the opportunities for waste minimization recom-
mended for the facility. The type of waste, the minimization opportu-
nity, the possible waste reduction and associated savings, and the
implementation cost along with the payback times are given in the
table. The quantities of waste currently generated at the facility and
possible waste reduction depend on the level of activity of the facility.
All values should be considered in that context.
It should be noted that the economic savings of the minimization
opportunity, in most cases, result from the need for less raw material
and from reduced present and future costs associated with waste
treatment and disposal. It should also be noted that the savings
given for each opportunity reflect the savings achievable when
implementing each waste minimization opportunity independently
and do not reflect duplication of savings that would result when the
opportunities are implemented in a package. Also, no equipment
depreciation is factored into the calculations.
This Research Brief summarizes a part of the work done under
cooperative Agreement No. CR-815165 by the New Jersey
Institute of Technology under the sponsorship of the New
Jersey Department of Environmental Protection and Energy
and the U.S. Environmental Protection Agency. The EPA Project
Officer was Mary Ann Curran. She can be reached at:
Pollution Prevention Research Branch
Risk Reduction Engineering Laboratory
U.S. Environmental Protection Agency
Cincinnati, OH 45268
Table 1. Summary of Current Waste
Waste Generated
Generation
Source of Waste
Rinsing Wastes
Waste Aqueous Ink
Flammable Waste Ink
Ink Spill Solids
(Aqueous)
Ink Spill Solids
(Flammable)
Solvent
Waste Oil
Oily Rags
Waste Acid
Acid Cleanup Solids
Rinsing equipment in ink
production area
Flushing of ink pumps and
disposal of off-spec products
Flushing of ink pumps and
disposal of off-spec products
Residues from machinery cleaning
and adsorbents from spill control
Residues from machinery cleaning
and adsorbents from spill control
Degreasing
Equipment maintenance
Maintenance operations
Etching and pickling of metal
Wipers for metal after pickling
or etching
Annual Quantity Annual Waste
Generated Management Costs
30,000 gal
800 gal
200 gal
12,000 Ib
1,500 Ib
$10,000
$2,000
$500
$15,000
$2,000
300 gal
400 gal
2500 Ib
ital 60 gal
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Table 2. Summary of Waste Minimization Opportunities
Minimization Opportunity
Waste Stream
Reduced
Annual Waste Reduction
Rinsing Wastes
Rinsing Wastes
Ink Spill Solids
Schedule batch production where
possible to go from light
to dark colors to reduce the need
for extended rinsing of equipment
For rinses from filling equipment
segregate them and then use them
as makeup water for the next similar
batch.
Quantity
3000 gal
1500 gal
Net Implementation Payback
Percent Annual Savings Cost Years'
Institute spill prevention plan to 3,000 Ib
improve movement of materials around
the facility, improve transfer techniques
between containers, catch spills to reduce
need for cleanup
Flammable Ink Wastes Improve scheduling of production runs 20 gal
Flammable Ink Spills Devise spill prevention plan 1751b
10%
5%
25%
10%
25%
$1,000
$500
$3,750
$50
$500
$0
$200
$500
0
$500
Degreasing Solvent
Oily Rags
Change to non-chlorinated solvent
Investigate use of commercial
laundry for cleaning of maintenance
wipes *
(actual volume may stay constant, but level of risk would
decrease)
25001 b 100% $3000 $2400
(This is an annual charge)
immed
0.4
0.2
immed
1.0
0.8
' Savings result from reduced raw material, and treatment and disposal costs when implementing each minimization opportunity independently.
t Addresses minimization of waste rags, but not of the oily wastes contained in them.
United States
Environmental Protection Agency
Center for Environmental Research Information
Cincinnati, OH 45268
Official Business
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