vvEPA
United States
Environmental Protection
Agency
Risk Reduction
Engineering Laboratory
Cincinnati, OH 45268
Research and Development
EPA/600/S-94/008 September 1994
ENVIRONMENTAL
RESEARCH BRIEF
Waste Minimization Assessment for Manufacturer
of Gravure-Coated Metalized Paper and Metalized Film
Richard J. Jendrucko*, Thomas N. Coleman*,
and Gwen P. Looby**
Abstract
The U.S. Environmental Protection Agency (EPA) has funded
a pilot project to assist small and medium-size manufacturers
who want to minimize their generation of waste but who lack
the expertise to do so. In an effort to assist these manufactur-
ers Waste Minimization Assessment Centers (WMACs) were
established at selected universities, and procedures were
adapted from the EPA Waste Minimization Opportunity As-
sessment Manual (EPA/625/7-88/003, July 1988). That docu-
ment has been superseded by the Facility Pollution Prevention
Guide (EPA/600/R-92/088, May 1992). The WMAC team at the
University of Tennessee performed an assessment at a plant
that manufactures gravure-coated metalized paper and film.
White coated paper purchased as a raw material is coated with
a water-based or solvent-based mixture, and a thin layer of
aluminum is deposited on the coating. Another coating is ap-
plied on top of the metalized surface. Rolls of film bought by
the plant also receive a thin layer of aluminum. The team's
report, detailing findings and recommendations, indicated that
a large quantity of solvent evaporates from the plant's pro-
cesses and that a large quantity of unused coating mixture is
wasted. The greatest cost savings can be achieved by the
plant through the installation of an automated system for mix-
ing and diluting coating mixtures.
This Research Brief was developed by the principal investiga-
tors and EPA's Risk Reduction Engineering Laboratory, Cincin-
nati, OH, to announce key findings of an ongoing research
project that is fully documented in a separate report of the
same title available from University City Science Center.
* University of Tennessee, Department of Engineering Science and Mechanics.
** University City Science Center, Philadelphia, PA.
Introduction
The amount of waste generated by industrial plants has be-
come an increasingly costly problem for manufacturers and an
additional stress on the environment. One solution to the
problem of waste generation is to reduce or eliminate the
waste at its source.
University City Science Center (Philadelphia, PA) has begun a
pilot project to assist small and medium-size manufacturers
who want to minimize their generation of waste but who lack
the in-house expertise to do so. Under agreement with EPA's
Risk Reduction Engineering Laboratory, the Science Center
has established three WMACs. This assessment was done by
engineering faculty and students at the University of
Tennessee's WMAC. The assessment teams have consider-
able direct experience with process operations in manufactur-
ing plants and also have the knowledge and skills needed to
minimize waste generation.
The waste minimization assessments are done for small and
medium-size manufacturers at no out-of-pocket cost to the
client. To qualify for the assessment, each client must fall
within Standard Industrial Classification Code 20-39, have gross
annual sales not exceeding $75 million, employ no more than
500 persons, and lack in-house expertise in waste minimiza-
tion.
The potential benefits of the pilot project include minimization
of the amount of waste generated by manufacturers and re-
duction of waste treatment and disposal costs for participating
plants. In addition, the project provides valuable experience for
graduate and undergraduate students who participate in the
program and a cleaner environment without more regulations
and higher costs for manufacturers.
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Methodology of Assessments
The waste minimization assessments require several site visits
to each client served. In general, the WMACs follow the proce-
dures outlined in the EPA Waste Minimization Opportunity
Assessment Manual (EPA/625/7-88/003, July 1988). The WMAC
staff locate the sources of waste in the plant and identify the
current disposal or treatment methods and their associated
costs. They then identify and analyze a variety of ways to
reduce or eliminate the waste. Specific measures to achieve
that goal are recommended and the essential supporting tech-
nological and economic information is developed. Finally, a
confidential report that details the WMAC's findings and recom-
mendations (including cost savings, implementation costs, and
payback times) is prepared for each client. '
Plant Background
The plant produces gravure-coated metalized paper and metal-
ized polypropylene and polyester film for use in labeling and
wrapping food products. It operates 8,760 hr/yr to produce > 14
x 10* Ib/yr of product.
[
Manufacturing Process
The plant's products are manufactured from raw paper and film
received in bulk rolls. Other raw materials include water-based
and solvent-based coating mixtures, aluminum wire (for vapor
deposition coating), liquid nitrogen, and diluting solvents. ;
Diluting solvents (three different organic-solvent-based coating
mixtures and a water-based coating mixture) are receiveqi in
bulk quantities and stored. The organic-solvent-based coating
mixtures are diluted with methyl ethyl ketone (MEK) as:re-
quired and transported to the pre-coater. Water-based coating
mixture is diluted with isopropanol and transported to eitherithe
pre-coater or top-coater.
Raw white coated paper is processed in the pre-coater where
a coating is applied to enhance the gloss of the paper knd
provide a good surface for aluminum adhesion during l^ter
vacuum metalization. Two coatings are applied to the paper,
and in some cases, both sides of the paper are coated. On£ of
the three organic-solvent-based coatings or the water-based
coating is used for each coating application; the first jand
second coating applications may or may not use the same
coating mixture. Following coating, the paper is dried in: the
pre-coater oven. ;
Each coated paper roll from the pre-coater is transported to
one of two vacuum metalizers. Rolls of polypropylene and
polyester film are processed in a specialized vacuum metalizer.
A thin layer of aluminum is deposited on the paper and .film
through vapor-deposition. About half of the metalized film is cut
to specification in the metalizer and sent directly to shipping.
The rest of the film is sent to the finishing, rewind, and slitting
area of the plant prior to shipping. :
The metalized paper is transported to the top-coater where a
coating is applied to the metalized surface in the same mariner
that the initial coating was applied in the pre-coater. The top
coat (supplied by the water-based coating) acts as a printing
primer and provides a clear protective layer. The coated paper
Is dried In the top-coater oven and sent to the finishing, rewind,
and slitting area prior to shipping.
An abbreviated process flow diagram is shown in Figure 1i
MEK
isopropanol
Water-based and
solvent-based
coating mixtures
White coated
paper
Polypropylene
film, polyester
film, Al wire,
liquid N2
Metalized
1 paper and film
Figure 1. Abbreviated process flow diagram.
Existing Waste Management Practices
This plant operates an onsite solvent recovery still to recover
MEK from solvent wastes. Recovered solvent is used for dilut-
ing coating mixtures and cleanup.
Waste Minimization Opportunities
The type of waste currently generated by the plant, the source
of the waste, the quantity of the waste, the waste management
method, and the annual waste management cost for each
waste stream identified are given in Table 1.
Table 2 shows the opportunities for waste minimization that the
WMAC team recommended for the plant. The minimization
opportunity, type of waste, the possible waste reduction and
associated savings, and the implementation cost along with the
simple payback time are given in the table. The quantities of
waste currently generated by the plant and possible waste
reduction depend on the production level of the plant. All
values should be considered in that context.
It should be noted that the financial savings of the minimization
opportunities result from the need for less raw material and
from reduced present and future costs associated with waste
management. Other savings not quantifiable by this study in-
clude a wide variety of possible future costs related to chang-
ing emissions standards, liability, and employee health. It also
should be noted that the savings given for each opportunity
reflect the savings achievable when implementing each waste
minimization opportunity independently and do not reflect du-
plication of savings that would result when the opportunities
are implemented in a package.
This research brief summarizes part of the work done under
Cooperative Agreement No. CR-814903 by the University City
Science Center under the sponsorship of the U.S. Environmen-
tal Protection Agency. The EPA Project Officer was Emma
Lou George.
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United States
Environmental Protection Agency
Center for Environmental Research Information
Cincinnati, OH 45268
Official Business
Penalty for Private Use
$300
BULK RATE
POSTAGE & FEES PAID
EPA
PERMIT No. G-35
EPA/600/S-94/008
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