United States
Environmental Protection
Agency
Risk Reduction
Engineering Laboratory
Cincinnati, OH 45268
Research and Development
EPA/600/S-92/045 Oct. 1992
ENVIRONMENTAL
RESEARCH BRIEF
Waste Reduction Activities and Options for a
Manufacturer of Artists Supply Paints
Alan Ulbrecht 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 assessments at 30 small- to medium-sized busi-
nesses in the state of New Jersey. One of the sites selected
was a manufacturer of artists' supply paints. A site visit was
made in 1990 during which several opportunities for waste
minimization were identified. These opportunities include
changes in product formulation, reduction of spills and leaks of
solvents, improved solvent handling techniques, improved
equipment cleaning techniques, and recovery of waste solvents.
Implementation of the identified waste minimization opportuni-
ties 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 Investiga-
tors and EPA's Risk Reduction Engineering Laboratory in Cin-
cinnati, OH, to announce key findings of this completed as-
sessment.
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.
* New Jersey Institute of Technology, Newark, NJ 07102
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 operations
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
Division of Hazardous Waste Management, NJDEPE, is pursu-
ing the goals of waste minimization awareness and program
implementation in the state. HWAP, with the help of an EPA
grant from the Risk Reduction Engineering Laboratory, con-
ducted an Assessment of Reduction and Recycling Opportuni-
ties for Hazardous Waste (ARROW) 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 assessments following the
approach outlined in EPA's Waste Minimization Opportunity
Assessment Manual (EPA/625/7-88/003). Under contract 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 assessment of a manufacturer of artists' supply paints (1 of
the 30 assessments 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 minimizatidn 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
Printed on Recycled Paper
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with which the facility staff could apply the manual. In some
cases, NJIPs role. was to provide advice. In others, NJIT
conducted essentially the entire evaluation.
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 lo 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 complications developed, the team offered assis-
tance in the technical review, inspections, and option develop-
ment.
The Artists' Supply Paints Manufacturer
The facility is a manufacturer of specialty artistic paints for
application on designer wear clothing, tops, scarfs, and home
decor items such as wall paintings, quilts, and pillows. The
paints, which come in a variety of colors, are packaged in
either aluminum or polyethylene tubes. The product line includes
both solvent-based and water-based paints. Generally the
products are marketed as a kit including the homecraft article,
the necessary paints, and other accessories.
In addition to the paint manufacturing/formulation operation,
the facility has a high speed printing department and a cutting/
assembly area for the kits. Some items are silk-screened and
specialty items are hand embroidered.
The paint manufacturing/formulation process is a batch process
and both water-based and solvent-based paints are formulated
to a maximum batch size of 50 gal in a 55-gal drum. For the
solvent-based paints, the required raw materials are mixed with
a combination of solvents such as mineral spirits and light
aromatic naphthas to achieve the desired color specification.
The water-based or latex paints similarly require that pigments
and other raw materials be mixed with water to the required
color specification.
All of the components of the paints are purchased from outside
suppliers. Moreover, both types of paints must have the ap-
propriate consistency and viscosity to allow tube filling and
customer use. The customer desired performance characteris-
tics for this particular use include fast drying time, color fastness,
and product durability. Therefore, the formulations must address
these needs in addition to any manufacturing requirements.
The formulated batches are analyzed for color and other prop-
erties, and once approved are transferred to the filling line. Air
diaphragm pumps are used to fill the small tubes with the paint.
In order to prevent the paint from plugging the fill line tubing or
to prevent color cross-contamination when changing from one
product to another, the tubing is rinsed with either water or
solvents, depending upon the last product filled. Moreover,
when it is necessary to change the filling equipment from
water-based to solvent-based products, or vice-versa, a second
rinse with the new solvent is required to minimize the opportu-
nities for product contamination and solids precipitation in the
filling equipment.
Waste Streams and Existing Waste
Management
Solvent wastes are sent offsite for disposal through fuel blend-
ing. Aqueous wastes are drummed and sent offsite for treatment
as a non-hazardous waste. Off-specification raw materials and
formulated paint are sent offsite for disposal.
The company has already instituted some product formulation
and manufacturing scale practices which have led to a reduction
in the total amount of waste generated at the facility. The
appearance of the facility shows that the management and
employees recognize the waste reduction value of ease of
movement of raw materials, good maintenance of equipment,
and spill control and spill prevention activities.
Summary of Waste Minimization Opportunities
The type of waste currently generated by the facility, the
source of the waste, the quantity of the waste and the annual
treatment and disposal costs are given in Table 1.
Table 2 shows the opportunities for waste minimization recom-
mended for the facility. The type of waste, the minimization
opportunity, the possible waste reduction and associated sav-
ings, 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 in most cases the economic savings of the
minimization opportunity results 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.
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Tad/0 1. Summary of Current Waste Generation
Waste Generated
Source of Waste
Annual Quantity
Generated
Annual
Costs
Fugitive Solvents Losses during transfer and
mixing of organic solvents
Solvent Wastes Residues from paint formulation
and rinsing of filling equipment
Aqueous Wastes Residues from paint formulation
and rinsing of filling equipment
Off-Specification Inferior raw materials and formulated
Materials paints which do not meet specifications
* By use of the senses, such as smell.
Cannot be determined
from available records
but can be detected
organoleptically *
3000 gal
16,000 gal
1000gal(solvent)
2250 gal(water)
No direct management
costs, but is a direct
financial loss of raw
materials
$3545
$23,273
$1,300
$3,280
Table 2. Summary of Waste Minimization Opportunities
Waste Stream
Reduced
Annual Waste Reduction
Minimization Opportunity
Quantity
Percent
Net Implementation Payback
Annual Savings Cost Years*
Solvent Wastes Distillation for inhouse 2700gal 90% $15,000 $4000 0.3
recycling and reuse
Aqueous Wastes Use of final rinses as 4000 gal 25% $5,800 0 immed.
process water
Dewatering of waste stream 14,400 gal 90% $20,000 $20,000 1
using ultra-filtration
Off-specification Re-formulate into products 200 gal (solvent) 20% $1,000 0 immed.
Paints perhaps with darker colors 250 gal (water) 20% $1,000 0 immed.
Fugitive Solvent Re-formulate products into
Emissions all water-based products
Install condensing equipment
to capture solvents during
container filling operations
Stage manufacturing and tube
filling operations to go from
lighter to darker colors and
runs as long as possible of
solvent-based or water-based
product. This reduces amount
of solvent used and thus reduces
fugitive emissions.
(It should be noted that because it was not possible to quantify fugitive emissions, it is not possible to accurately determine costs and payback. On the
other hand, goodpollution prevention practices wouldencourage and support efforts of this type. Changes in product formulation may meet with customer
resistance leading to hesitation on the part of the manufacturer to make such changes.)
* Savings result from reduced raw materials and treatment and disposal costs when implementing each minimization opportunity independently.
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
•&U.S. GOVERNMENT PRINTING OFFICE: 1994 • S3MC7/MM7
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Environmental Protection Agency
Center for Environmental Research Information
Cincinnati, OH 45268
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