United States
Environmental Protection
Agency
National Risk Management
Research Laboratory
Cincinnati, OH 45268
Research and Development
EPA/600/SR-95/097
EPA Project Summary
July 1995
Improved Equipment Cleaning
for the Coated and Laminated
Substrate Manufacturing Industry
(Phase II)
J, B. Vitas, Beth W. McMinn, and Geary D. McMinn
The report discusses EPA efforts to
identify, demonstrate, and publish pol-
lution prevention information and op-
portunities for equipment cleaning for
the coated and laminated substrate
manufacturing industry. It summarizes
initial data collected and summarized
during industry observation and dem-
onstration visits. Demonstrations took
place at a small batch facility and a
small dedicated-line facility.
The focus at the batch facility was to
decrease the number of solvents used
for cleaning, reduce the quantity of
material used for cleaning, and stan-
dardize cleaning practices. While con-
solidating from three chemicals (i.e.,
toluene, xylene, and methyl ethyl ke-
tone—MEK) to a single solvent for
cleaning may not be feasible because
of the varied product mix, the facility
could eliminate one cleaning solvent
(MEK), thereby reducing handling and
disposal costs. An estimated emission
reduction of 65% could be achieved by
eliminating MEK. Raw material and dis-
posal cost savings are approximately
$30,000 annually. It was also demon-
strated that the facility could reduce
consumption of cleaning solvent by at
least 50%, thus reducing raw material
costs by approximately $20,000 per
year.
The focus at the dedicated-line facil-
ity was to investigate the use of alter-
native cleaners, reduce the quantity of
material used for cleaning and stan-
dardize operating practices. Both odor-
less mineral spirits and Varsol were
tested as alternative cleaners. Results
showed that, except for acrylic adhe-
sives, either Varsol or odorless min-
eral spirits could be used to replace
the facility's current cleaning solution.
For this facility, the replacement could
reduce emissions by 25% and could
save the facility $500 annually. How-
ever, the incompatibility of the alter-
nate cleaners with the acrylic adhesive
could not completely eliminate the need
for their current cleaning solution.
This Project Summary was developed
by the National Risk Management Re-
search Laboratory's Air Pollution Pre-
vention and Control Division, Research
Triangle Park, NC, to announce key
findings of the research project that is
fully documented in a separate report
of the same title (see Project Report
ordering information at back).
Background
As a result of the Pollution Prevention
Act of 1990, the Environmental Protection
Agency (EPA) established the 33/50 Pro-
gram which calls for voluntary industry
reductions in releases of the following 17
high-priority toxic chemicals, listed by mass
of emissions.
Toluene
Xylenes
1,1,1-Trichloroethane
Methyl Ethyl Ketone
Dichloromethane
Chromium and Compounds
Lead and Compounds
Trichloroethylene
Methyl Isobutyl Ketone
Tetrachloroethylene
Printed on Recycled Paper
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Benzene
Chloroform
Nickel and Compounds
Cyanide and Compounds
Carbon Tetrachloride
Cadmium and Compounds
Mercury and Compounds
The goal of the 33/50 program is to
reduce the total amount of these chemi-
cals released into the environment and
transferred off-site by 33% by the end of
1992 and by 50% by the end of 1995.
These reductions will be based on the
Toxic Chemical Release Inventory (TRI),
with 1988 as the base year.
In support of the 33/50 Program and
the Agency's pollution prevention goals,
EPA's Air and Energy Engineering Re-
search Laboratory (AEERL) is investigat-
ing ways to reduce air emissions and other
media impacts of these 17 chemicals
through pollution prevention. The Pollu-
tion Prevention Act of 1990 defines pollu-
tion prevention as "any practice which re-
duces the amount of any hazardous sub-
stance, pollutant, or contaminant entering
the waste stream or otherwise released to
the environment (including fugitive emis-
sions) prior to recycling, treatment, or dis-
posal; and reduces the hazards to public
health and the environment associated with
the release of such substances, pollut-
ants, or contaminants." Pollution preven-
tion may offer economic, health, and eco-
logical benefits that may not be available
through traditional pollution control meth-
ods.
In 1991, AEERL representatives met
with Industry, academia, and state envi-
ronmental agency representatives to iden-
tify several source categories deserving
pollution prevention research. Two criteria
were used to select the industrial catego-
ries for study: actual annual toxics emis-
sions and the potential for pollution pre-
vention opportunities. Rrst, the TRI was
reviewed to identify categories with the
greatest mass emissions of the 33/50
chemicals. Categories with the greatest
emissions were then ranked according to
their potential for successful pollution pre-
vention projects resulting in significant re-
ductions of 33/50 chemical releases. One
of the industries identified during the 1991
meeting was the adhesives-coated and
jaminated paper manufacturing industry
[Standard Industrial Classification (SIC)
2672]. This industry was chosen because
of significant air emissions of 33/50 Pro-
gram chemicals methyl ethyl ketone (MEK)
and toluene as reported through the TRI.
In October 1991, AEERL convened a
focus group of industrial personnel, pollu-
tion prevention experts, and representa-
tives of the Pressure Sensitive Tape Coun-
cil (PSTC) and the Tag and Label Manu-
facturers Institute (TLMI) to discuss spe-
cific pollution prevention projects that would
support the 33/50 Program. Meeting par-
ticipants indicated that emissions of tolu-
ene and MEK from equipment cleaning
operations are second only to emissions
from the coatings and coating application
steps. Because industry is currently fo-
cusing research efforts on coating formu-
lations, it was suggested that this project
be focused on equipment cleaning. As a
result of this meeting and preliminary in-
dustry inquiries, the scope of the industry
investigation was later expanded to in-
clude other coating and substrate variet-
ies (such-as those included in SIC 2671- -
Coated and Laminated Packaging Paper
and Plastics Film) because the manufac-
turing methods and cleaning processes
are similar; therefore, technology transfer
is possible over a wider range of indus-
tries. The improved equipment cleaning
project fulfills part of EPA's goal to stimu-
late the development and use of products
and processes that result in reduced pol-
lution.
During the Phase I information gather-
ing effort, literature searches of the EPA
on-line databases, local university library
databases, and Dialog® were conducted.
The Pollution Prevention Information Clear-
inghouse (PPIC) and the Pollution Pre-
vention Information Exchange System
(PIES) were accessed on a biweekly ba-
sis. The E-Mail capabilities of PIES were
also used to communicate with other PIES
users with knowledge of the coated and
laminated substrate manufacturing indus-
try.
The second source of project back-
ground information, also conducted dur-
ing Phase I activities, was data retrieved
through industry questionnaires. Two ques-
tionnaires were distributed to 14 adhe-
sive-coated and laminated paper manu-
facturers, primarily pressure sensitive tape
manufacturers and tag and label manu-
facturers. A separate questionnaire was
prepared for manufacturers operating un-
der either SIC 2672 or SIC 2641 (Paper
Coating and Glazing) depending on their
SIC. Neither questionnaire was sent to
more than eight manufacturers. The re-
sults of the questionnaires were clarified
through follow-up contacts with the recipi-
ents and through revised questionnaires.
Over 30 additional facilities (i.e., not re-
cipients of the original questionnaires) were
contacted for further information on equip-
ment cleaning practices. The second group
of facilities contacted was representative
of the expanded scope of the research
project, and consisted of facilities involved
in the coating and laminating of flexible
substrates (SIC 2671) as well as those
included in SIC 2672.
Contacts made during Phase I contin-
ued to be consulted during the Phase II
demonstration activities. These contacts
included industry and pollution prevention
experts with the Massachusetts Office of
Technology Assistance (OTA), the North
Carolina Office of Waste Reduction (OWR,
the PSTC, the TLMI, and equipment manu-
facturing firms.
Objectives
This report presents the results of Phase
II of an effort to demonstrate improved
equipment cleaning technologies in the
_coated_and Jaminated substrate manufac-;
luring industry, to quantify air emissions
and other media wastes, record produc-
tion parameters, and make other observa-
tions and measurements necessary to as-
sess the impacts of the alternative tech-
nology. The information presented in this
report is largely the result of data col-
lected, analyzed, and summarized during
industry observation and demonstration
visits. These data were supplemented by
information from sources including the
Phase I project report, literature searches,
industry questionnaires, plant visits, pollu-
tion prevention experts, and industry and
trade association personnel.
The primary source of information for
this report was data collected during four
facility observation visits and two demon-
stration visits. The purpose of the obser-
vation visits (conducted at two large, dedi-
cated line facilities; one small, dedicated
line facility; and one small, batch facility)
was to observe plant operations and to
collect data to establish a waste genera-
tion baseline. The demonstration visits
sought to demonstrate waste-reducing al-
ternative cleaning technologies. Demon-
strations were conducted at the small,-
batch facility and the small, dedicated line
plant.
Together, the information gathered dur-
ing the Phase I and II efforts will form the
foundation for Phase III technology trans-
fer efforts. Focused documents such as
conference papers, journal articles, and
newsletters will be prepared and presented
at industrial workshops, pollution preven-
tion conferences, and other events where
industrial application of pollution preven-
tion technologies is discussed. Trade as-
sociations and contacts made during
Phases I and II will be targeted audiences
and vehicles used for technology transfer.
PPIC, the National Pollution Prevention
Roundtable, and other groups focused on
pollution prevention will also be contacted
to help distribute information.
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Report Organization
The report consists of four chapters and
two attachments. Chapter 2 describes the
Phase II project approach and includes a
brief description of the coated and lami-
nated substrate industry and the manu-
facturing process. It also summarizes the
purpose of the observation visits including
the data collection needs and the identi-
fied pollution prevention opportunities.
Chapter 3 explains in more detail the pol-
lution prevention cleaning opportunities that
can be used at coated and laminated sub-
strate manufacturing facilities. Some of
the technologies that are discussed are
alternative cleaners, solvent consolidation,
recycling, best operating practices, and
operator training. These waste-reducing
techniques are evaluated for emission re-
duction potential and economic impact.
Chapter 4 presents standard operating
practices which many coated and lami-
nated substrate manufacturing facilities can
use to improve their cleaning efficiency.
Attachment A contains copies of two ob-
seivation visit reports and two observa-
tion/demonstration summary reports. At-
tachment B contains product information
sheets for a number of low volatile or-
ganic compound cleaners.
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J. Vitas, B. McMinn, and G. McMinn are with TRC Environmental Corp., Chapel Hill,
NO 27514
Michael Kosusko is the EPA Project Officer (see below).
The complete report, entitled "Improved Equipment Cleaning for the Coated and
Laminated Substrate Manufacturing Industry (Phase II)," (Order No. PB95-
246245; Cost: $27.00, subject to change) will be available only from:
National Technical Information Service
5285 Port Royal Road
Springfield, VA 22161
Telephone: 703-487-4650
The EPA Project Officer can be contacted at:
Air Pollution Prevention and Control Division
National Risk Management Research Laboratory
(formerly Air and Energy Engineering Research Laboratory)
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
United States
Environmental Protection Agency
Technology Transfer and Support Division (CERI)
Cincinnati, OH 45268
Official Business
Penally for Private Use $300
BULK RATE
POSTAGE & FEES PAID
EPA
PERMIT No. G-35
EPA/600/SR-95/097
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