United States Environmental Protection Agency National Risk Management Research Laboratory Cincinnati, OH 45268 Research and Development EPA/600/SR-96/115 September 1996 &EPA Project Summary Pollution Prevention Assessment U.S. Postal Service Materials Distribution Center Topeka, KS Carole O. Bell, Mary Hoel, Henry Huppert, and Steven Rolander 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 conduct of pollution preven- tion opportunity assessments (PPOA). The PPOA summarized here was con- ducted at a USPS facility in Topeka, KS. The PPOA documented and quanti- fied waste generation at the USPS Ser- vice Materials Distribution Center, which consists of the Materials Distri- bution Center, Central Repair Facility, and Label Printing Center located in Topeka, KS. 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 (NRMRL), Cincin- nati, OH, to announce key findings of the research project that is fully docu- mented in a separate report of the same title (see Project Report ordering infor- mation 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. In this report, the findings of the PPOA conducted for the United States Postal Service at the facilities associated with the Materials Distribution Center in To- peka, KS are described. The PPOA was conducted during the week of March 6, 1995. ------- Facility Description The Materials Distribution Center (MDC) is located in Topeka, KS. The USPS op- erations occupy eight buildings on the site. Four buildings are owned by the USPS and four are leased. The mission of the MDC is the specifi- cation, acquisition, storage, distribution and maintenance of more than 16,000 parts, supplies, and pieces of equipment for the USPS automation and computer systems, nationwide. The MDC encompasses five distinct operations: Materials Distribution Center, Inventory Control, Inventory Sup- port, Systems Integration, and the Topeka Purchasing Center. The Label Printing Center (LPC) pro- duces variable data bag and tray labels for 40,000 customers, including USPS na- tionwide and a variety of bulk mailers. The mission of the Central Repair Facility (CRF) is to repair electronic equipment, including circuit boards, monitors, printers and motors from USPS facilities nation- wide. Waste Management Facility-wide, monthly solid waste man- agement fees are estimated at $5,034 for an annual expense in excess of $60,000. These charges are divided among the three organizational groups: the Material Distribution Center which pays three-fifths of the total, the Label Printing Center one- fifth, and the Central Repair Facility one- fifth. The MDC generates limited quantities of hazardous waste. In the past year two drums of waste paint were inadvertently shipped to the MDC and disposed of as hazardous waste. The LPC generates several hazardous wastes. These include gear oil, hydraulic oil, and cleaners, degreasers, and chemi- cals associated with the operation of the offset lithography presses. The offset presses generate three waste streams which are hazardous when spent. These include: Blanket wash (Blankrola) which contains tetrachloroethylene (F002 when spent); Electrostatic solution con- taining potassium hexacyanoferrate (po- tentially D003); and liquid developer con- taining isoparaffinic hydrocarbons (D001 if spent). The LPC generates approxi- mately one gallon of each per week. Facility-Wide Recommendations Pollution prevention recommendations applicable to the entire facility include op- tions in several categories as discussed below. General Rnvironmental Management • Appoint environmental coordinators to monitor the environmental issues at the facilities and identify opportunities to either reduce or recycle the wastes generated at the facility. • Reallocate waste disposal costs based on waste volume to provide incen- tives to reduce waste. • Determine the cost/benefit of replac- ing single-use corrugated boxes and jiffy bags in certain USPS shipping operations with distribution packag- ing that can be reused hundreds of times. • Use software to store information on all items purchased in a database that includes fields for tracking monthly use, quantity on-hand, price, vendor, and storage location. • Establish preference programs and adopt specifications for the purchase of products made with the percent- ages of recovered materials specified in EPA Guidelines. Cardboard For the cardboard that cannot be re- duced at the source, recycling is recom- mended as discussed below. Exhibit 1 presents a summary of facility-wide corru- gated cardboard recycling options. Exhibit 1. Corrugated Cardboard Recycling Maximize corrugated cardboard recycling Option 1: Continue current arrangement with Topeka Waste and Republic Paper Option 2: Negotiate a contract with another paper recycler Total additional pulls of dedicated 40 cu yds compacted corrugated per year Annual weight of corrugated Annual collection costs Annual avoided disposal Revenues from sale of corrugated 50 300 tons $15,250 ($305/pull) $15,650 $6,250 ($125/pull) 50 300 tons 0 $30,900 $22,500 - $30,000 ($75-100/ton) Total Savings $21,900 $53,400 - 60,900 ------- Establish a corrugated cardboard source separation policy, designate containers for cardboard only and train all employees to maintain separation of OCC for recycling. Continue cur- rent collection arrangement with To- peka Waste and Republic Paper. Establish a corrugated cardboard source separation policy, designate containers for cardboard only and train all employees to maintain separation of OCC for recycling. Establish a mar- ket with a local recycler willing to en- ter into a contract based on a fixed price plus a fixed percentage of cur- rent market price. Exhibit 2. Office Paper Recycling Commodity/Price Mixed Office Paper • Reduce computer paper usage by es- tablishing duplex-printing policy, us- ing electronic mail, and limiting distri- bution lists. • Establish a paper recycling program and enter into a long-term paper re- cycling contract indexed to the paper market. If the office paper is recycled as mixed paper, recyclers generally pay between $50 and $150 per ton. However, if the computer paper is separated from the mixed paper, the computer paper may receive up to $200 per ton. Mixed-paper recycling can often maximize the amount of paper recycled, but it can lower the Option 1: Mixed Paper Recycling revenues derived. Exhibit 2 pre- sents a summary of different mixed-paper recycling options available to the facility. • Train employees on the kinds of paper that should be recycled. Materials Distribution Center The MDC pays approximately $36,000 in annual waste disposal costs. Exhibit 3 presents a summary of the MDC's wastes, the current man- agement practices for each, and rec- ommended pollution prevention op- Option 2: Computer Paper Recycling/Mixed Paper Recycling Annual Paper Waste Generation White Paper (estimated 25% of waste stream) Mixed Paper (estimated 75% of waste stream) Price per ton Total 18.75 tons $100' per ton $1,875 18.75 tons 4.75 tons 14 tons $200 per ton (computer paper) $100' per ton (mixed paper) $2,350 ' May 1995 paper recycling figures. Exhibit 3. MDC Waste Generation Waste Current Management Opportunities Obsolete, damaged or defective equipment Corrugated cardboard Computer printout White paper Mixed paper Magazines Toner cartridges Pallets Plastic stretch wrap Strapping Dunnage USPS logo removed/defaced; auctioned or sold as scrap Some hauled to Republic Recycling by Topeka Waste Management for net cost of $180 per compactor load Some collected for recycling by Hunter; some discarded as waste Some collected for recycling; most discarded as waste Some collected for recycling; some discarded as waste Discarded as waste Refurbished and reused Reused then discarded as waste Discarded as waste Discarded as waste Discarded as waste Reduce generation Improve economics of scrap sales Reduce incoming boxes Improve diversion for recycling Improve economics of recycling Reduce generation Improve diversion for recycling Reduce generation, divert for recycling Reduce generation, divert for recycling Reduce generation divert for recycling Combine into single program Reduce variety, establish recycling options Reduce generation, divert for recycling Divert for recycling Reuse, divert for recycling ------- tions. Several options are discussed in more detail in Exhibit 3. Packaging • Reduce multiple layers of packaging, whereever product integrity will not be threatened. • Utilize reusable mail transport equip- ment rather than single-use corru- gated cardboard boxes and/or jiffy bags whenever possible. Paper • Minimize the number of printed items that become obsolete. Exhibit4. LPC Solid Waste Waste Label Printing Center Exhibit 4 presents a summary of the wastes generated by the Label Printing Center, the current management practices for each, and recommended pollution pre- vention opportunities. Other pollution prevention opportunities for the Label Printing Center include • Seek an alternative mechanism, such as bar code system, to label mail bags, boxes and reusable mail distri- bution equipment. • Specify tag paper with recovered con- tent in new procurement. • Modify the label printing process to reduce reject rate. Current Management - Replace degreasers and cleaners containing ODCs and EPA 33/50 chemicals. • Replace chemicals in pressure sensi- tive printing with nontoxic alternatives. • Replace petroleum-based inks with soy or aqueous-based inks. Central Repair Facility (CRF) A summary of the wastestreams, the current waste management practices for each, and a description of recommended pollution prevention opportunities for the CRF is presented in Exhibit 5. Opportunities Corrugated cardboard Computer paper Mixed office paper Test runs and defective printed label stock Banded label stock Cores and ends HOPE bottles Hauled to Republic Recycling by Topeka Waste Management for net cost of $180 per compactor load Some collected for recycling by Hunter; some discarded as waste Discarded as waste Recycled Recycled Discarded as waste Recycled Reduce incoming boxes Improve diversion for recycling Improve economics of recycling Reduce generation Improve diversion for recycling Reduce generation Divert for recycling Reduce generation Reduce generation Divert for reuse or recycling Reuse Exhibit 5. CRF Waste Sources Waste Current Management Opportunities Cardboard Foam Plastic film Tape Strapping Metal Batteries Paper Oil Computer parts Discarded as solid waste Discarded as solid waste Discarded as solid waste Discarded as solid waste Discarded as solid waste Collected for recycling Discarded as solid waste Accumulated for recycling through MDC Discarded as solid waste Discarded as solid waste Collected for recycling Sold as scrap Discarded as solid waste Replace with durables, reuse, recycle Replace with durable, reuse Reduce, recycle Eliminate Reduce, recycle Improve source separation for recycling Source separate Recycle Reduce paper use, recycle Dike drums to prevent runoff Sell to computer recycler Lead Solder Discarded as solid waste Less toxic substitute ------- Other pollution prevention opportunities for the CRF are highlighted below. • Use the procurement system to track hazardous materials throughout the facility. • Change purchasing specifications to stop purchasing materials containing chemicals on EPA 33/50 list. • Purchase reusable foam templates to replace the Instafoam packaging ma- terial. Exhibit 6 presents the pollution preven- tion opportunities that offer the USPS sig- nificant economic benefit in addition to reducing pollution. Recommendations and Conclusions The USPS has encouraged reduction and recycling activities in its facilities. By implementing many of the source reduc- tion and recycling options identified in the assessment, the Topeka Materials Distri- bution Center may be able to improve facility-wide environmental management, improve record keeping, reduce waste disposal costs and generate additional revenues from the sale of paper, paper products and other recyclables. On a fa- cility-wide basis, the Topeka facility should focus on appointing a single environmen- tal coordinator and purchasing software to coordinate purchasing and waste man- agement throughout the facility. Addition- ally, the MDC should focus on methods to reduce the disposal of obsolete forms and other printed material and the CRF should make it a priority to eliminate the use of Instafoam and replace this with reusable foam templates. The full report was submitted in partial fulfillment of Contract No. 68-C2-0148, Work Assignment No. 3-10 by Science Applications International Corporation un- der the sponsorship of the U.S. Environ- mental Protection Agency. Exhibits. Cost-Saving Pollution Prevention Opportunities Item(s) of Concern Facility Current Practice Pollution Prevention Opportunity Estimated Potential Savings/Revenues Old Corrugated Cardboard (OCC) MDC Warehouses LPC CRF Obsolete forms, MDC Supply publications, catalogs Warehouse Mixed office paper MDC, LPC, CRF Banded labels LPC Disposable shipping MDC, LPC, CRF containers Instafoam CRF Some OCC is recycled at a net cost of $180 per compactor load every other month Recycled through local recycler Most disposed in trash; small amount of computer paper is recycled 4,000 pounds of excess banded label stock is recycled through local recycler monthly; no revenue Purchase thousands of single- use corrugated boxes and jiffy bags to ship printed labels, supplies and equipment to other USPS facilities. Sprayed into shipping containers to protect contents from shifting and breakage Establish and enforce a corrugated cardboard source separation policy Continue with same recycler or contract with another firm Seek a long-term contract for paper recycling with a per-ton payment indexed to the paper market Establish paper recycling program and seek long-term contract for paper recycling with a per-ton payment indexed to the paper market Stop banding test runs Identify a substitute for the plastic bands Total potential savings from avoided disposal costs and increased recycling revenues are estimated between $21,900 and $60,900. Estimated revenue increase of $6,000 to $10,000 per year depending on market fluctuations. Total estimated revenues range from $1,875 - $2,350 Maximize use of existing Mail Transport Equipment Inventory Purchase additional reusable shipping containers Establish equipment tracking system Reusable foam templates Modify process to preserve boxes for reuse and recycling Reduction in contaminated label stock will reduce waste and potentially increase recycling revenues. Additional investment in capital equipment will yield long-term savings in reduced purchasing, labor and disposal expenses. Reduced liability and improved worker safety. Investment in capital equipment will yield long-term savings in reduced purchasing, labor and disposal expenses ------- Carole O. Bell, Mary Hoe/, Henry Huppert, and Steven Rolander 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 Materials Distribution Center Topeka, KS"(OrderNo. PB97-100069; Cost: $38.00, 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 BULK RATE POSTAGE & FEES PAID EPA PERMIT No. G-35 EPA/600/SR-96/115 ------- |