United States
Environmental Protection
Agency
National Risk Management
Research Laboratory
Cincinnati, OH 45268
Research and Development
EPA/600/SR-96/113 September 1996
&EPA Project Summary
Pollution Prevention Assessment
U.S. Postal Service Facilities
Merrifield, VA
Carole O. Bell, Mary Hoel, Henry Huppert, and John Nuckels
As part of its Waste Reduction Evalu-
ation at Federal Sites (WREAFS) Pro-
gram, the U.S. Environmental Protec-
tion Agency (USEPA) National Risk
Management Research Laboratory
(NRMRL) worked cooperatively with the
U.S. Postal Service (USPS) to integrate
waste prevention and recycling activi-
ties into the waste management pro-
grams at various postal facilities
through the conduct of pollution pre-
vention opportunity assessments
(PPOA). The PPOA summarized here
was conducted at the USPS Northern
Virginia Facilities located in Merrifield,
VA.
The PPOA documented and quanti-
fied waste generation at Engineering,
Research and Development (ERD), the
Processing and Distribution Center
(PDC) and the Vehicle Maintenance Fa-
cility (VMF). The report makes recom-
mendations concerning the procure-
ment of office supplies, maintenance
supplies and hazardous materials; man-
agement of hazardous materials and
wastes; purchase of chemicals on
USEPA's 33/50 list; improvement of
source separation and recycling of pa-
per and paper products, metals and
plastics; management of unwanted
equipment; and other options for re-
ducing or eliminating pollution.
This Project Summary was developed
by USEPA's National Risk Management
Research Laboratory, Cincinnati, OH 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).
Introduction
Since 1988, EPA's National Risk Man-
agement Research Laboratory (NRMRL)
has managed a technical support effort
known as the Waste Reduction Evalua-
tions at Federal Sites (WREAFS) Program.
WREAFS was established to provide pol-
lution prevention solutions to environmen-
tal issues through research, development
and demonstration of pollution prevention
techniques and technologies, and trans-
ferring lessons learned within the federal
community and related private sector in-
dustries.
The United States Postal Service
(USPS), in cooperation with NRMRL's
WREAFS program is engaged in an effort
to integrate pollution prevention and recy-
cling activities into the waste management
programs at postal facilities. The purpose
of this project was to perform pollution
prevention opportunity assessments
(PPOAs) at Postal Service facilities, rec-
ommend implementation strategies, and
develop facility guidance that can be in-
corporated into a revision of the USPS
Waste Reduction Guide. The project was
funded by the U.S. Postal Service through
an interagency agreement with EPA
NRMRL.
This report describes the findings of the
PPOA conducted for the United States
Postal Service's Northern Virginia facili-
ties located in Merrifield, VA. The site
assessment was conducted during the
week of January 23, 1995.
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Facility Description
The USPS Northern Virginia operations
are located in Merrifield, Fairfax County,
VA on approximately 15.5 acres of land
and include three main organizational
groups operating multiple sites within and
around the Merrifield location. The three
resident organizational groups include:
Engineering, Research and Development
(ERD), mail Processing and Distribution
Center (PDC), and Vehicle Maintenance
Facility (VMF).
Facility-Wide Opportunities
Exhibit 1 provides a summary of facility-
wide pollution prevention opportunities.
Following Exhibit 1 is a more detailed
description of some of those options.
Paper
• Establish a duplex copying policy for
all multi-page documents and provide
staff with training in the use of the
double-sided function on copying
equipment. As equipment is replaced,
specify easy to use, rapid, duplex ca-
pability.
Exhibit 1. Merrifield Waste Sources and Pollution Prevention Opportunities
Waste or Waste Source Pollution Prevention Opportunities
Procurement
Hazardous materials and hazardous
waste management
Corrugated cardboard
Paper
Products containing EPA 33/50 or
ozone depleting chemicals
Spent solvent
Computer equipment
Energy
Centralize procurement
Establish material tracking system
Reduce credit card purchases
Purchase products containing recycled content
Eliminate purchase of products with EPA 33/50
chemicals
Establish Hazardous Materials Inventory Control System
(HMICS)
Reduce quantity entering facilities
Use permanent mail transport equipment
Reuse corrugated containers
Recycle old corrugated cardboard
Reduce paper use
Reuse
Recycle
Deplete existing stock
Replace with less- or non-hazardous products
Replace solvent sinks with aqueous or semi-aqueous
parts cleaners
Repair
Donate to schools or nonprofit organizations
Recycle
Establish lights out policy
Use motion sensitive lighting where appropriate
Procure Energy Star-compliant computer equipment
- In office and laboratory settings, ex-
pand and encourage the use of elec-
tronic mail rather than paper memos
and distribution copies.
• Limit distribution lists. If paper copies
are necessary, circulate one memo
or report with a cover sheet indicating
distribution.
• Identify opportunities to reuse paper
and paper products. Manila envelopes
and other packaging materials are re-
usable for their original function; pa-
per can be turned over and used as
scratch paper or made into message
pads.
• Encourage staff to save information
on disks rather than file copies.
Undeliverable Bulk Business
Mail (UBBM)
• Determine whether reduction or recy-
cling is the most cost effective man-
agement practice for UBBM by per-
forming a cost-benefit analysis to com-
pare the combined revenues from bulk
mailing and recycling of UBBM to the
costs associated with sorting, han-
dling, transporting and processing un-
deliverable mail and associated pack-
aging.
• Reduce the quantity of UBBM man-
aged by postal facilities by expanding
the USPS mailing list maintenance
service. Annual mailing list updates,
particularly for third and fourth class
mail, could be integrated into the bulk
mail permitting process.
Engineering Research and
Development (ERD)
Engineering, Research and Develop-
ment (ERD) is responsible for the perfor-
mance of engineering, chemical, metallur-
gical and other kinds of research and de-
velopment activities for the Postal Ser-
vice. These activities include development
and testing of new mail processing equip-
ment, development and testing of new
materials and coatings for mail handling
and storage containers, chemical testing
of stamp inks and papers and installation
and testing of coatings, alternative fuel
equipment and retread tires for Postal Ser-
vice vehicles. The ERD employs approxi-
mately 800 people in administrative, engi-
neering, computer, maintenance and jani-
torial functions.
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Exhibit 2 presents the wastes and pol-
lution prevention opportunities specific to
the ERD.
Processing and Distribution
Center (PDC)
The Processing and Distribution Center
(PDC) is responsible for the handling and
distribution of regular and bulk mail in the
northern Virginia area. The PDC consists
of a 443,000-square-foot facility that in-
corporates a mail processing floor and a
basement containing storage areas, ma-
chine shops, and equipment maintenance
and repair facilities. The PDC also con-
tains many ancillary rooms including bat-
tery shops, Undeliverable Bulk Business
Mail (UBBM) operations, and a public Post
Office (Customer Service Center). Daily
mail processing volume of the PDC is
approximately six million pieces. Exhibit 3
summarizes the wastes sources and po-
tential pollution prevention opportunities
for the PDC. Following Exhibit 3 is a brief
cost analysis of employing reusable
dishware and cutlery and pollution pre-
vention options for other cafeteria wastes.
Reusable dishware and cutlery
The weekly cost of purchase of dispos-
able food service items is $573.57. An-
nual cost to purchase disposable dishes,
cutlery, napkins and straws is $29,825.64.
Since these disposables represent approxi-
mately 70% of the waste generated, weekly
disposal costs for these materials can be
estimated at $104.16 for an annual dis-
posal cost of $5,416.32. Total annual pur-
chase and disposal costs for disposable
food service is $35,241.96.
Replacement of plates, bowls, cups,
drinking glasses and cutlery with perma-
nent reusable substitutes would result in
savings in purchasing costs ranging from
$11,813 to $13,617. In addition, a change
to reusable food service materials could
potentially reduce solid waste generation
by as much as 70%. The PDC would avoid
$5,416 in annual disposal costs.
Additional waste prevention opportuni-
ties for the cafeteria include
• Combine the corrugated packaging
and pallets for recycling with the same
materials at the PDC loading dock.
• Separate metal food and beverage
containers and place in the metals
recycling container at the VMF.
• Separate glass and plastic food and
beverage containers and establish a
recycling option for these materials.
• Contract with a grease recycling ser-
vice for grease collection and reuse.
Exhibit 2. ERD Waste Sources and Pollution Prevention Opportunities
Waste Source Pollution Prevention Opportunities
Waste inks Analytical Limit quantity received to amount needed
laboratory for testing and evaluation
Halon Computer rooms Convert to a non-halon based fire
Warehouse suppression system
Transfer excess halon to DOD
Photoprocessing Photo Lab Transfer equipment and chemicals to
chemicals another location or USPS facility
Hazardous waste Shops, labs Improve procurement, management,
tracking
Control ink inventory
Eliminate parts washer
Improve storage of chemical wastes
Exhibit 3. PDC Wastes Sources and Pollution Prevention Opportunities
Waste Source Pollution Prevention Opportunities
Pallets All areas
Hazardous waste All Areas
Polystyrene food service (cups, Cafeteria
bowls, plates etc.)
Polypropylene cutlery Cafeteria
Aluminum, Steel and Glass food Cafeteria
and beverage containers
Reduce variety, reuse, recycle
Set up a secure waste storage area,
close and label all drums
Replace with permanent dishware
Replace with reusable cutlery
Recycle
Grease
Cafeteria
Recycle
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• Specify that beverage makeup syr-
ups be delivered in refillable metal
canisters rather than disposable bag-
in-box.
Vehicle Maintenance Facility
The Merrifield Vehicle Maintenance Fa-
cility (VMF) is responsible for vehicle main-
tenance activities for the Northern Virginia
region. The facility employs 45 people to
maintain approximately 2,903 Postal Ser-
vice vehicles, ranging in size from pas-
senger cars to tractor trailers. Exhibit 4
provides a summary of the wastes gener-
ated in VMF operations and potential pol-
lution prevention opportunities.
Cost Saving Pollution Prevention
Opportunities
Some of the opportunities discussed in the
previous sections simply reduce the generation
of pollution, while others offer the USPS eco-
nomic as well as environmental benefits. Ex-
hibit 5 presents the pollution prevention oppor-
tunities that offer the USPS significant cost re-
ductions in addition to reducing pollution.
Conclusions and
Recommendations
This Pollution Prevention Opportunity Assess-
ment report documents the processes per-
Exhibit 4. VMF Waste Sources and Pollution Prevention Opportunities
Waste Source Pollution Prevention Opportunities
Paint, paint cans, paint filters
Paper, tape
Paint booth
Construct new paint booth with better
painting technology, recycle paint cans
Masking vehicle surfaces Use reusable templates for masking
during painting
Wastewater
Antifreeze
Used oil
Wash rack
Shop
Shop
Install water recirculating system
Purchase on site recycling unit
Purchase rerefined motor oil
formed, wastes generated and cur-
rent waste management practices at
the USPS Engineering Research and
Development facility, the Processing
and Distribution Center and the Ve-
hicle Maintenance Facility in
Merrifield, VA. The PPOA identified
opportunities to reduce both the
quantity and toxicity of the wastes
generated by this facility and recom-
mended techniques for implementa-
tion of those pollution prevention op-
tions.
The USPS has begun to develop
a comprehensive waste generation
and management plan and is insti-
tuting source reduction and recycling
activities in its facilities. Emissions to
air and water from the Merrifield fa-
cilities are minimal. The facility should
provide extensive attention to con-
trolling the materials that enter the
facilities. Annual solid waste expen-
ditures could be reduced by coordi-
nation of reduction and recycling ac-
tivities.
The full report was submitted in
partial fulfillment of Contract No. 68-
C2-0148, Work Assignment No. 3-
10 by Science Applications Interna-
tional Corporation under the spon-
sorship of the U.S. Environmental
Protection Agency.
Exhibit 5. Cost-Saving Pollution Prevention Opportunities
Item(s) of Concern Current Practice
Pollution Prevention
Opportunity
Estimated Potential Savings
PDC Cafeteria
Pine pallets
Solvent parts
washers
Use of disposable food
service items
Disposed
Most parts washers are
solvent sinks
Replace with
reusable food service items
Divert for recycling
Replace solvent sinks
with aqueous parts
washers
Savings in purchasing costs ranging
from $11,813 to $13,617, savings from
avoided disposal of $5,416 in annual
disposal costs
More than $32,000 per year, assuming
four pulls per week at $49 per pull
plus actual landfill tipping fees
averaging $115 per load
Potential savings are not quantifiable at
this time
ERD oil water
separator and oil
tank
Recyclables
Procurement of
supplies and
materials
Plans for replacement
Collect aluminum,
plastic and glass food
and beverage containers,
and paper products
Decentralized process
Since no oil is present,
do not replace tank.
Prevent oil from
entering drains
Establish one multi-
facility recycling
program
Centralize ordering and
inventory control
Cost of tank replacement
potential savings are not quantifiable at
this time
Reduction in waste disposal costs based
on anticipated reduction in size and
number of waste containers and
number of pulls
Eliminate expenses associated with
overstocking and disposal of expired or
unused materials or chemicals
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Carole O. Bell, Mary Hoe/, Henry Huppert, and John Nuckels are with Science Applications
International Corporation, Newport, Rl 02840.
James S. Bridges and Theresa T. Hoagland are the EPA Project Officers (see below).
The complete report, entitled "Pollution Prevention Assessment U. S. Postal Service Facilities
Merrifield, VA," (OrderNo. PB97-100044; Cost: $57.00, 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 Officers can be contacted at:
National Risk Management Research Laboratory
U.S. Environmental Protection Agency
Cincinnati, OH 45268
United States
Environmental Protection Agency
Center for Environmental Research Information (G-72)
Cincinnati, OH 45268
Official Business
Penalty for Private Use $300
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EPA/600/SR-96/113
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